Man-00120 - Genio Repair Manual

REPAIR MANUAL
(BS-III & BS-IV)
MAN-00120
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
Rev1 – MARCH 2011
www.teknetmahindra.com
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS.
© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without
the written permission of Mahindra & Mahindra Ltd.
Repair Manual MAN-00120
GENIO (BS-III & BS-IV) MAR 2011/Rev 1
About the Repair Manual
This Repair Manual is published for the information and guidance of the service technician of
authorized MAHINDRA & MAHINDRA dealers to help them provide efficient and correct
service and maintenance on Mahindra vehicle. It contain information on the operation and
maintenance of the GENIO – mDI CRDe (BS-III & BS-IV) as well as descriptions of the major
units and their functions in relation to the other components of the System.
To ensure customer satisfaction with Mahindra products, proper service and maintenance by
Mahindra Dealer Technicians is essential. Technician should know and understand the
content of this manual before starting actual work on the vehicle. The copy of this manual
should be kept in a handy place on the shopfloor for quick and easy reference.
This manual includes special notes, important points, service data, precautions that are
needed for the maintenance, adjustments, service, removal and installation of Engine and
other aggregate components.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. Dealers will be provided
Technical Service Bulletins or Supplementary Notes in case modifications done in future.
All rights are reserved to make changes at any time without prior notice.
Pictures, photographs used in this manual are illustrations only and may pertain to some
variation than actual in the vehicle.
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 i n t he pr oduction of the various c omponent uni ts and ac cessories f rom w hich t he vehicles ar e m anufactured. The r eproduction, translation, transmission, i n par t o f or w hole of t he pr esent
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra
1
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Main Contents…
• How to use this manual………………………………………………………………………. 03

• Safety Instructions………………………………………………………………………………. 04
• Vehicle Specification…………………………………………………………….……………. 06
• Vehicle Maintenance……………………….…………………………………….…………… 10
• Engine……………………………………………………………....................…………… 11
• Air Intake System……………………………………………………………………..……………… 93
• Cooling System………………………………………………………………………….……………… 107
• Fuel System…….………………………………………………………………………..……………… 125
• Emission Control System………………………………………………………….……………… 152
• Clutch……………………………………………….……………...................…………… 161
• Transmission………………………………………………………………………………………… 186
• Propeller Shaft...………………………………………………………………….. ………….. 242
• Rear Axle……………..……………………………………………………………………………… 256
• Steering System…………………………………………………………………….……………. 309
• Front Suspension………………………………………………………………………………… 348
• Rear Suspension……………………………………………………………………..…………… 373
• Brakes……………………………………………………………………………………..…………… 383
• Wheels and Tyres…………………………………………………………………..…………… 421
• Chassis…………………………………………………………………………………….…………… 433
• Electricals……………………………………………………………………………………………. 443
• Appendices………………………………………………………………………………………….. 447
2
How to use this manual
There is table of contents for the whole manual on the second page of this manual, where the
required section can be easily found. Also, there is content on the first page of each section, where
the main objects in that section are listed. Each section is further divided in to sub-sections –
• Description section gives an overview of the functioning of the system.

• Specification section provides information on the dimensions and type of system.
• Construction, Operation and Identification section gives details of construction of System, its
operation and serial number identification.
• Care of the system details the maintenance and adjustments, if any, to be carried out on the
system to keep it functioning at its best performance level.
• Trouble shooting section details a generic trouble shooting for major problems.
• In-car repair outlines the procedure to carryout minor repairs/adjustments without removing the
aggregate from the vehicle.
• Dismantling/overhauling section covers the detailed process and procedures to be followed,
while repairing the system. This is generally carried out after removing the aggregate/system from
the vehicle.
• Assembly section covers the detailed process and procedures to be followed, while repairing the
system.
• Tightening torques is the specified torque values for all crucial fasteners in the Component/
vehicle system.
• Repair & maintenance data provides information on the dimensions of a new part as well as how
much wear can be tolerated on a specific part, respectively.
• Mahindra Special Tools (MST) lists out the special tools should be used for the service and repair
work described in that section.
• Appendices are provided in the last section of this manual. It includes of Abbreviations, measuring
units, Lubrication chart, Greasing points, Do’s & Don’ts, Vehicle preservation notes and List of
MST’s applicable to this model.
The proper performance of service is essential for both the safety of the technician and the efficient
functioning of the system. The service methods in this repair manual are described in such a manner
that the service may be performed safely and accurately. Service varies with the procedures used, the
skills of the technician and the tools & Parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by MAHINDRA & MAHINDRA must first
completely satisfies himself that neither his safety nor the vehicle’s safety will be jeopardized by the
service method selected.
In spite of our best efforts to make the manual error-free, a few errors could have inadvertently
crept in. If you identify errors, functional or typographical, please inform your TEKline or
pillay.ajay@mahindra.com. Suggestions to improve the manual and make it more user-friendly
are also welcome.
3
Safety Instructions
1. General Precautions –
• Make sure that vehicle is in neutral, parking brakes is ‘ON’ and wheels are blocked before doing
any work or diagnostic procedure on the engine or vehicle.
• When it is necessary to do service work with the engine running, make sure that the parking
brake is set fully and the transmission is in Neutral. Keep hands, hair, clothing, tools, etc. away
from the fan and belts when the engine is running.
• Make sure the work area is ventilated and well lit. When it is necessary to run the engine
indoors, make sure that the exhaust gas is forced to stream outdoors.
• Do not perform service work in areas where combustible materials can come in contact with a
hot exhaust system. When working with toxic or flammable materials, make sure that the area
you work in is well-ventilated.
• Make sure that the Transmission, Transfer Case, Oil/ Exhaust system has cooled down
sufficiently before attempting to remove any components, for your safety.
• Use correct lifting devices. Whenever raising a vehicle for service, be sure to follow the
instructions.
• Keep work area clean, dry and well organized.
• Keep tools and parts off the floor or in a trolley.
• Use safety blocks and stands.
• Wear proper safety equipment as recommended and authorized for the job. Wear proper
hearing protection.
• Wear protective safety glasses/ goggles or face shields. Wear safety shoes.
• Wear correct work clothing, do not wear wrist watches, jewelry, rings, loose or hanging
apparel, such as ties, torn clothing, unzipped jackets that can catch on moving parts.
• New and used engine oil, Brake or Clutch oil, Radiator Coolant, Transmission and Differential
oils can be hazardous. Continuous contact with used engine oil has been found to cause [skin]
diseases. Brief contact with used oil may irritate skin. To minimize your exposure to used
engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves)
when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and
water.
• Recycle or properly dispose the used Coolant, oil and filters.
• Make sure that charged fire extinguishers are available in the workshop.
• Make sure a first Aid Kit is available in workshop.
2. Vehicle Safety –
• Before starting any service work, cover fenders, seats and any other parts that are likely to get
scratched or stained during servicing. Also, be aware that what you wear (e.g. but-tons,
buckles) may cause damage to the vehicle’s finish.
4
• When servicing an electrical part that does not require use of battery power, disconnect the
negative cable of the battery.
• When removing the battery, be sure to disconnect the negative cable first and then the
positive cable. When reconnecting the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.
• Whenever you use oil seals, gaskets, packing, O-rings, locking washers, split pins, self-locking
nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new
gaskets, packing, etc., be sure to remove any residual material from the mating surfaces.
• Make sure that all components are cleaned properly before reassembling. When use of a
certain type of lubricant, bond or sealant is specified, be sure to use the specified and
recommended type only.
• Safety Terms -
Three terms are used in this manual to stress Technician/ workman safety, safe and sound operation
of the vehicle and its aggregates: Warning, Caution and Note.
Term Symbol Denotation
WARNING Hazard and unsafe practices that can cause injury or death.
CAUTION
Practices that can cause damage to the Transfer Case or vehicle.
Procedure that must be followed for correct, efficient Transfer
NOTE NOTE
Case operation.
• Legend -
Symbol Denotation
Place
Locate
Move/ Fit
Turn Clockwise
Turn anti-clockwise
5
Vehicle Specification
Refer following chart for GENIO mDI CRDe (BS-III & BS-IV) vehicle specifications data –
Vehicle data
Basic model Mahindra GENIO SC 2-WD BS-III & BS-IV
Type / Description Goods Carrier
Category of vehicle N1
Type / Description Cab & Chassis
Category of variant (s) N1
Engine
mDI CRDe-4 Cyl 2.5L JE/ Opt m-Falcon /optional mDI
Model
CRDe BS III
Type Engine No. starting with JE XX X XXXXX
Fuel used High Speed Diesel
No. & layout of cylinders & firing order 4 Cylinder, Inline, 1-3-4-2
Bore x stroke (mm) 88.9 x 100.3
Swept volume cc 2489
Compression ratio (Specify tolerance) 18.5 :1 +/- 0.5
Max. Engine output (kW @ rpm) 56 +/- 2% kW @ 3200 RPM
Max. Torque (Nm @ rpm) 220 Nm @ 1400-2200 RPM
Air cleaner type Foam Type
Clutch
Type Single Plate Dry
Gear box
Make & model NGT 520
Type Manual
No. Of gears 5 Forward 1 Reverse
Floor Shift
Gear shifting control system (Sketch

showing gear shifting arrangement)
Gear ratio
1st 3.78
2nd 2.24
3rd 1.38
4th 1.00
5th 0.79
Reverse. 3.524
Drive Axle ( front/Rear/All) Rear
Rear axle ratio 4.1:1
6
Steering
Description Hydarulic Power Assisted, Rack & Pinion Type
Type / Model Tilt & collapsible Type
Maximum No. of rotation of steering wheel
3.3
from lock to lock
Offset of the steering column with respect
50.0 mm to left of Seat centre line
to the seat
Steering wheel diameter, mm 395 mm
Steering Gear Ratio 17.8:1
Wheel lock angle(deg) Inner Outer
Left 37 39
Right 34 36
Frame
Long member size ( mm ) 4900 mm
Number of cross members 9
Suspension
FRONT-INDEPENDENT SUSPENSION WITH COIL SPRING
Type / Description
REAR-RIGID WITH LEAF SPRING
FRONT-COIL SPRING
Spring
REAR-LEAF SPRING
Anti-roll bar STABILIZER BAR
FRONT-TELESCOPIC DOUBLE ACTINGHYDRAULIC SHOCK
Shock absorbers
ABSORBER
Brake
Service brake( Brief description) Vacuum Assisted Hydraulic with Auto Adjuster
Auto Slack Adjuster Fitted Yes
ABS Fitted (Yes /No /optional) No
Front ( Disc/ Drum) Ventilated Disc
Rear ( Disc/ Drum) Drum
PULL TYPE,OPERATING ON REAR WHEEL HAND
Parking brake
OPERATED
Secondary brake Unfailed portion of Service brakes.
Wheels and Tyres
Wheel rim size 6.0J X 15
Tyre size designation including ply rating 215 /70R 15
Speed Index S
Load index / Load rating 109
Tyre Type(Radial/ Cross/ Tube /Tubeless RADIAL
Front: 2.4 kg/cm²
Laden Tyre pressure (front & rear) (kg/cm²)
Rear: 4.2 kg/cm²
Electrical system
System voltage (V) 13.5V
Battery rating (Ah) 65Ah
7
Wiper motor M/s Lucas TVS Ltd, 12V

Wiping system (Brief description) Electrically Operated, 2 Speed Link Type
Fuel tank
Material Sheet Metal, CRC Steel - EDD (Al - Si Coated)
Capacity (L) 55L
Seating
Seating capacity D+1
Vehicle Dimensions :
Overall Length mm 5275
Overall Width mm 1840
Overall Height (Unladen) (mm) 1870
Wheel base (mm) 3200
Front track 1500
Rear track 1500
Front end 825
Rear end 1250
Min. ground clearance (mm)at differential 200
Cargo box dimensions (mm) 2420X1600X480
Load body platform area (mm) 2420X1600X480
Weights :
Maximum FAW (kg) 1040
Maximum RAW (kg) 1890
Kerb weight with 90% fuel
1680
(with spare wheel, tools, etc) (kg)
Gross vehicle weight kg (for rigid vehicles ) 2930
Maximum Gradeability in 1st gear 12 deg
Tyres :
Tyre type (Radial/cross ply) (with Tube /
RADIAL,TUBE LESS,
Tube less) size designation including ply
215/70 R15,109/107S
rating, Speed rating/ Load rating/Load index
Dynamic rolling radius, mm. 331mm
Inflation pressure – Unladen (kg/cm2 / kPa)
Front 2.4
Rear 2.4
2
Inflation pressure – Laden (kg/cm / kPa)
Front 2.4
Rear 4.2
8
• Refer below chart for vehicle manufacturing month and year details –
Code for Month and Year of production

Code for month of production: Code for year of production:
Month Code Year Code
January A 2010 A
February B 2011 B
March C 2012 C
April D 2013 D
May E 2014 E
June F 2015 F
July G 2016 G
August H 2017 H
September J 2018 J
October K 2019 K
November L 2020 L
December M 2021 M
2022 N
2023 P
2024 R
2025 S
2026 T
2027 V
2028 W
2029 X
2030 Y
2031 1
2032 2
2033 3
2034 4
2035 5
2036 6
2037 7
2038 8
2039 9
Position of the code for Month of
production in the Chassis number : MA1YE2JEKA6EXXXXX
Position of the code for Year of MONTH CODE (10 digit from right)
production in the Chassis number : YEAR CODE (08 digit from right)
Height of the Chassis number : 7 MM.
Example of Engine No. JE xxxxxxxx (xxxxx :- Last 5 digits represent Sr. No which is Variable)
Example of Chassis No.(Vehicle
Identification Number) with Month & MA1YE2JEKA6EXXXXX (xxxxx: - Sr. No. Variable )
Year of Manufacture :-
9
Vehicle Maintenance
Refer following chart for GENIO mDI CRDe (BS-III & BS-IV) vehicle maintenance schedule -
10
Engine
2.49L mDI CRDe (BS-III & BS-IV)
Contents…
• Description…………………………………………………………………………………………… 12
• Engine Identification & Component Locations……………………………………… 13
• Trouble Shooting…………………………………………………………………………………… 16
• Care of the System………………………………………………………………………………… 21
• In Car Repairs………………………………………………………………………………………… 22
• Dismantling & overhauling of the Engine……………………………………………… 66
• Inspection……………………………………………………………………………………………… 75
• Assembly………………………………………………………………………………………………. 76
• Specifications & Wear Data…………………………………………………………………… 82
• Lubricants & Sealants…………………………………………………………………………… 88
• Tightening Torque’s……………………………………………………………………………… 89
• List of the MST……………………………………………………………………………………… 92
11
Description
The 2489 cc/ 2.49-liter Turbocharged common rail direct injected diesel engine with a bore of 88.9
mm and stroke of 100.3 mm develop 56kw/ 75 BHP at 3200 RPM and a torque of 220 Nm at 1400 to
2200 RPM.
A waste gated turbocharger controls the boost to 2.2 bars. The compressed air is cooled by the charge
intercooler which is mounted upstream of the turbocharger. The cooled air enters the inlet manifold’s
plenum and it enters the Cast iron cylinder head through the inlet valves having a 45-degree angle.
The piston features re-entrant type combustion chamber and having ferrous ring insert in the Top ring
groove. A 3-ring pack is used. The top ring is asymmetrical barrel face and with CKS coating and
keystone shape. The 2nd ring is taper faced. The 3rd is Conformable Oil Ring. The piston is having an
offset of 0.5 mm.
The forged connecting rod is connected to induction-hardened crankshaft. The small end of the
connecting rod is trapezoidal shaped to reduce the mass as well as to ensure higher loading. The
crankshaft is induction hardened with the filets hardened & ground. The flywheel has a shrunk fit ring
gear and also a ball bearing to act as pilot for the gearbox input shaft. The front end is having a rubber
moulded dampener pulley.
NOTE: GENIO 2.49L mDI CRDe TC BS-IV engine is equipped with Intercooler, EGR Cooler & Catalytic
Converter where as BS-III engine doesn’t have Intercooler, EGR cooler and Catalytic converter.
Silent features of mDiCRDe: Cast Iron Cylinder block with parent bore. Exhaust manifold is integrated
with turbine housing. Aluminum make Intake manifold, the intake venture integrated with EGR Valve.
Vacuum pump is stand alone driven by Chain drive. Stand alone Water pump coupled with Modulating
fan. Lobe type oil pump driven by crankshaft through plastic gear. The high pressure pump & camshaft
are chain driven. HP Pump is driven by Oldham coupling. Rocker arms with HLA mechanism are used.
Phase sensing actuator is integrated with camshaft. Integral Bracket for auto tensioner, alternator, AC
compressor & idler pulley is used.
Engine Identification: Engine Serial Number
The engine serial number is stamped on engine

crankcase, near HP Fuel pump is mounted.
Refer illustration shown.
The engine serial number code is stamped as -

JE XX X XXXXX for BS III &
JFXX X XXXXX for BS IV
The engine accessories like Alternator, AC
Compressor, Starter Motor, HP Pump,
Turbocharger and Power Steering Pump may
have manufacturer’s labels or identification
plates. This labels or identification plates
include information and specification may be
helpful to vehicle operator and technicians.
12
Engine Component Locations
1. Engine components location – front view
Engine Component Location – Front View
1
2
13
3
12
4
11 5
10 6
9
7
14
Engine Component Location – Front Side Refer illustration.

1. Oil refill spout 8. Dummy Pulley
2. Breather hose from crankcase 9. Oil Filter Assembly
3. Dip stick 10. Auto tensioner
4. Water Pump 11. Front cover
5. Vacuum Pump 12. Alternator
6. Damper Pulley 13. Thermostat Housing
7. Steering Pump Pulley 14. Oil Sump
13
2. Engine component location – LH & RH Side Views
Component Location – LH & RH Side Views
7 11 12
8 9 13
6 10
14
15
5
17
4 3 17 18
21 20 19 16
2 1
Engine Component Location – LH & RH Side

Refer illustration.
1. Starter Motor Location 12. Turbocharger/ Exhaust manifold
2. Oil Sump 13. Oil filler spout bracket
3. Steering Pump mtg. bracket 14. Engine lifting hook - front
4. TDC Sensor location 15. Alt/ AC Comp/ Tensioner bracket
5. HP Fuel Pump 16. Cam phase Sensor
6. Radiator Fan 17. Engine mtg. bracket RH & LH
7. EGR Valve Assembly 18. Oil Filter assembly
8. Rocker Cover assembly 19. Drain Plug on Oil sump
9. Intake Manifold assembly 20. Rear Oil Seal retainer plate
10. EGR Pipe 21. Flywheel assembly
11. Cyclone assembly
14
3. Engine component location – Rear view.
3
1 2 Engine Component location –
Rear view.
4
Refer illustration.
1. Engine lifting hook - Rear

2. Cylinder head
5 3. Rocker cover
4. EGR pipe
5. TC with exhaust manifold
6. Oil cooler coolant line
6 7. Heat shield on oil filter
8. Flywheel assembly
7
4. Engine component location – Top view.
1 2
Engine Component location –
Top View.
Refer sample illustration.
1. Thermostat Valve
2. Oil refill cap
3. Injector assembly
4. HP Pipe line, CR to Injector
5. HP Pipe line, HP Pump to CR
assembly
6. CR assembly
6 5 4 3
15
• Trouble Shooting
Refer to the Service diagnosis charts described in Diagnostic Manual. Additional tests & diagnostic
procedures may be necessary for specific engine complaints that cannot be isolated using only the
diagnostic chart.
Information concerning the additional checks is provided within the following diagnostic.
Cylinder compression pressure Test
The results of the cylinder compression test can be utilized to diagnose several engine malfunctions.
Before carrying out the compression test ensure that the battery is in good working condition.
Otherwise the indicated pressures may not be valid for diagnostic purpose.
 Remove all the injectors.

 Fit the dummy injector (MST Tool) and connect it with the compression gauge.
 Disconnect the engine RPM sensor or phase sensor connector so that the engine does not start.
 Crank the engine.
 Note the compression value should be 30 bars.
 Repeat the procedure for the other cylinder.
 Refer to the Specification for the value.
Engine cylinder Head Gasket Failure Diagnosis
A leaking engine cylinder head gasket usually results in loss of power, loss of coolant and engine
misfiring, overheating and poor fuel economy.
An engine cylinder head gasket leak can be:
A. Between adjacent cylinders

Or
B. Between a cylinder and adjacent water jacket.
Cylinder head gasket failure between cylinders is indicated by

Loss of power and /or engine misfiring.
Cylinder head gasket leaking between a cylinder and coolant passage results in coolant foaming or
overheating and loss of coolant indicate an engine water jackets.
Cylinder to Cylinder Leakage Test
Check the cylinder compression pressure as already explained. Leakage between cylinders will be
result in drop of compression pressure by nearly 50 to 70% in the affected cylinders.
16
Cylinder to Water jacket Leakage Test -
• Remove the radiator cap.

• Warm up the engine and allow it to warm up until the engine thermostat opens.
• If large combustion /combustion pressure leak exist, bubbles will be visible in coolant.
• If bubbles are not visible, install a radiator pressure tester and pressurize the cooling circuit. If a
cylinder is leaking combustion pressure into the water jackets then the tester’s needle will pulsate
with every combustion stroke of the cylinder.
Symptom Causes Remedial action

Engine not starting and 1. Air intake obstructed  Replace the element.
emits black smoke  Check for free operation of
Turbocharger.
2. Defective injectors  Replace
3. Lack of compression.  Check compression pressure.- if
low check for valve seat ,rings.
4. Cylinder head gasket  Replace the cyl. Head gasket.
failure
5. Engine timing- Valve  Check timing chain.
6. CR system  Refer diagnostic manual.
Noisy engine & black 1. Faulty injectors.  Replace injectors
smoke. 2. Loose main bearings  Tighten the main bearings.
3. HLA leak/ jam  Check and replace HLA.
4. Broken parts.  Inspect and replace the broken
parts.
Engine does not give full 1. Air intake restricted.  Replace air cleaner element if
power. required.
2. Clogged fuel filter.  Replace filter.
3. HLA leak/ jam  Check and replace HLA.
4. Defective injectors.  Replace
5. Air leaks in pressure line  Plug the leaks, replace hose or clip
after turbocharger( if required.
Turbo to intercooler,
intercooler & intercooler
to intake manifold)
6. Fuel return pipe to tank  Locate the kink/block in return pipe
blocked. and rectify.
7. Boost pressure pipe/  Check the pipe, washer & rectify.
hose assembly damaged.
8. Valve leak.  Check the compression, re-lap if
required.
9. Turbocharger damaged.  Get the Turbocharger repaired at
authorized TEL dealer.
10. Gas leaks between  Replace gaskets.
TC/exhaust manifold.  Replace Turbocharger/ exhaust
11. Restricted exhaust manifold.
system.  Tighten the exhaust pipe mounting
17
bolts. Replace gasket if required.

12. Gas leak between EGR  Change the gasket or the pipe.
pipe joints
13. EGR pipe leak.  Replace the pipe.
14. Fuels supply line kink  Remove the restriction.
creating restriction.
15. EGR valve improper  Check the EGR using the blink
functioning. codes. Proceed appropriately.
16. Compression leak.  Check compression.
17. Jammed piston rings  Replace piston rings.
18. Viscous fan continuously  Check the VFD as outlined in
engaged. cooling. Replace if required.
19. Check CR system Refer the diagnostic manual
Noisy engine & high smoke 1. Cylinder head gasket  Replace the cylinder head gasket.
( White/ Grey) defective.  Lap the valve seats or regrind.
2. Worn out or damaged
valve seats.
3. Leaking injector holder  Tighten the injector holder.
Black smoke. 1. Air intake restricted.  Check for hoses, replace air cleaner
element.
2. Defective HLA.  Check and replace HLA.
3. Defective injectors  Check injectors.
4. Air leaks.  Check for leaks between
Turbocharger to intercooler,
intercooler and intercooler to inlet
manifold.
5. EGR valve stuck open  Check the EGR valve
6. Restricted exhaust  Remove restriction or replace
system. parts.
7. Gas leak between  Replace manifold gasket or parts.
exhaust manifold &
cylinder head.  Overhaul engine/ cylinder head.
8. Worn out rings, valves.
9. Cylinder bore scuff.  Overhaul engine, replace block.
Excessive oil consumption 1. Cracked vacuum line  Check the vacuum line from the
hoses. Vacuum pump to the EGR valve -
check for leaks, crack. Replace
cracked hoses.
2. Clogged air filter  Replace element.
element.
3. Restriction in air intake  Locate & remove restriction.
to compressor duct.
4. Restrictions in  Remove the restriction in the
turbocharger oil drain drainpipe.
line.
5. Restriction in crankcase  Check the crankcase ventilation &
breather. rectify.
6. Damaged oil separator  Replace the oil separator
18
7. Worn out rings, liners,  Change oil, filter, service the

and valves. Turbocharger & use recommended
oils & drain intervals. Follow the
recommended procedure while
shutting down.
8. Turbocharger damaged.  Repair Turbocharger.
9. External oil leaks
10. Leakages through inlet  Overhaul engine.
manifold mounting face  Stop the external oil leakages.
allowing dust entry.
11. Bend/kink in any of the
oil return pipe’s/vacuum  Change the vacuum hoses.
hoses.  Change the manifold gasket or
replace the manifold.
12. Defective vacuum pump.  Remove the bend or kinks.
 Replace the vacuum pump.
Blue smoke. 1. Clogged air filter  Replace element.
element.
to compressor duct.
3. Air leak between the  Locate the leaks, change hose or
Turbocharger to intake clamp if required.
manifold.
4. Excess oil.  Correct the oil level.
5. Wear in valve seal.  Check the valve stem seals, replace
if required.
6. Wear in piston rings.  Check the compression pressure,
replace rings.
7. TC oil seal leaks  Check the Turbocharger if defective
get it attended.
White smoke. 1. Improper timing  Check sprockets & chain for wear.
Rectify
2. Defective cylinder head  Replace the cylinder head gasket.
gasket.  Remove the restrictions.
3. Restriction in fuel supply
Starter will not work or only 1. Electrical complaints.  Refer the electrical section.
cranks slightly 2. Check coolant level.  If coolant level reduced drastically
then check for hydrostatic lock.
3. Hydrostatic lock  Remove the water in the cylinder
and find the cause for water entry.
Starter will not crank the 1. Weak battery.  Check the battery specific gravity.
engine.  Clean & tighten battery
2. Corroded or loose connections.
battery connection  Repair starter.
3. Faulty starter.  Rectify earthing.
4. Improper earthing.
Noisy valves 1. Defective HLA.  Check and replace HLA.
2. Rocker arms touching  Install the correct rocker cover
19
the rocker cover. gasket. If after that also the

problem persist change the rocker
cover.
3. Thin or diluted oil.  Change oil.
4. Low oil pressure.  Check the oil level.
5. Bent push rods.  Install new push rods.
6. Worn rocker arms.  Replace the rocker arms.
7. Worn valve guides.  Replace the valve guides.
8. Excessive run out of  Grind valve seats and valves.
valves seats
9. Oil thickening  Replace oil & find the reasons of
thickening, rectify.
Oil pressure drop 1. Low oil level.  Check engine oil level.
2. Defective oil pressure  Install new sensor.
sensor.
3. Clogged oil filter.  Replace filter.
4. Clogged oil cooler  Clean the oil cooler.
5. Clogged oil strainer.  Clean the strainer.
6. Pressure relief valve in  Clean the valve & bore and
oil filter bracket stuck. assemble.
7. Oil leaks- internal  Check the gasket between the
block & front cover or any of the
MOG plugs
8. Worn parts in oil pump.  Replace the worn parts or pump.
9. Excessive oil clearances  Check oil clearances.
10. Thin or diluted oil.  Change oil to correct viscosity.
11. Excessive bearing  Inspect the parts & replace.
clearance.
12. Oil pump relief valve  Remove the valve, inspect, clean &
stuck. refit.
13. Oil pumps suction tube  Remove sump, inspect the parts &
loose, bent or cracked. replace.
14. Oil pump cover warped  Install new pump.
or cracked
15. Drive gear plastic broken  Replace it.
Oil leaks 1. Worn oil seals  Replace seals.

2. Misaligned or  Replace gasket.
deteriorated gaskets.
3. Loose fastener, broken  Tighten fastener
or porous metal parts  Repair or replace.
20
• Care of the System -
The performance of the engine is dependent on ensuring that the following maintenance is carried out
as per the schedule without fail.
Accessory Drive Belt: To be checked and adjusted at 60,000 & 80,000Kms. To be replaced at every
100,000 Kms.
Auto Tensioner: To be checked at 60,000 & 80,000Kms. To be replaced at every 100,000 Kms.
Air cleaner: The element should be replaced at every 60,000 Kms or when (filter chocking) red
indicator band shows. For the detailed procedure, refer to the Air Intake System.
Engine Oil: The engine oil should conform to API CH4+ grade and with a viscosity Index of SAE 15W40.
It should be kept in mind that in the turbocharger engine the oil has to have do an additional load of
lubricating and cooling the Turbocharger shaft, if any oil of lower specification is used it can break
down under the high thermal load at the turbine end of the shaft especially during the hot shutdown.
This oil grade also ensures that the oil consumption is within the desire limits. Use MAXIMILE Crown
(SAE 15W-40) Exceeds - API CH4 Grade of oils. The Oil change intervals are first at 5000 Kms. then
20000 kms & subsequently every 20000 Kms.
Cooling system: Ensure that no leakages are present. For details of the coolant and ratio refer the
Cooling System.
Turbocharger: The engine is having an exhaust gas driven turbocharger. The turbocharger shaft speed
varies from about 40, 000 when engine is idling to about 1,70,000 when the engine is having the full
rated RPM. The exhaust manifold is integrated with turbocharger (turbine housing unit) and it should
not be separated from Turbocharger assembly during Exhaust Manifold and/ or Turbocharger R&R.
EGR: On vehicles fitted with EGR system the following additional points check have to be done during
scheduled maintenance.
If the pipes are removed then it is essential that while fitting back; new gaskets to be used. EGR pipe
has to be removed from both the ends. Do not open the pipe from one end only; it will cause the pipe
to twist.
• Check for any exhaust gas leakage through sealing faces, EGR pipe. Formation of any black
soot indicates leakage.
• Check the vacuum hoses for any leaks, cracks.
• Retighten all nuts and bolts as per the recommend torque.
Tappet setting is not required since hydraulic lash lift adjusters (HLLA) are used.
21
• In Car Repairs
Refer below index for list of Repair activities described in this section:
Job Description Page No. Job Description Page No.

Intercooler Assy R&R 23 Engine Mount Front R&R 45
Electric Fan R&R 24 Engine Mount Rear R&R 46
Main Drive Belt R&R 25 Air Filter Element Change 47
Auto Tensioner R&R 26 Engine Oil Sump R&R 48
Breather Pipe R&R 27 Flywheel R&R 50
Rocker Cover R&R 28 Rocker Arm R&R 51
Alternator R&R 29 HLLA R&R 52
Alternator mtg. bracket R&R 30 Camshaft R&R 53
PSP Drive Belt R&R 31 Cylinder Head R&R 54
PSP R&R 32 Battery & Cables R&R 57
Vacuum Pump R&R 33 Radiator Drain Cock R&R 57
HP Pump R&R 34 Oil Pressure sensor Removal 58
Front Cover R&R 36 Water temp Sensor Removal 59
Front Oil Seal R&R 38 Starter Motor R&R 59
Chain Assy R&R 39 Cooling hoses R&R 60
Chain Assy Subcomponent 40 Vacuum Hoses R&R 60
Engine Timing Setting 41 Radiator Assy R&R 61
ROSR R&R 42 Radiator Grill bkt R&R 62
Oil Filter & Cooler Assy R&R 43 Transmission Assy R&R 63
Oil Cooler Lines R&R 44 Engine Assy R&R 64
Engine Overhaul 65
22
• INTERCOOLER* ASSEMBLY – R&R

(* applicable for GENIO mDI CRDe BS-IV engines only)
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
 NVH Cover mtg. bolt 03 10 mm. 07 ± 02
 Intercooler mtg. bolts 03 13 mm. 22 ± 02
 Hose clamp 04 7 mm. 05 ± 0.5
 Intercooler bracket mtg. bolts 04 12 mm 20 ± 02
Mounting
locations
NVH Cover
Oil filling
spout
location
Mounting Locations
Removal Steps –
Intercooler Intercooler Assembly
1. Remove NVH cover.
bracket
mtg. bolts 2. Remove intercooler hoses.
Intercooler 3. Remove intercooler assembly.
Mountings Refitting Procedure –
1. Before installation check the hoses
for crack or distortion.
2. Hoses can be cleaned by air
pressure before refitting.
3. Refit intercooler assembly.
4. Connect Intercooler with intake &
outlet hoses and connect other
end of hoses to TC and Intake
manifold respectively.
5. Refit the NVH cover assembly.
 Intercooler has bracket support on
its RH side it is mounted with help
of 04 bolts fixed to the intake
manifold.
23
• ELECTRIC FAN & SHROUD – R&R
 NVH Cover mtg. bolt (BS-IV) 01 10 mm. 07± 02
Electric Fan Shroud

Mounting Locations
Removal Steps –
Refer illustrations.
1. Remove Coolant reservoir tank [A].

2. Remove the electric fan wiring harness socket.
3. Press the upper LH & RH side locks and Lift Shroud in upward direction to remove. Fan and
shroud assembly can be removed out of the engine compartment.
4. The fan assembly and the shroud assembly to be removed together.
 Do not tamper or service the fan assembly.

 Assembly is reverse to the removal procedure.
24
• ACCESSORY MAIN DRIVE BELT – R&R
DUMMY PULLEY
ACCESSORY DRIVE BELT LAYOUT
Removal & Refitting – Refer illustration shown.

1. Remove NVH cover; remove Fan & shroud
2. Remove power stg. Drive belt.
3. Turn Autotensioner clockwise by using allenkey (shown by arrow mark) & remove accessory
drive belt.
4. Installation of Accessory main drive belt is in reverse order to the removal.
 Check the drive belts visually for any crack, fraying.

 Refer specifications and follow Torque chart while assembling.
 Accessory drive belt tension: 114 ± 5Hz (between Alternator & dummy pulley)
 Recommended interval for accessory drive belt replace at every 100000kms.
25
• AUTO TENSIONER – REPLACE
Auto tensioner mtg. bolt 01 14 mm. 35 ± 05
A B
Dummy pulley DRIVE BELTS - LAYOUT
C Auto Tensioner D
Auto Tensioner dowel

Pin mounting hole
NOTE: Auto tensioner is provided with dowel-pin on its mounting face; while assembling the dowel
should match & fixed carefully. Refer sketch [D] Dowel Pin location shown by arrow mark.
Removal Steps – Assembly Procedure –

Refer illustrations. Refer illustrations.
1. Remove NVH cover. 1. Refit Auto tensioner assy.

2. Remove power steering belt & 2. Refit Accessory drive belt & power
Accessory drive belt steering belt.
3. Remove Auto tensioner assy. 3. Refit NVH cover.
26
• BREATHER PIPE – R&R
Refer illustrations shown for breather pipe layout on rocker cover and oil separator.
A B C
Refer illustrations shown -

[A] Removal of Oil breather
hose.
[B] Oil breather hose view
from Engine front.
[C] Removal of Oil filling hose
& Removal of hose on
cyclone filter.
Rocker Cover Fitment & Cut section view

showing Oil Circulation Layout
27
• ROCKER COVER – R&R
 Rocker Cover mtg. screw 11 10 mm. 5.5 ± 0.5
A B
1. Remove NVH cover. 1. Check gasket for any damage.

2. Remove intercooler hoses. 2. Refit Rocker cover with gasket.
3. Remove intercooler assembly. 3. Refit Plenum appliqué assembly.
4. Remove Oil separator hoses. 4. Refit oil separator hoses.
5. Remove Plenum appliqué assembly. 5. Refit intercooler assembly.
6. Remove Rocker cover with gasket. 6. Refit intercooler hoses.
7. Refit NVH cover.
 Start the engine and ensure no oil leak from rocker cover gasket, after completion of
job.
• Rocker Cover mounting bolt Tightening Sequence –
28
• ALTERNATOR – R&R
Alternator mtg. bolts 02 12 mm. 25 ± 03

Refer above illustrations. Refer above illustrations.
1. Battery terminal removal. 1. Assemble Alternator on its mounting

2. NVH cover removal. bracket.
3. Fan, shroud and drive belts removal (Steering 2. Assemble wiring harness sockets on
pump drive belt & water pump/ Alternator/AC Alternator.
Compressor drive belt). 3. Assemble drive belts, Fan and shroud.
4. Wiring harness sockets on Alternator removal. 4. Refit battery terminal connection.
5. Alternator mounting bolts removal. 5. Check drives belt tension.
6. Refit NVH cover.
 Check correct belt tension and adjust if required. Follow the procedure in drive
belt tension adjust section.
29
• DUMMY PULLEY/ ALTERNATOR MOUNTING BRACKET – R&R
Alt/Dummy pulley bkt mtg. bolts 06 12 mm. 25 ± 03
Removal Steps – Refer illustration.

• 1. Battery terminal removal.
2. NVH cover & intercooler removal.
3. Fan, shroud and Steering pump drive belt & water pump/
Alternator/Dummy pulley drive belt removal.
4. Disconnect wiring sockets on Alt/ AC comp & Alternator
assembly removal.
5. Remove AC compressor hoses & assy.
6. Auto tensioner & Idler assy removal.
7. Remove bracket assembly.
Assembly Procedure – Refer illustration.

1. Refit bracket assy on cylinder block.
2. Refit Idler, auto tensioner, dummy pulley & Alternator on
bracket.
3. Reconnect hoses & wiring sockets on AC comp/ Alternator.
4. Refit both drive belts. Check & adjust belt tension if
required.
5. Refit fan & shroud assembly.
6. Refit Intercooler assy & NVH cover.
7. Reconnect battery terminal.
8. Check engine performance.
 Check correct belt tension and adjust if required. Follow the procedure in drive
belt tension adjust section.
30
• POWER STEERING PUMP DRIVE BELT - R&R
A 3 B
[A]&[B] - Power Stg. Pump mounting on Engine

[C] - Power Stg. Pump drive belt position
POWER STEERING PUMP DRIVE BELT – REPLACE

Refer illustrations shown.
1. Remove NVH cover, Fan and Shroud.
2. Loosen pump fixing bolts 1 & 2 and loosen the lock nut 3 in sketch [A].
3. Remove power steering pump drive belt.
4. Refer belt tensioning procedure while refitting steering pump drive belt.
5. Check belt tension, correct if required.
Procedure for belt tensioning:
1. Loosen pump fixing bolts 1 & 2 And Loosen the Lock Nut 3
2. Screw tension bolt 4 as shown in fig to tighten the belt by appropriate amount.
3. Check tension value, should be between 200 – 230 Hz, if found less, screw in clockwise
direction, if found more than 235Hz unscrew in anticlockwise direction.
4. Final set value, New Belt: 255 - 260 Hz; & Used Belt: 200 – 235 Hz.
5. Tighten the fixing Bolts 1, 2 & 3 to 25 N-m.
 If the belt is loose then it will give belt noise. If tightened excessively then it can cause
the power steering pump failure.
 Power Steering Pump Drive Belt tension to be check at 5000, 20000, and then at every
20000kms.and adjust (if required)
 Power Steering Pump Drive Belt replacement interval is at every 100000kms.
31
• POWER STEERING PUMP – R&R

Power stg. Pump mounting bolt 04 12 mm. 25 ± 03
PSP Pulley Mtg Bolt 01 12 mm. 15 ± 02
Belt tension adjust bolt/ nut 01 16 mm N.A.
Removal Steps –
1. Remove NVH cover, Fan and shroud.

2. Remove steering pump drive belt; Refer 1.14.0
3. Remove Oil hose connections on Power steering
Pump assembly.
4. Remove Power steering Pump assembly. Refer
sketch for mounting bolts.
Assembly Procedure –
1. Refit Power stg. Pump.

2. Reconnect oil hose connections on power stg. Pump and clamp it properly.
3. Refit power steering drive belt.
4. Refit Fan, shroud & NVH cover.
5. Add and check Power stg. oil level. Top up and correct it if required.
6. Check accessory drive belt & power steering drive belt tension.
 Always use specific recommended Brand and grade of steering fluid.

 Recommended steering fluid is Shell DONAX TG Special
 M&M Part No.4280106 (1 Lit.)
32
• VACUUM PUMP – Removal.

 Vacuum pump mounting bolt 03 12 mm. 25 ± 03
Vacuum Pump Assembly

Vacuum Pump
mounted on ‘O’ ring
Engine
Vacuum Pump drive
Removal Steps –
Refer illustration.
Vacuum Pump
and mounting 1. Remove NVH cover.
bolts
2. Remove Vacuum pump hose.
3. Remove Vacuum pump

assembly.
 Ensure to check and arrest vacuum line leakages after installation.

 Ensure proper alignment of Oldham coupling and vacuum pump tongue/ drive
while assembling pump.
 Check vacuum lines for leakage if any.
 Check vacuum level develops by pump, if required.
33
• HIGH PRESSURE FUEL PUMP – R&R

 HP pump mtg. nut 03 11 mm 20 ± 02
 HP pump shaft nut 01 12 mm 25 ± 03
Vacuum
pump
HP Pump
HP Pump
Sprocket
Vacuum Pump
Drive Nut
Removal Steps –
1. Remove NVH cover. (if applicable)
2. Remove Intercooler assy. (if applicable)
3. Remove intake manifold hose for better
access.
4. Remove the vacuum pump assy, HP fuel
line & fuel hoses on fuel pump.
5. Remove the HP pump shaft lock nut and
washer.
6. Use MST (0305BAC0008ST) fix it with 2
mounting bolts on Front cover.
7. Use 04 mounting bolts to hold sprocket.
8. Loosen and remove HP fuel pump mounting nuts.
9. Start rotating MST centre bolt in clockwise direction so that HP pump can be pushed out slowly.
10. Remove HP fuel pump safely.
34
HP Pump Mounting – Genio mDI CRDe HP Pump – Genio mDI CRDe
1. Refit HP pump assembly. Ensure that HP pump Sprocket is intact and properly holds by MST.
2. Fix the HP pump by tightening its 3 mounting nuts.
3. Remove the MST by removing 04 nos. bolts holds the sprocket and 02 nos. bolts used to fix the
tool on front cover.
4. Replace new washer and HP pump shaft nut.
5. Torque tightens the shaft lock nut.
6. Refit the vacuum pump assembly.
Ensure that the vacuum drive shaft lug is aligned and Inserted properly into HP pump shaft lock
nut grove; Vacuum pump will not work in case it is not aligned properly.
7. Reconnect fuel hoses and HP pipe lines on pump.
8. Refit intercooler assembly & NVH cover.
9. Check & insure for no fuel leakage from the system.
 Special tool required to remove & refit HP pump in Genio mDi CRDe Engine.
 Special tool no. MST 0305BAC0008ST.
35
• ENGINE FRONT COVER – R&R

 Engine front cover flange bolts. 17 12 mm 25 ± 03
 Flange bolt – Vacuum pump 03 12 mm 25 ± 03
Removal Steps – Refer illustration shown Assembly Procedure –

1. Recover the coolant from Radiator and 1. Clean the surface on engine block before
engine block. fitting front cover.
2. Remove NVH cover, Fan & shroud. 2. Apply recommended sealant over front
3. Remove intercooler assembly. cover facing area & refit the assembly.
4. Remove steering pump drive belt & 3. Refit damper pulley.
accessory drive belt & auto tensioner. 4. Refit vacuum pump & connect hoses.
5. Remove damper pulley, cam phase 5. Refit stg. Pump & mtg. bracket and refit oil
sensor along with wiring connector. sump front two bolts.
6. Remove Vacuum pump assembly. 6. Refit both drive belts.
7. Remove stg. Pump & mtg. bracket and 7. Remove intercooler assembly
remove oil sump front two bolts. 8. Refit Fan, shroud & NVH cover.
8. Remove engine front cover. 9. Check both belt tensions.
10. Check for no oil leak from front cover.
 Check and ensure for no oil leak from front cover after fitment.
 Use recommended sealant for front cover assembly.
 Refer below chart for front cover mounting bolt tightening sequence.
36
• Front/ Timing Cover Mounting bolts Tightening Sequence -
NOTE –
Refer illustration.
Front C over M ounting

Bolt Torque sequence
numbers for all bolts are
marked to the respective
locations on T iming/
Front Cover.
37
• ENGINE FRONT OIL SEAL – R&R
 Engine front cover flange bolts. 17 12 mm 25 ± 03
 Flange bolt – Vacuum pump 03 12 mm 25 ± 03
Engine
Engine Front
Front
Oil
Oil Seal
Seal
Removal & refitting of Engine Front oil seal –

Refer illustration shown
 The front oil seal is fitted in the front cover therefore removal & refitting of oil seal requires
front cover R&R. Refer SOP No. 1.21.0 for Front Cover R&R;
 Oil seal is press fitted in front cover and can be removed easily.
 Always replace oil seal with new whenever removed.
 Oil seal once removed should not be reused.
38
• CHAIN ASSEMBLY – R&R

Damper pulley mtg. bolt 01 22 mm 180 ~ 200
Hydraulic Chain Tensioner 02 10 mm. 10 ± 01
Chain Guide 02 10 mm 14 ± 01
Chain Oil Jet 01 10 mm 12 ± 01
Removal Steps – Assembly Procedure -

Refer illustration shown. 1. Check chain assembly before refitting.
1. Remove NVH cover, Fan & shroud. 2. Refit Chain assembly.
2. Remove steering pump drive belt and 3. Refit chain guides &.release hydraulic
accessory drive belt. tensioner.
3. Remove stg. Pump and its mtg. bracket. 4. Apply sealant, sock and Refit engine
4. Remove damper pulley. front cover.
5. Remove engine Front cover. 5. Refit damper pulley.
6. Lock hydraulic tensioner assy. 6. Refit both drive belts.
7. Remove chain guides. 7. Refit fan, shroud and NVH cover.
8. Remove Chain assembly. 8. Check both drive belt tension.
 Check chain links for rust and damage if any.

 Check oil jet micro holes for blockage, clear it if required.
 During Chain assembly follow the procedure given below.
39
• CHAIN ASSEMBLY & SUB COMPONENTS – R&R
Guide mtg. bolts 02 13 mm. 25 ± 03
Tensioner mtg. bolts 02 13 mm. 25 ± 03

1. Drain the coolant from radiator as well
as from engine block.
2. Remove NVH cover (if applicable).
3. Remove steering pump drive belt and
accessory drive belt.
4. Remove damper pulley and Front
cover.
5. Remove chain guide and lock the
hydraulic tensioner.
6. Remove chain assembly.
7. Remove oil spray jet.
8. Remove Idler shaft & sprocket.
9. Remove HP pump sprocket.
10. Remove cam sprocket.
Refer below SOP for sub components
removal.
Oil Spray Jet Hydraulic Tensioner and Hydraulic Tensioner in

its Locking clip holes Locked Condition
OIL SPRAY JET – HYDRAULIC TENSIONER –

Refer illustrations. Refer illustrations.
Oil spray jet is provided to lubricate the chain Hydraulic tensioner is located between Cam and
assembly by spraying oil during engine running Crank shaft sprocket. It gives sufficient tension
condition. to chain which avoids chain sleep and ensures
It is mounted by means of 01 nos. bolts on the Cam sprocket timing.
engine block. It has 03 nos. of micro holes Ensure to lock the hydraulic tensioner before
provided to spray the oil. removing the chain assembly. Use special tool to
lock the tensioner.
40
HP PUMP SPROCKET –
Refer illustration.
HP pump sprocket is driven by timing chain which in turns
rotates the HP pump and Vacuum Pump. There is Oldham
coupling which drives the Vacuum Pump as well as HP Pump.
This Sprocket is fitted located in between HP Pump and Vacuum
Pump assembly. It is mounted on the block with help of housing
with brass bush. Oil is supplied through main gallery to lubricate
the bush and sprocket.
HP pump needs to be removed before its Sprocket is removed. It
is for ease of installation and to avoid mismatch and damage of
Oldham coupling during assembling. Idler Assembly
IDLER –
Refer illustration.
Idler assembly is mounted with help of three bolts on block. It is
located between Crank sprocket and HP pump sprocket.
Idler assembly needs to be removed before attempting chain
assembly removal.
CHAIN GUIDE ASSEMBLY –

Refer illustration.
Chain guide is fitted with 2 mounting bolts; it is located in
between the HP Pump Sprocket and Crank Sprocket. It guides
the chain and avoids sleep while running. Chain Guide Assembly
• Timing Chain alignment in mDI CRDe engine (GENIO/ XYLO) –

Ensure 1st cylinder in TDC position and set the chain timing as shown in the figure -
(High pressure pump timing does not required)
• ENGINE REAR OIL SEAL – R&R
41
Rear oil seal retainer plate flange bolt 07 13 mm. 25 ± 03
A B
Oil Seal
Oil Seal retainer plate
Removal Steps – Refer illustrations [A] & [B]. C

1. Remove Propeller shaft & TM assembly.
1. Remove Clutch & Flywheel assembly.
2. Remove Rear oil seal retainer plate.
3. Remove Rear Oil seal.
Assembly Procedure – Refer illustrations.
1. Replace with new oil seal in retainer assembly.
(Refer illustration [C] cut section view to ensure proper
installation of oil seal in retainer plate)
2. Refit retainer assembly on block.
(Ensure cleaned surface on retainer face and block before
installation, replace with new gasket whenever retainer plate is
removed)
3. Refit Flywheel & Clutch assembly.
4. Refit TM assembly and Propeller shaft.
• Bolt tightening Sequence –

 Check oil seal for damage, replace if

required.
 Check for oil leak after completion of job.
42
• OIL FILTER & OIL COOLER ASSEMBLY - R&R

Engine oil filters cartridge -- Special tool 10 ~ 12
Heat shield mtg. bolt 02 10 mm 10 ± 01
Stud oil cooler mounting 01 26 mm 25 ~ 30
A B
Oil Leak - Check Points near Oil Filter
Oil Filter & Cooler disassembly
Oil filter Removal –

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
43
• OIL COOLER LINES – R&R
Flange bolts 04 10 mm. 10 ± 01
A B
Removal Steps –
Refer illustrations [A] & [B] as well as below photos.
1. Remove NVH Cover, Intercooler assembly.
2. Drain the coolant from Radiator and Cylinder block.
3. Remove the hose connected from block to Oil cooler & Hose fitted between Oil cooler to
Water pump.
4. Remove another hose fitted on Oil cooler to Water pump & hose connected from Oil cooler
to Thermostat valve.
 Ensure to refill recommended coolant after proper installation of all hoses.
 Check coolant level; check and arrest coolant leak through system if any.
44
• ENGINE MOUNT (FRONT LH & RH SIDE) – R&R
Engine mount bolts (LH & RH) 04 + 04 20 mm. 45 ± 05
Front LH Side Engine mounting bracket
Removal Steps – Refer sample illustration.

2. Support Engine with proper lift & bottom support.
3. Remove Engine mounting bracket Nut from one side.
4. Remove bracket mounting bolts and take out that mounting bracket.
5. Similarly remove Engine mounting bracket Nut on other side.
6. Remove bracket mounting bolts and take out other side mounting bracket.
Installation Process –
1. Mount has to be refit immediate after removal to avoid damage of engine components.
2. Refit mounts one by one and tight mounting bolts and nut as per recommended torque.
3. Check engine performance after completion of engine mount installation.
 Before removing the engine mount make sure that the lift and bottom support is
provided, to avoid any damage.
45
• ENGINE MOUNT (REAR) – R&R
Engine rear mounts bracket bolts 04 17 mm. 40 ± 05
TM Assembly
Engine Rear Mount
Removal Steps – Assembly Procedure – Refer illustration.

Refer illustration. 1. Refit engine rear mount bracket on
1. Remove propeller shaft assy. removed cross member assembly.
2. Support TM assembly from bottom side. 2. Assemble cross member on chassis
3. Disconnect engine rear mount bracket frame.
from TM rear cover. 3. Align and Refit rear mount bolts with TM
4. Remove Cross member below TM rear cover.
assembly connected to chassis frame. 4. Refit propeller shaft assembly.
5. Remove engine rear mount bracket. 5. Remove TM bottom support.
 If engine rear mount replacement job done on vehicle, ensure that the Transmission is
supported firmly. Use four post lift to avoid damages.
46
• AIR FILTER ELEMENT – CHANGE

Air filter top cover Allen screw 07 05 mm 4.5 ± 05
Hose clamp – Filter to manifold 04 07 mm 4.5 ± 05
HFM sensor mtg. bolts 02 10 mm 4.5 ± 05
Air filter assy mtg. bolts 03 13 mm 25 ± 03
A B
Hose Dirt
side
Hose Clean Air Filter

side Assembly
D
HFM Sensor
C Top Cover
C
Top Grate
Filter element
Bottom Grate
Removal Steps - Refer illustrations.

1. Open the clean hose clip and separate 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 & replace he air filter element.
5. Assemble the top cover & tighten bolts in diagonally opposite order – torque is 4.5 Nm.
6. Assemble the clean hose on the air cleaner outlet – Air Mass sensor neck and tight the hose
clip.
 Never try to clean and reuse the Air filter cartridge.
47
• ENGINE OIL SUMP & OIL PUMP – R & R
Oil sump mtg. bolt 20 12 mm 25 ± 03 Nm.
Oil drain plug 01 22 mm 22 ± 02 Nm.
Oil Pump mtg. bolts 02 15 mm 49 ± 05 Nm
Oil Sump Gasket Oil Pump Assembly
Oil Pump &

mounting bolts
Oil Sump &

mounting bolts
Drain
Plug Oil Sump with Gasket- mDi CRDe
Removal Steps – Refer illustration. Assembly Procedure – Refer illustration.

1. Drain engine oil, remove dipstick. 1. Refit oil pump assembly. Ensure proper
2. Remove cross member below engine alignment of Oil pump gear with
assembly. crankshaft drive gear while assembly.
3. Remove oil sump. 2. Replace gasket, apply sealant on cleaned
4. Remove sump gasket/ sealant. sump surface.
5. Remove oil pump mounting bolts and 3. Assemble oil sump on engine block.
take it out. 4. Replace gasket & refit drain plug &
dipstick.
 Always replace the oil drain plug gasket 5. Refit cross member on frame.
whenever opened. 6. Refill engine oil, check level.
7. Check for no oil leakage.
48
 Refer below sketch/ chart for oil sump mounting bolt torque sequence.
 Oil Sump mounting bolts tightening Sequence -
Refer below illustration and torque tightens the oil sump mounting bolt accordingly.
8
9
7
20 19 18 2 10
3 5
Bottom view of Oil Sump –
Showing Oil Sump mounting bolts Drain Plug
4 6
13 11 1
12 14
17
15
16
49
• FLYWHEEL – R&R
Flywheel mtg. bolts 06 19 mm 45+ 60°
Flywheel &
Flywheel ring
Drive shaft
bush
Flywheel & mounting bolts
Removal Steps – Assembly Procedure – Refer illustration.

Refer illustration. 1. Refit flywheel ring gear on flywheel.
1. Remove Transmission assembly. 2. Refit flywheel bush.
2. Remove Clutch & Pressure plate assembly. 3. Refit Clutch & Pressure plate assembly
3. Remove Flywheel assembly. using special tool.
4. Remove Flywheel bush. 4. Refit Transmission assy.
5. Remove flywheel ring gear. 5. Check vehicle operation for satisfactory
performance.
 Flywheel ring is available and can be replaced separately.
50
• ROCKER ARM ASSEMBLY – R&R

Pedestal mtg. nuts 04 17 mm 35 ± 05
Oiler bkt flange bolt 01 10 mm 10 ± 01
Extreme support mtg. bolts 02 12 mm 25 ± 03
Oiler bkt flange mtg. bolt 01 15 mm 35 ± 05
Rocker Arm Assembled on Cylinder Head Removal Steps –
1. Remove intercooler assy.
2. Remove oil filler cap & breather
hoses.
3. Remove rocker cover assembly.
4. Remove rocker assembly.
 Assembly is in reverse to the
removal procedure.
Hyd. Lash Adjuster

Rocker Arm Removal
NOTE –
 Ensure that whenever the Rocker Arm and/ or HLA assembly is removed from cylinder head or
stored or while handling; should be kept in straight direction.
 Before assembling the HLA back, fill oil using a syringe through the hole shown in the sketch.
 Ensure proper fitment of Rocker support/ pedestal; the pedestal no.2 (from engine front side) is
made for oil supply to the rocker assembly.
51
• ROCKER ARM/ HLA – Removal

Pedestal mtg. nuts 04 17 mm 35 ± 05
Oiler bkt flange bolt 01 10 mm 10 ± 01
Extreme support mtg. bolts 02 12 mm 25 ± 03
Oiler bkt flange mtg. bolt 01 15 mm 35 ± 05
Rocker Arm Assy. Removal
Rocker Arm - Disassembly Different views of Hyd. Lash Adjuster
Removal Steps – Refer illustrations.

1. Remove Rocker Arm assembly.
2. Remove circlips fitted on rocker shaft assembly.
3. Remove Rocker arm supports/ Pedestals and HLA assemblies.
 Ensure that whenever the Rocker Arm and/ or HLA assembly is removed from cylinder head or
stored or while handling; should be kept in straight direction. Before assembling the HLA back, fill
oil using a syringe through the hole shown in the sketch.
 Ensure proper fitment of Rocker support/ pedestal; the pedestal no.2 (from engine front side) is
made for oil supply to the rocker assembly.
 In case any HLLA found jam/ leak, it is recommended to replace and don’t reuse
52
• CAMSHAFT – Removal
Thrust plate mounting bolt 02 13 mm. 25 ± 03
Removal Procedure –
Refer illustration.
1. Remove NVH cover & intercooler
assembly.
2. Remove front grill with add-on.
Cam Sprocket
3. Drain the coolant from radiator &
recover AC gas from system.
4. Remove radiator & condenser
assembly along with hoses.
5. Remove both drive belts.
6. Remove damper pulley.
7. Remove vacuum pump assy.
8. Remove oil breather pipes.
9. Remove rocker cover.
10. Remove rocker assy & push rods.
11. Remove front cover assembly.
12. Lock hyd. tensioner & remove
Cam Shaft Assembly with locator along with chain assy.
Sprocket & Thrust plate 13. Remove Cam sprocket.
14. Hold all tappets by magnetic sticks
before removing Cam shaft, to
avoid tappets falling into oil sump.
15. Remove cam sensor.
16. Remove Thrust plate & Cam shaft
assembly.
Cam trigger
Assembly Steps – Refer illustration.

1. Refit cam shaft assembly along with thrust plate and sprocket.
2. Remove magnetic sticks used to hold tappets.
3. Refit push rods, rocker assembly.
4. Check gasket & refit rocker cover.
5. Check timing marks on chain assembly match it with cam as well as crank sprocket & assemble
chain along with locator & tensioner.
6. Apply sealant and refit front cover assembly, take due care of seal while refitting cover.
7. Refit Damper pulley, Vacuum pump assembly; connect vacuum hoses.
8. Refit drive belts, fan & shroud.
9. Refit radiator assembly and condenser assembly connect hoses.
10. Refit front grill and accessory along with add-on.
11. Refill Radiator coolant.
12. Check for no oil leakage through front cover & rocker cover.
13. Check engine performance.
53
• CYLINDER HEAD & GASKET – Removal.
Cylinder head mtg. bolts 16 18 mm 60Nm + 60° + 60°
Cylinder head Stud 04 - 35 ± 5
Rocker CoverRocker Cover
Oil Filling Breather HoseBreather Hose

Spout bracket Injectors
Cylinder HeadCylinder Head
Engine lifting
hook bracket Common RailCommon Rail
Intake Manifold
Intake Manifold
Thermostat
Housing
EGR Valve EGR Valve
Removal Steps – Refer sample illustration. 9. Remove vacuum connections.

1. Coolant draining. 10. Remove High pressure fuel line & fuel
2. Disconnect battery negative terminal. return line.
3. Remove NVH cover & intercooler assy. 11. Remove Rocker cover, rocker assy.
4. Remove Air filter assembly. 12. Remove all push rods.
5. Remove oil filler spout with bracket, 13. Remove TC assembly including
breather/ supply lines. incorporated exhaust manifold.
6. Remove radiator coolant hoses. 14. Remove Intake manifold assembly.
7. Remove HP pipe lines, Injectors & CR. 15. Remove cylinder head bolts, refer torque
Coolant temp. sensor & Alt. connectors. chart for sequence.
8. Remove engine lifting hooks front & rear. 16. Remove Cylinder head assy. & gasket.
Cylinder Head
mounting bolt
Cylinder Head
Assembly
Cylinder Head Assembly
54
Cylinder Head Assembly Removal
NOTE
 Cylinder head can be removed along with Exhaust & Intake manifold using lifting device.
 Check all around cylinder head for any other parts required to be removed/ disconnected and
remove or disconnect necessary parts.
 Loosen & remove the cylinder head mounting bolts in order from outside to inside.
 Tap the rib portion with a plastic mallet to remove the cylinder head.
 When the head is removed, water and oil will leak from the water jacket and oil hole. When
placing the removed head on a working table lay a cloth on the bench and let it absorb the oil to
keep the working area clean.
Cylinder Head
Top Side identification mark on Gasket
Gasket
55
 Refer below chart for cylinder head mounting bolt tightening sequence.
Cylinder head bolt tightening sequence
56
• BATTERY & CABLES – Removal
Refer illustration
Battery terminal connectors 02 10 mm 17.5 ± 2.5
Battery mounting bracket 02 12 mm 20 ± 2
Removal Steps and additional check points

for Battery are:
1. Remove Battery terminals.

2. Remove Battery mounting bracket.
3. Remove battery.
4. Remove battery cables from other end.
 Check for –
1. Check Battery electrolyte level visually with respect to ‘Max’ level indication; and
top up if found less (do not exceed ‘Max’!).
2. Check and ensure the Specific Gravity # using Hydrometer.
 Check the connections at –
 Battery Terminals for correctness & Tightness.
 Battery Earth for correctness & Tightness.
• RADIATOR DRAIN COCK – Removal
Radiator Cap
Refer illustration.
• Add and check coolant level after completion
of job.
• Refill the coolant in Radiator as per given
procedure.
Drain plug
57
• Oil Pressure Switch/ Drain Plug/ Crank & Cam Phase Sensor – Removal
Oil Pressure Switch 01 24 mm 17.5 ± 2.5
Drain Plug on Block 01 22 mm 45 ± 5
Crank speed/ Cam phase sensor bolt 01 each 10 mm 8±1
A
Coolant Drain Plug
Engine Oil Pressure Switch
C B
Cam Phase Sensor

Crank speed Sensor
Oil Pressure Switch: Refer illustration [A]

 Oil pressure switch is fitted on main oil gallery, refer above illustration.
 The oil pressure switch is located on crankcase behind HP fuel pump assembly.
 Check oil level and top up if required, after completion of job.
Coolant Drain Plug: Refer illustration [A]

 Coolant drain plug is located on bloc, behind HP Pump.
 While flushing coolant from cooling system, the drain plug can be used to drain the
coolant from engine block.
 Ensure that the gasket is replaced while reinstalling plug.
 Ensure correct torque tightness and check coolant leak if any after completion of
job.
Crank Speed Sensor: Refer illustration [B]

Crank speed sensor is mounted on cylinder block near PS Pump. It locates the TDC of no.1 or 4
cylinders; ECU calculates the speed based on no. of TDC/ unit time. It is 2 wires, inductive voltage
generator pickup.
Cam Phase Sensor: Refer illustration [C]
Cam phase sensor is mounted on cylinder block near Oil filter. It locates the firing TDC no.1 cylinder.
Purpose is synchronization for sequence of fuel injection. It is 3 wires hall effect switch.
58
• WATER/ COOLANT TEMPERATURE SENSOR – R&R

Temperature Sensor mtg. bolts 01 19 mm 22 ± 2
Temperature
Sensor
Thermostat
housing
Pre removal activity –

• Battery terminal removal.
• Drain small quantity of coolant to avoid spillage.
Post fitment activity –
• Check and add coolant, if required.
• Remove NVH cover.
• Disconnect battery terminal.
• Disconnect wiring socket on temperature sensor.
• Remove coolant hose on thermostat housing connected to oil cooler.
• Remove Temperature sensor
• STARTER MOTOR – R&R
Starter Motor mtg. bolts 03 16 mm 25 ± 3
Refer illustration.
 Remove battery terminals.

 Remove connections on starter
motor.
 Remove starter motor mounting
bolts.
 Starter motor can be taken out.
59
• COOLING HOSES – R&R Refer illustrations.
A B
2
2
Removal Steps -
 Drain the coolant from Radiator assembly.
 Remove NVH cover, Fan and shroud.
 Remove radiator upper hose [B] connected on radiator as well as Thermostat [1].
 Remove radiator lower hose [B] connected on radiator as well as water pump [2].
 Follow SOP given while refilling the radiator coolant.
• VACCUM HOSES – Removal
Vacuum Hoses Removal - Refer illustration below.

1. Vacuum hose removal from Vacuum pump assembly.
2. Remove vacuum hose from Air intake clean hose.
3. Remove vacuum hose from brake booster NRV.
4. Remove vacuum hose from EGR valve assembly.
60
• RADIATOR ASSEMBLY – R&R
Front grill add on mtg. bolts 06 10 mm 10 ± 02
Bonnet lock mtg. bolts 02 10 mm 10 ± 02
Upper bracket mtg. bolts 02 13 mm 12 ± 02
A Pre removal activities –

 Remove coolant recovery tank
and drain coolant from radiator.
 Removal of hoses on radiator.
 Removals of front grill add on.
Post fitment activities –
 Refill coolant as per SOP and
check coolant level.
 Check for coolant leakage, arrest
if any.
B C
Removal Steps – Refer above illustrations.

1. Remove radiator upper LH and RH mounting brackets [refer red arrow marks]
2. Remove upper and bottom rubber mountings on LH and RH side [refer red arrow marks]
3. Take radiator assembly out from engine compartment.
Radiator Coolant Replace Procedure –
1. Ensure proper fitment of radiator assembly and all the hoses.

2. Refit the drain plugs and close drain cock on radiator.
3. Fill fresh coolant in radiator assembly.
4. Check all the hoses ensure correct fitment and no leakage from hose, clips.
5. Start engine and run at approx. 1200rpm for 2-3 min.
6. Check coolant level in radiator and add coolant as per requirement.
7. Fill coolant in the recovery tank up to MAX level.
8. Refit the radiator cap.
10. Check coolant level in radiator and coolant recovery tank and add as required.
61
• RADIATOR GRILL UPPER BRACKET – R&R
Pre-removal Activities – Refer illustration.

 Removal of NVH cover, Intercooler assembly.
 Drain coolant & remove reservoir.
 Front grill add on, horns, bonnet cable & lock removal.

1. Remove radiator bottom shield.
2. Remove radiator upper LH & RH brackets. (Do not remove radiator assembly)
3. Remove radiator grill upper bracket.
 Refit coolant reservoir and rill it with coolant.
 Check coolant leakage if any, after completion of job.
 Check bonnet lock and horns for proper functioning, after completion of job.
62
• TRANSMISSION ASSEMBLY – R&R
Bell hsg. mtg. bolts 08 05 mm 80 ± 10
Slave cylinder mtg. Allen bolts 02 05 mm 50 ± 10
NGT 520 Transmission Assembly
Gear lever -
bottom
Bell housing
Clutch shaft TM - Intermediate

plate
Drain plug
Pre-removal activities –
 Lift vehicle on four post.
 Drain TM oil.
 Drain Clutch fluid.

 Refill and check TM oil level.
 Refill Clutch fluid and do the
bleeding.
 Check Clutch pedal free play.
 Take vehicle trial to check TM gear
shifting and proper functioning.

1. Remove battery negative terminal.
2. Remove Starter motor assembly.
3. Reverse light switch connector removal.
4. Bell housing upper mounting bolt removal
5. Disassembly of Gear lever and central console
6. Propeller shaft removal
7. TM rear mounting and Cross member bolts removal
8. Bell housing bolts removal
9. Take TM assembly out of vehicle.
 Use trolley while unloading/ loading TM assembly from vehicle to avoid damages.
 Use recommended adhesive while assembling Bell housing and TM assembly.
63
• ENGINE ASSEMBLY – Removal & Refiting

Engine Assembly Removal from Vehicle
WARNING:
 Make sure that jacks and safety stands are placed properly; hoist brackets are attached
to the correct position on the engine.
 Make sure that vehicle will not roll off stands and fall while working under it.
 Make sure that engine is cold before starting removal to avoid burning injury.
CAUTION:
 Use fender covers to avoid paint surface damage.
 Hold & unplug wiring connectors carefully to avoid damage.
 Mark all wiring and hoses to avoid misconnections.
 Cover all unplugged connectors and hose to avoid interfere with other parts.
 Drain all fluids/ recover AC gas before starting engine removal activity.
 Drained fluids are to be stored safely/ discarded properly in case not reused.
ENGINE REMOVAL STEPS –

1. Park the vehicle properly on lift arm.
2. Open and remove the bonnet/ hood assembly.
3. Disconnect the battery terminals & remove the battery.
4. Remove NVH cover, radiator fan, shroud and the Intercooler assembly.
5. Put the tray below radiator and drain the coolant from radiator by opening drain cock.
Recover the coolant - if it is clean, it may reused for top up.
6. Remove the wiring socket connectors on: Oil pressure switch, Water temperature sensor,
HFM sensor, Rail pressure, Cam Phase sensor, TDC sensor, Starter motor, AC Compressor, all
Injectors and the main wiring harness connector on ECU.
7. Remove air filter hose connections and remove the filter assembly.
8. Remove hose from Turbocharger and intake manifold.
9. Remove the exhaust pipe from the Turbocharger outlet elbow.
10. Remove the oil filter using the MST 545
11. Remove heater inlet & outlet hoses.
12. Remove AC pipe connections on AC Compressor.
13. Remove Power steering pump hose connections; put tray below to avoid splashing.
64
14. Remove the starter motor assembly.

15. Remove the fuel lines from filter; High Pressure fuel Pump and injectors return line.
16. Remove hoses connected on the water pump.
17. Remove front grill add on, horns and hood lock assembly along with cable.
18. Remove radiator upper mounting bracket assembly.
19. Remove Radiator and AC condenser assembly.
20. Remove plenum appliqué along with wiper motor assembly.
21. Remove all the vacuum hose connections.
22. Remove steering intermediate shaft assembly.
23. Remove the propeller shaft assembly.
24. Remove Gear upper lever, reverse light switch connector, Speedo sensor connector on TM
assembly and remove bell housing mounting bolts from engine assembly.
25. Put trolley support below the TM assembly and remove the cross member below TM
assembly, detach TM assembly from engine and take it out safely.
26. Drain the oil from the engine oil sump.
27. Attach lifting device and wire ropes to the engine front and rear lifting hooks.
28. Put firm support below the engine for safety; remove the engine front LH & RH side
insulators mounting bolts; slowly lift the engine upward and remove both insulators.
29. Check all around the engine and compartment for any other parts required to be removed/
disconnected and remove or disconnect necessary parts, connections.
30. Support the engine with lifting device and pull out the engine from compartment.
 Make sure that engine parts or/ and body parts are not getting damaged while taking engine
out from vehicle.
ENGINE INSTALLATION –
Engine installation is in the reverse order of removal. Refit the mounts to the assembled engine
before locating it in engine compartment. Perform following checks and adjustments-
 Refill the engine oil, check and correct oil level if required.
 Refill the coolant in radiator & reservoir, check & correct fluid level as per procedure.
 Refill the TM with oil, check & correct the level.
 Refill the clutch fluid, Bleed the clutch system.
 Clean the battery posts and terminals, apply jelly/ corrosion prevent before assemble it.
 Inspect for fuel leakage after installation of fuel lines. Turn ignition switch on (do not crank
engine) so that the fuel pump will operate for 2-3 seconds and the fuel line can be pressurizes;
repeat this for two to three times and check and arrest fuel leakages.
 Attach the diagnostic tool to coupler and check for any fault code; attend the fault, correct the
connections and erase the code. If still fault code persists, follow diagnostic manual procedures
to clear the code.
65
• ENGINE OVERHAUL
WARNING:
 Make sure that jacks and safety stands are placed properly; hoist brackets are attached
to the correct position on the engine.
 Make sure that vehicle will not roll off stands and fall while working under it.
 Make sure that engine is cold before starting removal to avoid burning injury.
CAUTION:
 Use fender covers to avoid paint surface damage.
 Hold & unplug wiring connectors carefully to avoid damage.
 Mark all wiring and hoses to avoid misconnections.
 Cover all unplugged connectors and hose to avoid interfere with other parts.
 Drain all fluids/ recover AC gas before starting engine removal activity.
 Drained fluids are to be stored safely/ discarded properly in case not reused.
Removal Steps/ Procedure Illustration

Make sure that the engine is mounted
properly on work stand.
Remove the Power steering drive belt and

main accessory drive belt.
Remove the rocker cover assembly
66
Remove the High-pressure pipes and the leak

off pipe
 Loose inj. Side nut, Loose rail side nut,

Remove inj. Side nut Remove rail side nut,
Reverse for assembling.
Remove the water pump assembly
Remove the auto tensioner and idler
Remove Alternator assemblies. Remove its

bracketroy system.
Remove damper pulley. While assembly take

care that main drive pulley is assembled
correctly.
-It should be noticed that the main drive
pulley can be assembled in either direction;
however the front end is identified by holes
drilled for balancing (this is not thorough
holes). If assembled wrongly it will cause
misalignment by 5 to 6 mm.
67
Remove oil cooler lines from block to cooler

to water pump.
Remove oil breather pipes.
Remove the oil filter assembly and oil cooler

assembly.
Remove the accessory like power steering

pump
68
Remove all the injector assemblies
Bring the first cylinder into compression.
Remove the front cover
Ensure that the “O” rings on the front cover is kept securely so that it can be reused if not damaged
while reassembly
Remove the HPP mounting nut
Remove the rocker shaft assembly
69
Remove the cylinder head mounting bolts
Remove the cylinder head; it can be removed

along with the inlet and exhaust manifold/ TC
assembly
Rotate the engine
Remove the oil sump
Remove the oil pump along with the suction.

Ensure that the oil sump gasket is removed.
70
Rotate the engine by 90 degree.
Remove the oil jets along with the gaskets
Remove the connecting rod caps and take

out the pistons
Rotate the engine by 90 degree
Remove the idler gear
71
Remove the camshaft’s main bolt and the 2-

thrust plate locking bolts
Remove the camshaft
Lock the flywheel using the MST 252 and loosen the flywheel mounting bolts
Remove the flywheel
72
Remove the rear end oil seal with the

retainer plate
Remove the main bearing bolts
Remove the bearing caps along with bearing

shell halves
Remove the crankshaft
Remove the bearing shells & thrust washers
Remove the Trigger wheel (it is fitted with

help of three screws and provided with
dowel)
73
Remove the Oil pump drive gear (it is press

fitted on the crankshaft)
Rotate the engine
Remove the tappets by reversing the engine
74
• Inspection:
All the components should be inspected for wear. Any components, which are beyond the wear limits,
have to be replaced.
Over & above the wear limits, the following points also need to be ensured -
Piston: Check for scuffing/ scoring on the skirt. A hard thick layer of carbon lacquer on top land is
acceptable. (If the thick layer is present on the piston check that the liner does not have scuffing)
Parent Bore
However scuffing of the top land and skirt giving
indication of overheating which is not acceptable. No Cam
Bush
Bore: Any scoring/ scuffing on the parent bore are not
acceptable.
Crankshaft:
Check for scoring on the main as well as connecting
rod journal. If scoring is nominal and will not the
increase the oil clearance then the
crankshaft can be used in, as it is
condition. However if it is
unacceptable then the journal has
to be ground up to service limits
only.
Any deep groove in the rear end oil

seal seating area is unacceptable. It
will result in oil leaks.
Valve: If valve tip is worn out/ ridged then not acceptable.
Main bearing and connecting rod bearing — If the scoring is nominal and oil clearance is not affected,
then it can be reused. However if flaking /peeling of the bimetal in any particular zone only is present
then use new shell. Look for foreign particle embedded, deep scratches.
Dampener pulley rubber bonding – inspect for any gap between the rubber ring and the outer/inner
ring, Cracks on ring. Any deep groove in the front oil seal seating area is unacceptable. It will lead to
leakages.
If any deterioration of rubber or gap noticed between the ring and the rubber replace the dampener
pulley.
It is suggested that the dampener pulley be replaced at every 3,00,000 Kms.
While measuring the inner diameter of the connecting rod big end and main journal
please take the measurements after torque tightening only. For measurement
purpose the torque should be 35 Nm ± 60°. Do not reuse this bolt.
75
• Assembly –
The assembly sequence is the reverse of the dismantling procedure. To obtain a good life of the rebuilt
unit absolute cleanliness of the parts is taken as a prerequisite and also the fact that all the parts have
been inspected. The additional points which are mentioned are necessary to give you the engine life
same as the original engine.
Bolts: The following bolts are recommend to be replace every time they are opened-if the Maximum
length exceeds the specification. However the connecting rod bolt has to be changed every time
without exception.
The bolts have to be tightened by base torque then 2 stage angular torques. The angular torque’s
ensures that the bolts are torque tightened up to yield point. And the 2 stage ensures that the
clamping load for each bolt is within a very close tolerance.
Cylinder head bolts - 16 no: Maximum length 129.5mm
Main Bearing Bolts - 10 no: Maximum length 85.0 mm
Connecting rod bolts- 08 no: Replace every time, once removed.
Flywheel bolts – 06 no: Maximum length 32.0 mm
Cylinder block – Top face --

Ensure that the tapping for the
cylinder head bolt as well as the
crankshaft’s main journal is fine.
Ensure that no water or oil after
cleaning is in the bolt holes
(especially in the cylinder heads.)
Remove it, if observed. Use
cotton cloths instead of using
cotton waste.
If the oil /water are not removed then it is possible that while tightening the bolt. It may not allow
complete tightening of the bolts and one will get a false reading. The block does not have serviceable
liners.
Cylinder head gasket –

It is a multi layer steel gasket type. Do not use any oil or shellac on the cylinder head gasket or on the
block face or the cylinder head face. The gasket has to be fitted dry.
Ensure top face positioning of gasket while assembling. It is suggested that the face with the marking
and numbers should be facing up. Refer illustration below.
76
Piston & Rings –

While fitting the piston rings ensure that the rings end gap are
staggered in 120°. The first ring end gap should not be on the thrust axis
but the minor axis i.e. on the gudgeon pin axis. Please note that the first
ring is keystone shaped hence the top mark has to face up. The 2nd ring
is taper faced. The face, which should be on the top, has to be facing up.
The 3rd ring is the conformable type oil ring. It can be assembled either
way.
While assembling the piston on to the liner- apply clean oil liberally on
the liner surface.
Bearing shells –
Before fitting the bearing shell ensure that the parent bore of the
block/connecting rod are clean.
Wipe with a clean cloth the back end of shells before assembling on to
the block or connecting rod. Ensure that the bearing shells are located
properly in the notches.
Valve Train System/ HLLA –

 Check the rocker arm assembly for sponginess.
- If the HLA element can be easily pressed & if it doesn’t show
spring back action, reject it. This is due to leaking of oil during
transit
 Assemble acceptable rocker arms on engine.
 Run the engine on low idle for 4 to 5 minutes.
 Observe for tappet noise.
Cut section of HLLA
Plunger
Housing
Completely filled
with oil
Oil Reservoir Chamber

(Above Check Valve)
High Pressure Chamber

(Below Check Valve) Ball head
77
Oil seals –
Ensure that:
 Correct position of oil seal.

 All the oil seals are fitted using the dolly MST.
 Always ensure that the lip is coated with grease before fitment.
 Apply engine oil on the outside diameter of seal. The receiving
bore should be free of burrs, dent.
Testing –
After the engine is reassembled in the engine stand; it is recommended that: The engine is assembled
back to the vehicle. All the connections are made.
 Start the engine.

 Run at idle for 5 minute. Observe for leaks.
 Drive the vehicle at 50% of the max. speed in each gear for about 10 to 30 Km each (Aprox.)
 Hand over the vehicle to customer to drive with speed limitation for 2000 Kms.
 After 5000 Kms. Check the coolant. Change the engine oil and oil filter.
 Do not run the engine without load for hours for bedding in. this process only harms
the engine
 Running the engine without load cause ring fluttering and damage to rings as well as
liners.
 Running the engine at idle for prolonged time has serious consequences on major
engine component.
78
• Working principle of Crankcase Ventilation System –
The ventilation system is closed ventilation type. A

hose connects the crankcase to the oil separator. The
oil separator is a labriyanth type as well as cyclone
type integrated with rocker cover. The oil goes
through the labriyanth, the oil collected drops down.
The excess pressure acts below the diaphragm. The
diaphragm is acted from below by the crankcase
pressure and from top the suction by air cleaner. A
spring also acts on top of the diaphragm. Once the
pressure exceeds the diaphragm lifts and the excess
crankcase pressure goes to the air intake system.
Certain amount of oil will be carried from the oil

separator to the Air inlet hose, which is normal.
However if it is excessive please look for all the causes
mentioned in the high blow bye.
Oil circulation system –
An external gear type pump sucks the oil through the

strainer. The oil pump is driven by the gear, which is
mounted, on the crankshaft.
The oil pump delivers pressurized oil to the supply

bore in the block. This oil is delivered to the oil cooler
and after getting cooled comes on the outer side of
the element. The filtered oil goes through the centre
of the oil filter and is connected to the main oil gallery.
The main oil gallery runs to the front of the block
79
where it is delivered to the timing cover. From therein it takes a small loop in the timing cover and
again comes to the front of the block. Goes to another oil gallery. Oil from this gallery supplies oil to
the piston cooling jets
Oil from the main oil gallery goes to the crankshaft main journal and camshaft, while from the rear
end it is supplied to the alternator’s vacuum pump. The oil supply for the turbocharger is from the oil
filter bracket.
The oil routed from the main oil gallery lubricates the timing gears and the idler gear bush. Part of this
oil gets sprayed from idler shaft hole. The camshaft gear and the thrust plate are lubricated by engine
oil routed from the first camshaft bore through the camshaft hole.
The oil from the First camshaft bore goes to the top of the cylinder and enters an oil gallery, which
extends up to 110 m from the front. Oil from this gallery comes to the base of the second rocker shaft-
mounting bracket. The oil then enters the rocker shaft. Oil enters the rocker bushing at through two
holes facing the bottom half. At the same time it sprays from the oil hole at the side of the rocker to
lubricate the valve stem and the surfaces over which the valve cap slides. The oil then returns to the
sump through the push rod holes in the cylinder head.
In both the oil cooler and oil filter, bypass valves are provided which operate if the differential
pressure exceeds 0.8 bar.
Oil filter bracket & pressure relief valve in oil filter bracket is deleted. Crack opening pressure of relief
valve in oil pump has been reduced from 6 bar to 4.5 bar. Oil pressure sensor, is mounted on main oil
galleries (which is on exhaust side.)
Oil gallery is drilled from front bottom side for oil supply to hydraulic tensioner. This oil gallery is
plugged by M9 tapered plug from bottom side.
Oil supply to turbo charger is from opening in exhaust side main oil gallery.
80
• Refer below layout for oil flow diagram in mDI CRDe engine.
Rocker shaft
Idler gear
To alternator
1
vacuum pump
Main bearing
2
Oil jet
Cam bearing
3
Main Oil gallery
Main PRV
4
Oil filter
bypass Oil
filter
5
Safety
Valve
Oil filter Supply to

Pump
bracket Turbocharger
Strainer
81
• Specifications & Wear Data –

Figure Description Value
Bore 88.9 mm
Stroke 100.3 mm
Power- Max 75 BHP @ 3200 RPM
Torque-Max 220 Nm@1400-2600 RPM
Firing Order 1-3-4-2
Direction of rotation Clockwise from fan side
Compression Pressure Standard

30 bar
Piston Re-entrant Bowl
Piston Pin Full floating. Surface hardened & ground.
Oil grade & Quantity API Grade CH4

Viscosity Index 15W40
6.0 litres
Maximile Crown
Cylinder liner N.A.
82
Tappet clearance (Cold)

Inlet
Not required since HLA is used.
Exhaust
Oil filter bypass opening 0.8 bar

pressure
Oil pressure at -
Idle ( 60∼80°C) 1.5 bar (Idle)
Max speed( 60∼80°C) 4.0 bar (Max)
Piston ring end gaps Standard
1st ring 0.25 / 0.45

2nd ring 0.45 /0.60
3rd ring 0.25 /0.50
Gudgeon pin O.D φ 30 / 29.995
Connecting rod – Small end Standard

bush I.D φ in assembled 30.046 /30.025
condition
Gudgeon pin to connecting rod Standard
small end bush clearance. 0.046 / 0.025
Gudgeon pin to piston pin hole Standard

clearance 0.019 /0.0007
Connecting rod grading as per

weights
A 1.05 – 1.054
B 1.055 – 1.06
C 1.061 – 1.065
D 1.066 – 1.07
E 1.071 – 1.075
F 1.076 – 1.08
G 1.081 – 1.085
H 1.086 – 1.09
I 1.091 – 1.095
J 1.096 – 1.1
K 1.101 – 1.105
L 1.106 – 1.110
M 1.111 – 1.115
N 1.116 – 1.12
83
O 1.121 – 1.125
Recommended for service
replacement
Connecting rod end play Standard Service Limit

0.15 / 0.35 0.5
Crankshaft end play Standard Service Limit

0.1 0.3 0.5
Camshaft end play Standard Service Limit

0.2 / 0.4 0.4
Liner projection from Parent bore Type

crankcase top surface
X Axis- Along C/s Standard Limit

Y Axis- Perpendicular to
cranks shaft φ ID 88.9 (+0.018)
Roundness/Ovality- Difference
in X & Y plane at any pt. Roundness ≤ 0.06
Cylindricity/Taper -Difference
in same plane x/y at any point Cylindricty ≤ 0.01
X-axis
Crankcase top surface Flatness Standard

0.05
0.03 / 100 mm
Cylinder head bottom face Standard
distortion 0.05
Height of cylinder head from Standard

top to bottom face 95.504 / 95.250
Rocker lever bush I.D ( in 22.0 / 22.02

pressed condition)
84
∅ Rocker shaft O.D 21.959 / 21.980
Rocker to shaft clearance Standard

0.02/0.061
Push rod bent Standard

≤ 0.25
Valve spring Standard

Free Length 54.16
0.80
Squareness 302.7 N/42 mm
Installed Load/Installed length
Valve seat angle 44°45′ to 45°
Valve stem O.D

Inlet 8.695 / 8.710
Exhaust 8.675 / 8.690

Valve to Valve guide clearance
Inlet
0.030 / 0.065
Exhaust
0.050 / 0.085
Thickness of the valve head Standard
Inlet 3.25 / 3.65
Exhaust 3.55 / 3.95
Pitch-3/8”,Duplex bush type

Chain 102 Links, Endless & Riveted.
Crank Sprocket 18 Teeth
Idler Sprocket 36 Teeth
HPP Sprocket 36 Teeth
85
Difference between Cam Standard

height & base circle diameter
Inlet
Exhaust 6.28
6.30
Camshaft Bush I.Dφ No Bush
Camshaft Journal O.D No Bush

Camshaft hole in block to cam Standard
journal clearance 0.05 / 0.100
I.D of tappet hole in crankcase

14.631
Tappet to tappet hole Standard

clearance 0.012 / 0.080
Crankshaft pin Standard
Roundness / Ovality ≤ 0.005

Cylindricity /Taper ≤ 0.008
Main Bearing oil clearance Standard

0.031 / 0.091
Crankshaft journal Standard

∅ OD 53.994 / 53.980
Roundness/ Ovality ≤ 0.006
Cylindricity/ Taper ≤ 0.005
Crankshaft Hardness Minimum 50 HRC
Connecting rod Bearing oil Standard

clearance 0.025 / 0.046
86
The Maximum length of bolts

after which they can not be
used
Cylinder head bolts Replace every time

Main Bearing Bolts Connecting Replace every time
rod Replace every time
Flywheel bolts length Replace every time
Thermostat
Starts opening at 90~94°C
Fully opens at 98°C
Water pump pulley ratio 1.29
Flywheel 37.02 ± 0.5

Width from Mounting face to
clutch face
Flywheel Standard Service Limit

Flatness ≤ 0.05 0.1
Run-out ≤ 0.05 0.1
87
 Engine parameters with values-
PARAMETER VALUES
Crank shaft end play (mm) 0.1 ~ 0.3
Cam shaft sprocket end play (mm) 0.2 ~ 0.4
Idler sprocket clearance (mm) 0.2 ~ 0.4
Connecting rod bug end clearance (mm) 0.15 ~ 0.35
Intake valve recess from head joint face (mm) 0.7 ~ 1.1
Exhaust valve recess from head joint face (mm) 1.0 ~ 1.4
Block joint face to ROSR face projection (mm) ± 0.10
Block joint face to front cover face projection (mm) ± 0.10
Valve timing – Inlet opening 41° BTDC
Valve timing – Inlet closing 81° ABDC
Exhaust Opening 76° BBDC
Exhaust Closing 56° ATDC
Injector projection (mm) 2.5 ~ 3.0
BS3 (mm) 2.5 ~ 3.0
Oil quality (lit.) 6.0
Piston projection above top of crankcase face 0.35 ~ 0.65
Front oil seal runout (mm) 0.25
Rear oil seal runout (mm) 0.25
Crank rotation torque (non-max)
When main bearing caps & conn rod bearing caps are assemble & torqued 25
– bearing first & forth position to TDC. Measure the rotational torque
required to rotate the crankshaft by one rotation
• Lubricants & Sealants –

Mahindra Maximile Crown Or any other engine oil conforming to API grade CH4 or above and a
viscosity Index of 15W 40. If any oil conforming to CG4 grade is used then the oil change interval is
7000 Kms. Oils of MIL 2104 C or below are not acceptable
RTV silicone sealant - RHODOSEAL. Part number 0024532 to be used:

 Between Rear oil seal retainer & Block
 Between ladder frame & block
All other places Loctite 547. Part number 0084337 is used. Hard gaskets are used only at: -
Cylinder head Gasket.
 Exhaust manifold to EGR pipe  Exhaust manifold to cylinder head.
 EGR pipe to elbow.
Rust cleaning solution:
Brand Name: WD-40---
Manufacturer- WD-40 COMPANY
MARKETEDBY—Hardcastle & Waud Manufacturing Co. Ltd.
Brabourne Stadium,
87, Veer Nariman Road, MUMBAI-20.
88
• Tightening Torque’s -
Description Thread Size Torque Value Quantity

Crankcase
Main Bearing cap M12 X 1.5 60 Nm + 90° 10
Nipple Oil Cooler Inlet M16 X 1.5 32±3 Nm 1
Piston Oil jet Flange bolt M6 X 1.0 10 ± 1 Nm 4
Flange bolt - ROSR M8 X 1.25 25± 3 Nm 4
Flange bolt – Ladder Frame M8 X 1.25 25± 3 Nm 6
Cylinder Head
Bolt - Cylinder head M11 X 1.5 60Nm+ 60°+ 60° 16
Stud - Cylinder head M10 X 1.5 35 ± 5 Nm 4
Stud integral exhaust manifold M10 X 1.5 35 ± 5 Nm 4
Stud intake manifold short M8 X 1.25 25 ± 3 Nm 6
Crankshaft
Speed Sensor M6 X 1.0 8 ± 1 Nm 1
Screw Trigger Wheel Mounting M8 X 1.25 15 ~ 20 Nm 3
Crankshaft Pulley
Cranks shaft pulley M14 X 1.5 190 ± 10 Nm 1
(apply oil on bolt before tightening)
Connecting Rod
Connecting rod cap Mounting bolts M9 X 1.0 35 Nm+ 60° 8
Oil Pan
Flange bolt Crankcase M8 X 1.25 25 ± 3 Nm 16
Flange bolt Front Cover M8 X 1.25 25 ± 3 Nm 2
Flange bolt ROSR M8 X 1.25 25 ± 3 Nm 2
Front Cover
Flange bolt - Crankcase M8 X 1.25 25 ± 3 Nm 17
Flange bolt – Vacuum Pump M8 X 1.25 25 ± 3 Nm 3
Rocker Cover
Screw socket M6 X 1.0 5.5 ± 1 Nm 11
Flywheel
Bolt Flywheel M12 X 1.5 45 Nm + 60° 6
Cam Shaft
Bolt Flange M8 X 1.25 25 ± 3 Nm 2
Phase sensor M6 X 1.0 8 ± 1 Nm 1
FEAD & Chain Drive
Flange bolt Idler Pulley M10 X 1.5 30 ~ 35 Nm 1
Flange bolt Auto tensioner M10 X 1.5 35 ± 3 Nm 1
Flange bolt Idler sprocket M6 X 1.0 9 ~11 Nm 1
Hydraulic Chain tensioner M6 X 1.0 Gr. 8.8 9 ~11 Nm 2
Chain Guide M6 X 1.0 13 ~ 15 Nm 2
Chain Oil jet M6 X 1.0 11 ~ 13 Nm 1
Belt tensioner main drive Installation 135 Hz Stabilized 114 ± 5 Hz.
Belt PSP drive Installation 246 Hz Stabilized 207 ± 5 Hz.
89
Valve Gear Train

Flange bolt extreme bracket M8 X 1.25 25 ± 3 Nm 2
Bolt oil bracket M10 X 1.5 30 ~ 40 Nm 1
Spring washer & Nut pedestal M10 X 1.5 30 ~ 40 Nm 4
Flange bolt Oiler bracket M6 X 1.0 9 ~ 11 Nm 1
Intake Manifold
Flange bolt M8 X 1.25 25 ± 3 Nm 6
Hex Nut Flanged M8 X 1.25 25 ± 3 Nm 6
Exhaust Manifold
Flange clinch nut M10 X 1.5 30 ~ 40 Nm 4
Engine support
Special bolt engine mtg. M12X 1.25 90 ± 10 Nm 8
Bolt engine lifting M8X 1.25 25 ± 3 Nm 4
Oil filter & oil level gauge
Dip stick guide nut 15 ~ 20 Nm 1
Dip stick mounting bkt M8 X 1.25 25 ± 3 Nm 1
Oil pump gear train
Flange bolt oil pump mtg. M10 X 1.5 49 ± 5 Nm 2
Strainer and pipe screw
Screw hex M6X 1.0 10 ± 1 Nm 2
Water Pump
Flange bolt crankcase M8 X 1.25 25 ± 3 Nm 5
Thermostat housing
Flange bolt - cylinder head M8X 1.25 25 ± 3 Nm 3
Flange bolt – thermostat cap M6 X 1.0 12 ± 2 Nm 3
Temperature sensor M12 x 1.5 22 ± 2 Nm 1
Oil Pressure Switch or Gauge
Oil pressure switch M12 X 1.5 15 ~ 20 Nm 1
Oil line engine
Banjo bolt TC oil inlet/ outlet M12 X 1.5 15 ~ 22 Nm 2
Nipple TC oil drain M16 X 1.5 32 ± 3 Nm 1
TC oil drain pipe M6 X 1.0 9 ~ 11 Nm 2
Flange bolt M6 X 1.0 9 ~ 11 Nm 2
Fuel Injection Pump
Screw 20AC 8.8Z5F M7 X 1.0 20 ± 2 Nm 3
HPP Pump end 20 ± 2 Nm 1
HPP Rail end 21 ± 2 Nm 5
HPP Injector end 27 ± 2 Nm 4
Bolt FIP adaptor M8 X 1.25 25 ± 3 Nm 3
Fuel injector nozzle
Clamp injector holder M8 X 1.25 25 ± 3 Nm. 4
Emission control system
Flange bolt EGR valve mtg M8 X 1.25 25 ± 3 Nm 4
Flange bolt EGR end M8 X 1.25 25 ± 3 Nm 2
Allen bolt exhaust end M8 X 1.25 25 ± 3 Nm 2
90
Engine oil cooler

Stud oil cooler mtg M20 X 1.5 20 ~ 25 Nm 1
Oil filter cartridge M20 X 1.5 10 ~ 12 Nm 1
Heat shield oil cooler mtg M6 X 1.0 9 ~ 11 nm 2
Engine oil cooler tube
Flange bolt M6 X 1.0 9 ~ 11 Nm 4
PS Pump
Flange Bolt Bracket Mtg M8 X 1.25 25 ± 3 Nm 4
Bolt PS pump mtg M8 X 1.25 25 ± 3 Nm 2
Alternator
Bolt Alt mtg on AC comp bkt M8 X 1.25 25 ± 3 Nm 1
Bolt Alt mtg on Idler bkt M8 X 1.25 25 ± 3 Nm 1
Plugs
2-X holes, 2Top FIP flange & 1 Bottom tens M10 X 1.0 10 ~ 15 Nm. 5
2AOG, 2MOG & 1 st X M13 X 1.5 18 ~ 22 Nm 5
Water drain plug M12 X 1.5 40 ~ 50 Nm 1
91
• Special Tools (mDICRDe Engine) –
Description / Part No. / Sketch Usage View

Lock Pin for Chain Tensioner
MST 273
Extractor Flywheel Bearing

MST – 543
Drift Flywheel Bearing

MST – 544
High Pressure Fuel Pump Removal

MST – 0305BAC0008ST
92
Air Intake System
Contents…
• Description……………………………………………………………………………. 94
• Trouble Shooting………………………………………………............... 96
• Care of the System….…………………………………………………………… 97
• In Car Repairs………………………………………………………………………. 98
• Specification…………………………………………………………………………. 106
• Tightening Torques…………………………………………………………….. 106
93
• Description -
The air is sucked through a foam type air cleaner. The air enters the air cleaner housing at the bottom
and leaves at the top.
The air cleaner is made up of 5 different layers of foam. Each layer is having different cleaning
Air Filter Assembly HFM Genio – Air Intake System (BS-III)

Breather Hose
Air Intake Hoses
Air Intake –
dirty hose
Air Intake
Pipe & Hose
Dummy Pulley
efficiency.
After filtration the air goes to the turbocharger.
A HFM sensor is attached to the outlet of the air cleaner. The air to the turbocharger passes through
HFM. The HFM measures the air mass going to the engine. The quantity of the air going is used to
compute the fuelling. The HFM also measures the air temperature
After the HFM and before turbocharger there is a service indicator. In case of choked air cleaner the
red indicator will appear.
The waste gated turbocharger controls the boost to 1.6. In Genio BS-III engines, the compressed air is
supplied to engine through intake pipe, hose and intake manifold. EGR valve is mounted on the intake
manifold.
94
In Genio BS-IV engines the compressed air is cooled by the charge intercooler, which is mounted
above the engine, covered by NVH cover. The cooled air enters the inlet manifolds. It enters the Cast
iron cylinder head through the inlet valves having a 45-degree angle.
Genio – Air Intake System (BS-IV)

Intercooler Assembly
Hose Intercooler
Inlet
Hose Intercooler
Outlet
Turbocharger
Assembly EGR Assembly
Exhaust Intake Manifold
• NOTE: The intercooler assembly applicable for Genio mDI CRDe BS-IV engine only.
95
• Trouble Shooting –

Engine does not Air intake obstructed  Check whether service indicator light glows
start & emits black or red band appears and replace element if
smoke light is on /red band appears.
 Refer to the care of the system also
 Check for free operation of Turbocharger
Engine does not 1. Air intake restricted.  Replace element
give full power. 2. Air leaks in system after  Plug the leaks, replace hose or clip if
turbocharger required.
3. Air leak in pipe –  Replace the hose or tighten
manifold to FIP
4. Boost pressure control  Correct the control valve & find the cause
valve stuck in open
condition.  Check the pipe, washer & rectify.
5. Boost pressure pipe/hose
assembly damaged  Get the Turbocharger repaired at
6. Turbocharger damaged. authorized TEL dealer.
Black smoke. 1. Air intake restricted.  Check for hoses, replace element.
 Check for leaks between Turbocharger &
2. Air leaks. inlet manifold
 Remove restriction or replace parts.
Excessive oil 1. Clogged air filter  Replace element.
consumption element.
to compressor duct.
3. Air leak between the
Turbocharger to intake  Locate the leaks, change hose or clamp if
manifold. required.
4. Restrictions in
turbocharger drain line.  Remove the restriction in the drainpipe.
5. Restriction in crankcase
breather.  Check the crankcase ventilation & rectify.
6. Thick oil/sludge or coke  Change oil, filter, service the Turbocharger
in the turbocharger’s & use recommended oils & drain intervals.
central housing Follow the recommended procedure while
shutting down.
7. Turbocharger damaged.  Repair Turbocharger.

Whining noise • Indication of air leak esp.  Tighten the clamps at the intercooler inlet
clearly audible in between: and outlet.
after 2000 RPM Turbocharger to inlet  Tighten the clamps at the Turbocharger
manifold. inlet & outlet.
 Check the hoses for leak.
 Check & replace the pipe to and from
intercooler.
96
• Care of the System
The air cleaner element should be replaced every 60,000 KMs or if service indicator light glows under
normal driving conditions.
Under extremely dusty conditions replace earlier than above.
It should be noted that if the engine is run with clogged air cleaner, then it will lead to seepage of oil
from turbocharger into the air intake system.
Ensure that the recommended engine oil only is used and the specified drain intervals are maintained.
To achieve an optimum cooling of the compressed air it is vital that the vehicle’s number plate
position is not changed and/ or an oversize number plate does not block the aperture for the air draft
for the intercooler.
The Turbocharger & boost control valve does not require any special maintenance. However check the
boost pressure pipe for proper fitment (connection from compressor to boost valve). Damage, cracks,
chips at ends, etc.
Check the operation of the waste gate valve by blowing compressed air with 2.0 bars in the valve
hose. The valve should open, pressing the turbocharger stem and opening the exhaust valve (flap
valve)
Check the oil separator system, in particular for any leak in vacuum leak. As any vacuum leak will lead
to a high-pressure build up and then it will go through the intake system and give a signal of high blow
by or be confused with compressor oil leak.
97
• In Car Repairs
This section consists of –
• Air Cleaner Element Removal
• Intercooler Assembly Removal
• Turbocharger / Exhaust Manifold Removal
• Intake manifold
98
• AIR FILTER ELEMENT- REPLACE
 Air filter top cover allen bolt 07 6 mm 4.5 ± 0.5
 Hose clamps – air cleaner side 02 11 mm. 2.5 ± 0.5
 Hose clamps – manifold side 02 11 mm. 4.5 ± 0.5
A B C
5
2
1 3
4
1
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 and in case
vehicle runs in very dusty condition replace air filter cartridge at 40000kms.
99
• INTERCOOLER* ASSEMBLY – R&R

(* applicable for GENIO mDI CRDe BS-IV engines only)
 NVH Cover mtg. bolt 03 10 mm. 07 ± 02
 Intercooler mtg. bolts 03 13 mm. 22 ± 02
 Hose clamp 04 7 mm. 05 ± 0.5
 Intercooler bracket mtg. bolts 04 12 mm 20 ± 02
Mounting
locations
NVH Cover
Oil filling
spout
location
Mounting Locations
Removal Steps –
Intercooler Intercooler Assembly
bracket
mtg. bolts 5. Remove intercooler hoses.
Intercooler 6. Remove intercooler assembly.
Mountings Refitting Procedure –
6. Before installation check the hoses
for crack or distortion.
7. Hoses can be cleaned by air
pressure before refitting.
8. Refit intercooler assembly.
9. Connect Intercooler with intake &
outlet hoses and connect other
end of hoses to TC and Intake
manifold respectively.
10. Refit the NVH cover assembly.
 Intercooler has bracket support on
its RH side it is mounted with help
of 04 bolts fixed to the intake
manifold.
100
• TURBOCHARGER or EXHAUST MANIFOLD – R&R

 Flange Clinch nut 04 17 mm 35 ± 03
 Tail pipe mtg. nut 03 13 mm 35 ±03
 TC oil supply banjo 01 10 mm 15 ±02
 TC oil outlet pipe mtg. bolt 02 10 mm 15 ±02
 TC oil adaptor on crankcase 01 22 mm 30 ±03
Removal Steps – Refer illustrations shown.

1. Remove NVH cover & intercooler assy.
2. Remove Air cleaner assembly to get more
TC Oil inlet Pipe access to remove TC assembly.
3. Remove TC suction hose.
4. Remove exhaust tail pipe fitted on TC turbine
Heat
end.
Manifold shield
gasket 5. Remove TC oil supply and oil outlet banjo &
pipes assy.
6. Remove Turbocharger assembly.
1. Replace gasket & Refit TC assembly on cylinder
head.
2. Replace washers, gaskets & reconnect oil
EGR pipe supply & outlet banjo and pipes on TC
gasket assembly.
3. Refit exhaust tail pipe to TC turbine.
4. Refit TC suction hose.
5. Refit Air cleaner assembly.
TC Oil outlet Pipe 6. Refit intercooler assy. & NVH cover.
7. Check for no exhaust gas leak.
Different
Views of TC
Assembly
 Always replace gasket fitted on TC oil outlet pipe whenever it opened.

 Do not apply sealant on oil supply line joints of TC; it may block the oil supply.
 Check and ensure for no oil leak from any joint on oil supply & return pipe.
 Keep air intake hose clips intact to avoid foreign material/ body entry in intake
system.
101
• INTAKE MANIFOLD – R&R
 Intake manifold mtg. bolts/ nuts. 06 + 06 12 mm. 25 ± 03
Removal Steps –
1. Remove NVH cover and intercooler

assembly.
2. Remove EGR valve assembly.
1. Remove all high pressure fuel lines.
2. Remove wiring socket connector on
CR assembly & remove CR assembly.
3. Remove Intake manifold assy.
1. Clean manifold & its mounting surface on cylinder head.
2. Replace manifold gasket with new.
3. Refit intake manifold.
4. Refit EGR assembly, ensure to clean the face and replace gasket with new.
5. Refit CR assembly and replace all fuel lines with new.
7. Check for air leak, if any.
 Replace the manifold gaskets as and when opened.

 Check and correct leakage from EGR assembly or manifold mounting.
 Refer below chart for intake manifold mounting bolt tightening sequence -
102
• Intake Manifold Mounting Bolts Tightening Sequence -
103
• Working Principle, Inspection & Fitment procedures of the Turbocharger –
The Turbocharger is basically an axial inflow air compressor, which is driven by an exhaust gas driven
turbine. The exhausts gases coming out of exhaust manifold impinge on the turbine blade give the
drive to turbine shaft. At the other end of the turbine shaft the compressor is assembled. The whole
assembly is supported on a floating bush. The bush gets an oil supply directly from the engine and has
oil film between the shaft and bearing as well as the bush and the central housing.
The exhaust gases from the Turbine impinge on the turbine blade & rotate the shaft. The compressor
blades at the other end suck the air from the air filter. After compression the temperature of the
compressed air increases thus reducing the air density. Hence if the air is cooled and then the air
density increases thus helping in getting more power as well as improve emissions. The compressed
air is sent to the intercooler, which is mounted on the top of the engine. Hence the incoming ram air
through the scoop on the bonnet also cools the compressed air and gives it to the intake manifold.
The turbocharger is matched to give an optimum boost for the desired engine speed band. A vacuum
controller controls the boost. Also the boost pressure sensor mounted on the Intercooler Outlet pipe
monitors the boost.
Inspection
o Inspect the suction side (i.e. up to the air cleaner) for oil traces. In a close crank case
ventilation system it is normal to have oil in this area. These oil particles are carried from blow
bye of the engine, which gets condensed from gas to oil. Look for any undue gumming of oil,
hard carbon particles in this area. If such an observation is present then all the causes for
excess blow symptoms have to be checked and eliminated.
o Inspect the compressor and turbine blades for any damage caused by foreign object. The
inspection can be done through the compressor housing inlet and turbine housings outlet.
o Inspect the blades outer edge and observe if any rubbing marks are noticed on the housing.
o Rotate the shaft wheel assembly by hand and check for freeness, and any binding.
o Push the shaft to side and rotate to check for wheel rub. It should turn smoothly.
o Lift both end of shaft up and down at the same time and feel for excessive journal bearing
clearance. If clearance is normal then very little shaft movement will be detected.
 If all the above checks are satisfactory then the turbocharger can be reused.
 If the turbocharger parts are damaged, wheel rubbing marks present, shaft not rotating
freely or binding or excessive journal clearance then the Turbocharger should be serviced.
o Do not attempt to service or overhaul the Turbocharger. It should be done only at the
authorized manufacturer service/ Turbo Energy Ltd service center. Any attempts to attend
without the use of special tools or procedure can damage to turbocharger or personnel.
104
• Turbocharger Installation –
Do not mishandle, tumbled, drop or keep any ports open.
Check
The inlet connection & outlet exhaust connection to turbocharger for foreign material, cracks,
blockages, sand particles, loose nuts etc. This check should be done more thoroughly if any damage
has been noticed in compressor or turbine blades as under normal operating conditions the blades
can damaged only if a foreign object hits them.
Check all the hoses and pipes from turbocharger outlet to intercooler and intercooler to inlet manifold
for crack, aging, leaks. Check the hose clips for proper functioning. If in doubt – replace. The oil supply
pipe should be checked carbon deposits, crack, distortions etc. Clean the supply pipe before fitting. Do
not attempt to change the orientation of turbocharger and ensure the correct gaskets are used.
Do not reuse any of metallic gaskets even if they appear to be good. It will lead to leakage & drop in
the performance of the engine.
Installation –
Once a new turbocharger is being installed
a. Fill fresh clean oil from the oil supplies port and after that give the shaft few rotations.
b. Fit the supply pipe.
c. Crank the engine till a steady stream of oil comes out through the drain pipe.
• Do not crank the engine for too long.

• Excessive cranking will result in emptying of the pump cavity causing the plunger to run dry.
This will ensure that the oil supply line to Turbocharger is purged of any air pocket.
d. After this fit the return line from turbocharger to sump, taking care to avoid any kinks. With
engine running condition, check the air, exhaust and oil connections for leaks.
105
• Specifications –
Description Value
Turbocharger Model K 04
Turbocharger specifications K0 4-2075 ECD5.82
Turbocharger supplier Turbo Energy Ltd.
Air velocity between the Air filter compressor inlet 35 M/sec
Air velocity between the compressor outlet and the inlet 50 M/Sec (Max)
manifold
Maximum static back pressure at downstream of turbine 60mbar
Oil pressure at upstream of turbocharger 2.5 bar
• Tightening Torque’s –
Bolt location
Torque in Nm
Turbocharger Mounting stud/ nut 25 ± 3 Nm
Inlet manifold 25 ± 3 Nm
Air cleaner top cover bolts 4.5 ± 0.5 Nm
Air filter top cover allen bolt 4.5 ± 0.5 Nm &
2.5 ± 0.5 Nm
Hose clamps – air cleaner side 2.5 ± 0.5 Nm
Hose clamps –manifold side 4.5 ± 0.5 Nm
106
COOLING SYSTEM
Contents…
• Description………………………………………………………………………………….. 108
• Trouble Shooting…………………………………………………………………………. 110
• Care of the system……………………………………………………………………… 113
• In Car Repairs…………………………………………………………………………….. 115
• Dismantling & Assembly of the Cooling System …………………….. 117
• Specification …………………………………………………………………………….. 123
• Tightening Torques……………………………………………………………………. 123
107
• Description
The cooling system is designed to cater to the following functions:

- Remove & dissipate excess heat from the combustion process.
- To maintain the optimum temperature for complete and uniform combustion.
- To provide cooling for the EGR system.
 Refer below illustration for cooling system structure in GENIO mDICRDe -
GENIO mDICRDe Cooling System -

Coolant
Reservoir
Radiator Inlet Hose

Cap
Radiator
Drain Outlet Hose

Oil Cooler
Hoses Cock
The cooling system includes the following components/ sub system:

 Radiator  Engine Oil cooler & hoses
 Radiator Pressure cap  Thermostat
 Coolant  Thermostat housing, cover and
 Electric fan thermostat.
 Water pump drive  Recovery tank
 EGR Cooler  Hoses & their clamp.
108
In cooling system coolant flows from Pump to the cylinder block and from the block to the cylinder
head and then to the bottom of thermostat. In case the thermostat is closed, coolant goes through the
bypass tube to pump. Once the thermostat opens the coolant goes to the radiator and after getting
cooled the coolant is again fed to the pump. One pipe goes from the water pump housing to the EGR
cooler and the return from EGR cooler is connected to thermostat housing.
Water Pump
The coolant from the outlet elbow of the cross flow type radiator enters the inlet of the pump. The
centrifugal pump delivers the coolant to the cylinder block. The Pump housing is made of CI. Pump &
thermostat housing by pass is connected by outside hose.
Thermostat
Thermostat
housing
Valve body
EGR Cooler
Hose from
Thermostat to
Pump
Water
Pump
Cylinder block & cylinder head

In the block the coolant enters a main cooling passage which runs along the length of the block in one
side (inlet manifold side). The top passage ensures that the maximum cooling is provided to the
hottest zone of the cylinder bore/ liners i.e. the top portion.
At the same time a passage at the front end connect the inlet to another gallery at the bottom of the
bore/ liner. In between the top and lower passage in the block the coolant flows between the block &
liners due to the thermos siphon effect. The coolant then goes to the cylinder head and from there to
bottom of the thermostat. One external pipe from the back end of the block goes to the oil cooler. The
return pipe form the oil cooler is connected to the inlet of the pump.
Radiator & No loss tank -

The radiator cap controls the system pressure to 0.9 bars. Once the pressure exceeds 0.9 bar the cap
lifts off the seat and the coolant is allowed to escape into a no loss tank.
As the engine cools down the system pressure falls and vacuum is formed .The vacuum valve in the
radiator cap opens and allows the water from the no loss tank to go back into the radiator. Thus the
system does not have any coolant loss during normal operation.
109
• Trouble Shooting -
Before going into the specifics of the cooling system it is worthwhile to find out under which driving
conditions the complaints is present.
Some of the causes are:

1. Prolonged /excess idling.
2. Very high ambient temperature
3. Slow traffic
4. Traffic jams
5. High speed
6. Steep Gradients.
To avoid overheating under such conditions it will be worthwhile to:

Idle with the AC off .In case the temperature indicator needle is close to the red band, increase the
engine idling speed.
Follow the trouble shooting chart given below while diagnosing the cooling related complaints –

Noise Fan shroud
1. Fan contacting the shroud  Reposition the shroud and inspect
Water pump the engine insulators.
1. Loose water pump impeller.  Replace the water pump.
2. Water pump bearing worn/
failure.  Replace water pump.
3. Loose mounting of pump
Belts  Tighten mounting bolt
1. Belt loose
2. Glazed/stretched fan belt.  Tighten belt
3. Rough surface on drive  Replace serpentine belt,
pulley.  Replace pulley.
4. Belt alignment
Alternator/Water pump  Check the belt alignment & rectify.
1. Alternator bearing failure  Replace alternator bearing
Belt tension mechanism
1. Idler pulley bearing failure  Replace idler bearing.
2. Idler mounting bracket
failure.  Replace the idler bracket.
3. Tension bolt failure.  Replace the tension bolt.
Coolant loss- boil over Coolant
1. Overfilled recovery tank.  Reduce the coolant level.
2. Insufficient coolant additive
causing lower boiling points.  Add the additive.
3. Additive deteriorated due to
aging/ contamination.  Replace the coolant
4. Low coolant level.
110
Hot shut down  Add coolant

1. Quick shut downs after a
long and hot run.  Allow the engine to run at idle for
Leakage’s some time before stopping.
1. Leaks due to lose hose
clamps, nuts, bolts drain  Find the area of leaks , replace hose
plugs, faulty hose or leaking or if necessary the clamp.
radiators.
Blockages
1. Casting flash in the block.
 Pressure tests the system to check
2. Casting flash in the cylinder for leaks and then repair as
head. necessary.
 The flash may be visible by
removing the cooling system
3. Blocked radiator causing components or the core plugs.
under filling of the system.  Repair or replace.
4. Air trapped in system.
5. Air in the system causing  Flush radiator.
occasional burping.  Purge the system.
6. Faulty expansion bottle cap
or pipe.  Replace the cap/ pipe.
Coolant loss- boil over Gas mixing

1. Cylinder head gasket failure.  Replace the cylinder head gasket
Pressurization
1. Defective radiator cap.  Replace the cap.
Timing
1. Improper engine timing  Check the engine timing, injector
Belt pressure.
1. Slipping belts  Adjust belt tension.
2. Belt failure  Replace belt
Water pump
1. Water pump shaft broken or  Replace water pump
damaged impeller.
Thermostat
1. Faulty Thermostat.  Replace Thermostat.
2. Hoses.  Replace hoses.
3. Radiator hoses collapsed  Replace hoses
Fan
1. Cooling fan not engaging.  Check the functioning of the VFD
Air flow replace if required.
1. Air flow reduced to choked  Clean the radiator fins.
fins
2. Airflow reduced due to  Remove the obstruction.
obstruction.
Vehicle
Brakes dragging.  Check the brake system.
111
High Temperature Improper indication

Indication 1. Faulty sensor  Replace the sensor.
2. Faulty gauge  Replace the gauge
Coolant entry into 1. Low cylinder head torque.  Replace the cylinder head gasket,
Crankcase or cylinder 2. Faulty head gasket. torque as per procedure.
 Replace the cylinder head gasket
3. Blow hole in crankcase, head  Replace the affected part.
, liner
Low Temperature 1. Thermostat stuck open  Replace thermostat.
Gauge Indication- 2. Faulty sensor.  Replace sensor.
Under cooling 3. Faulty gauge.  Replace gauge.
Coolant reserve system 1. Coolant level low  Replenish coolant to FULL level.
inoperative 2. Leak in system  Pressure test to isolate & repair.
3. Overflow tube clogged or  Remove clogging
leaking.
4. Recovery bottle vent  Clean vent.
blocked.
5. Radiator cap defective.  Change the cap.
No coolant flow trough 1. Restricted return inlet in  Remove restriction.
Heater Core water pump.
2. Heater hoses collapsed or  Remove restriction or replace hose.
restricted.  Remove flash or restriction.
3. Restricted heater core.  Remove restriction.
4. Restricted outlet in the
thermostat housing.  Repair controls.
5. Heater valve controls not
functioning.  Repair or replace
6. Heater valve stuck.
112
• COOLANT LEVEL – CHECK
MAX 2
MIN
1 1
Coolant Level
Indication on
Reservoir
B C
Coolant Level - Check

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
 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.
113
• COOLANT – REPLACE
Coolant Type: MAXIMILE ULTRA COOL (Pre-mixed)

Capacity: 8 Lit.
A B
Coolant Drain Plug on Block
Coolant Drain cock

on Radiator
COOLANT – REPLACE
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.
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
 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.
114
• In Car Repairs
Dismantling & Assembly of the Cooling System Components –
 Water Pump Removal
 Radiator Assembly Removal
 Thermostat Valve & Housing Removal
 Drive Belt Check
115
• WATER PUMP
A centrifugal water pump is used to circulate the coolant through the water jackets, cylinder head,
hoses and radiator. The water pump is belt driven by the engine main drive pulley. It ratio of pulley
diameter ensures that the water pump rotates 1.25 times the engine speed.
The water pump impeller is pressed onto the shaft. The shaft is supported on two bearings that are
integral to the shaft.
The water pump seal is located between the impeller and the housing. The housing has a small hole to
allow the seepage to escape. That also acts as an indication point if the water pump seal fails.
• WATER PUMP – R&R

The water pump is not serviceable and has to be changed as an assembly; refer illustration.
‘O’ ring, Water Pump

assy. and its mounting
bolts
 Refer below mentioned procedure for removal and refitting of water pump assembly.
Removal Steps – Refer illustrations shown. Assembly Procedure – Refer illustrations.

1. Remove NVH cover. (if applicable) 1. Replace water pump ‘O’ ring with new.
2. Remove intercooler assembly. 2. Refit water pump assembly.
3. Drain the coolant from Radiator assembly. 3. Reconnect coolant hoses on water pump
4. Remove Power steering drive belt & assembly and clamp it.
accessory drive belt. 4. Refit accessory drive belt and power
5. Remove coolant hoses on water pump steering pump drive belt.
assembly. 5. Refit intercooler & NVH cover.
6. Remove water pump assy. Ensure ‘O’ ring 6. Add & Check coolant level.
removal. 7. Check both drive belt tensions.
8. Check cooling system for leakage, if any.
 Always replace the ‘O’ ring whenever removed

 Recommended Coolant is Maximile Ultra Cool; it is Pre-mixed.
 Replacement intervals are 40,000kms; 120,000kms then at every 80,000kms.
 Coolant Capacity: 10 Lit.
116
• RADIATOR ASSEMBLY – R&R
A Pre removal activities –

 Remove coolant recovery tank
and drain coolant from radiator.
 Removal of hoses on radiator.
 Removals of front grill add on.
 Refill coolant as per SOP and
check coolant level.
 Check for coolant leakage, arrest
if any.
B C
Removal Steps – Refer above illustrations.

1. Remove radiator upper LH and RH mounting brackets [shown by red arrow marks]
2. Remove radiator rubber mountings on LH/ RH side [shown by black arrow marks]
3. Take radiator assembly out from engine compartment.
• Radiator Coolant Replace Procedure –

1. Ensure proper fitment of radiator assembly and all the hoses.
2. Refit the drain plugs and close drain cock on radiator.
3. Fill fresh coolant in radiator assembly.
4. Check all the hoses ensure correct fitment and no leakage from hose, clips.
7. Fill coolant in the recovery tank up to MAX level.
8. Refit the radiator cap.
10. Check coolant level in radiator and coolant recovery tank and add as required.
117
• THERMOSTAT HOUSING –R&R
Thermostat housing mtg. nuts 03 12 mm 25 ± 03
Thermostat Cap 03 10 mm 12 ± 02
Thermostat
Thermostat Housing
Housing Gasket
Assembly
Thermostat
Housing mounting
nuts
Removal Steps - Refer illustration shown. Assembly Procedure – Refer illustration.

1. Remove the NVH cover & Intercooler 1. While assembling the Thermostat
assembly. housing check for proper fitment of
2. Recover the Radiator coolant to avoid Thermostat gasket.
spillage. 2. Reconnect the Oil cooler and HVAC
3. Remove Radiator Fan and shroud. Hoses, clamp it firmly.
4. Remove Radiator upper hose connected to 3. Reconnect radiator upper hose.
Thermostat. 4. Reconnect the Temperature Sensor
5. Remove Hoses connected to Oil Cooler wiring socket.
pipe & HVAC. 5. Assemble the Fan and shroud.
6. Disconnect the Temperature Sensor wiring 6. Assemble the Intercooler assembly &
socket. NVH cover.
7. Remove gasket from mounting surface on 7. Top up the Radiator with recommended
cylinder head. brand coolant. Do not mix the different
8. Replace thermostat housing gasket brand coolant.
whenever opened. 8. Check system for coolant leak, if any.
118
• THRMOSTAT VALVE – R&R /CHECK
Thermostat Valve,
Body & its
mounting bolts
Thermostat Valve Function Check Process
Thermostat Valve Assembly Removal
Thermostat Valve Removal Steps –

1. Coolant drain.
2. Remove NVH cover, Intercooler assembly.
3. Remove radiator upper hose.
4. Remove thermostat valve body & thermostat.
5. Check thermostat valve functioning, refer SOP.
6. Check ‘O’ ring, replace if required.
Thermostat Valve Check Function Process –

(Use hot plate, vessel with water, calibrated thermometer gauge)
 Check the thermostat valve for no damage.
 Check the valve for closes completely at normal/ atmospheric temperature.
 Check the thermostat valve for rust free, clean if required.
 Keep thermostat in water. Stir to raise the water temperature and check and note
thermostat opening temperature. Also check and note the temperature at which the
thermostat valve opens fully. The total lift should be approx. 9mm.
119
• SERPENTINE 6 PK BELT
The mDI CRDe engine is having 6PK type accessory belt drive. The total length of belt is 1610mm, it is
Gates make drive belt. The layout of the belt along with auto tensioner is given below. The accessory
main drive belt tension has to be measured between the alternator pulley and the A/C Compressor
pulley.
Alternator
Pulley
Steering
Pump
Pulley
Auto
tensioner
Dummy Pulley
Damper Pulley
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
120
Belt Diagnosis -
When diagnosing serpentine accessory drive belt, small crack that run across the ribbed surface of the
belt from rib to rib are considered normal. Cracks running along a rib are not normal.
The correct belt tension is required to ensure optimum performance of the belt. Do not apply any
external means to reduce noise. Application of oil will reduce the belt life. Refer detailed drive belt
analysis with illustrations which are given below.

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 – 5. Misalignment –

Refer illustration shown. Refer illustration shown.
Belt shows damage to the side with the Sidewalls of the belt may appear glazed or the edge
possibility of breaks in the tensile cord cord may become frayed and ribs removed. A noise
or rough edged ribs. A thumping noise may result. In severe cases, the belt can jump off the
may also be heard when running. pulley.
 Recommended belt tension is 114±5 Hz. To be check between Alternator & A/c
Compressor.
 Recommended belt tension for Power Steering Pump drive Belt is – New: 255 to
260 Hz & Used: 200 to 235Hz.
 Power Steering Pump Drive Belt tension to be check at 5000, 20000, and then at
every 20000kms.and adjust (if required)
121
 Refer below chart while diagnosing the accessory drive belts -

Symptom & condition Possible reasons Correction
Rib chunking 1. Foreign objects embedded  Remove foreign objects from pulley
(One or more ribs has in pulley groove grooves. Replace belt
separated from belt 2. Installation damage.
body)- Chunking happens 3. Poor surface of grooves in  Replace belt.
when several cracks in one pulley.  Clean pulley, replace if required.
area of rib move parallel
to the cord line.
Piling- 1. Lack of tension  Adjust tension
Happens when the 2. Misalignment of pulleys  Correct the alignment.
material is sheared off the 3. Worn out pulleys
undercord and builds up in 4. Excessive tension.  Replace pulley.
the groove.  Correct the alignment
Rib or belt wear. 1. Pulley or pulley’s mis  Correct the alignment.
aligned.
2. Abrasive environment  Clean pulleys- replace if required.
3. Rusted pulley’s  Change pulley.
4. Sharp or jagged pulley
groove tips.  Replace belt.
5. Poor surface finish.
Tooth shear 1. Low belt tension  Correct the tension.
2. Seizure of driven part.  Replace belt.
3. Misalignment.  Align pulleys
Tooth Wear 1. Incorrect tension  Adjust tension.
2. Worn out pulleys  Change pulleys
Longitudinal Belt cracking 1. Belt has mis-tracked from  Replace belt.
(Cracks between two ribs.) pulley groove.
2. Pulley groove tip has worn  Change pulley.
out the rubber to tensile
member.
Belt slips 1. Belts slipping because of  Adjust belt tension.
insufficient tension
2. Belt or pulley subjected to  Clean pulleys.
substances that reduce the
belt life ( oil, grease,
ethylene alcohol)
3. Driven component’s
bearing failure.
4. Belt hardened and glazed  Replace the failed components.
from heat and excessive  Replace belt
slippage.
Groove jumping ( belt 1. Belt tensions either too  Adjust belt tension.
does not maintain correct high or too low.
position on pulley) 2. Pulleys not within design  Replace pulleys.
122
tolerances.
3. Foreign objects in groove.  Clean pulleys.
4. Pulley misalignment,
5. Belt cordline is broken.  Correct the alignment
 Replace belt.
Belt broken 1. Excessive tension.  Adjust belt tension
2. Tensile members damaged  Correct the alignment
during installation.
3. Severe misalignment.
4. Bracket pulley or bearing  Correct the alignment
failure.  Replace the failed component.
Noise 1. Belt slippage  Adjust belt.
Objectionable squeak, 2. Bearing noise  Replace the defective bearing.
squeal rumble heard or 3. Belt mis alignment  Adjust alignment.
felt while drive belt is in 4. Belt to pulley mismatch.  Use the correct belt.
operation 5. Driven component induced
vibration  Vary belt tension within
6. System resonant frequency specifications.
induced vibration.  Replace belt.
Tensile failure 1. Tension sheeting  Correct rubbing condition.

contacting stationary
object.
2. Excessive heat causing  Replace belt.
woven fabric to age.
3. Excessive installation
tension.  Correct the tension.
Oil contamination 1. Oil leaks.  Correct the oil leak condition.
Cord edge failure 2. Excessive tension  Adjust tension.

3. Belt contacting stationary  Remove the stationary objects
( Tensile member exposed objet. fouling.
at edges of belt or 4. Pulleys out of tolerance.  Replace pulleys.
separated from Belt body) 5. Insufficient adhesion
between tensile member &  Replace pulley.
rubber matrix.
123
• Specifications –
Radiator capacity 7 liters

Cooling system capacity 10 liters
Coolant Maximile ULTRA COOL (Pre-mixed)
Radiator pressure 0.9 bar
Belt replacement 100000 Km
Accessory Belt tension after fitting 114 ± 5 Hz.
Power steering Belt tension after fitting 255 to 260 Hz
Bolt location Torque in Nm

Viscous Fan clutch nut 40-50
124
FUEL SYSTEM
Contents…
• Description……………………………………………………………………………. 126
• Care of the System……………………………………………………………… 142
• In Car Repairs………………………………………………………………………. 143
125
• Description – Refer bellow layout for Genio-Fuel system.
The fuel system can be divided into following subgroups.

 Fuel filling.
 Fuel supply from tank to High Pressure pump.
 High Pressure Pump & injectors including the High pressure pipes.
 Return line from High Pressure Pump to tank
The fuel is filled from the opening provided at rear left. The fuel cap is ventilated and threaded type.
The cap is locked in place when further turning action result in clicking of the ratchet. The fuel tank lid
is electrically operated. The switch is fitted on the centre bezel. While filling the tank, the air
entrapped inside is vented by the vent tube, which is connected at the mouth of the inlet pipe. The
venting is done from the highest point in the fuel tank. The fuel tank has a capacity of 58 litres.
During operation the fuel pump due to the vacuum created by the internal feed pump the fuel is
sucked through the filter, to the high pressure pump.
The high pressure pump, pressurizes, & supplies the fuel to the common rail. The fuel then comes to
the injectors.
The fuel back leak from injectors and return from HPP comes through return line.
The entire length of the fuel tank is protected at the bottom by a stone guard.
For the detailed understanding of the Common rail system, please refer the Common Rail System (CR
System) explained separately.
Refer below layout for Engine ECU sensor input & actuator output details.
126
SENSOR INPUT ACTUATOR OUTPUT
• ENGINE SPEED FUEL INJECTOR

• MASS AIR FLOW
• MANIFOLD AIR
TEMP ENGINE MAP
EGR MODULATOR
• RAIL PRESSURE
• CAM PHASE
SENSOR
• ACCL. PEDAL
SENSOR
E PCRV
• COOLANT
TEMPERATURE
• VEHICLE SPEED
• BRAKE PEDAL
C DIAGNOSTIC
POSITION
• CLUTCH PEDAL
POSITION
U ENGINE CHECK
LAMP
• DIESEL
TEMPERATURE DIAGNOSTIC
• A/C REQUEST EXECUTIVE/
SWITCH FAULT TEMPERATURE
GAUGE
HIGH TEMP LAMP
System Block-
1. Sensors/Systems & set point generators: Used for registration of the operating conditions & the
desired values. These convert a variety of physical parameters into electrical signals.
2. ECU: For generating the output signal by processing the information using specified arithmetic
operations ( control algorithms)
3. Actuators: To control the output signal into mechanical parameters.
127
Crankshaft speed sensor: Location: On the crankcase behind the Power Steering Pump.
A B
Refer illustrations – C
[A] Crankshaft speed sensor.
[B] Location of crankshaft speed

sensor on crankcase.
[C] Trigger wheel fitted on crankshaft

assembly.
Function: The piston position in the combustion chamber is decisive in defining the start of the
injection. All the engine pistons are connected to the crankshaft by con rods. A sensor on the
crankshaft thus provides information on the position of all the pistons. The rotational speed defines
the crankshaft RPM. This important input variable is calculated in the ECU using the signal from the
inductive crankshaft speed sensor
Signal Generation
A 60 teeth ferromagnetic trigger wheel is attached to

crankshaft. Out of the 60 teeth, 2 are missing, so there are 58
teeth. This large gap is allocated to a defined crankshaft
position for the cylinder 1.
The crankshaft speed sensor registers the trigger wheels tooth

sequence. It comprises a permanent magnet and a soft- iron
core with a copper winding.
The magnetic flux in the sensor changes as the teeth and gaps
pass by, and a sinusoidal AC voltage is generated, the amplitude
of which increases sharply in response to higher engine speeds.
Adequate amplitude is already available from speeds as low as
50 min  1
128
Calculation of the engine speed
The angular relationship between the pistons is such that two rotations (720°) pass before the start of
each new working cylinder. So the angular ignition spacing is = 720 °/4 = 180 °
In other words the CSS scans 30 teeth between two ignitions. The period of time requires is known as
segment time and the mean of the crankshaft speed in the segment time is the engine speed.
Dos & Don’ts for the Engine Speed Sensor:
Do’s
 Rotational speed sensor must be removed from its packing just prior to installation in the vehicle.
 Sensor to be mounted by pushing it into place.
 The first support of wire after connection: Max 250 mm. It should be on the sensor carrier.
 Replace damaged O-Ring.
 Clean and grease O-Ring prior to installation with mineral oil-based grease.
 Fix with only partially self-sealing cylindrical screw M6X12.
 Tightening Torque specification should be 8 ± 2 Nm.
 Storage temperature: -20ºC to 50ºC.
Don’ts
o Don’t allow the sensor to fall down.

o Do not hammer the sensor while fitting.
o Do not bend sensor wire with radius less than R = 50 mm.
o The angle between sensor exit and first support of the wire should not be more than 90º.
o Do not short circuit the connector pins while the sensor is functioning.
o Sensor should not be kept near Hot medium or objects with Temp > 120 ºC.
o Sensor should not be kept near any strong Magnetic Materials.
o None of the application guidelines should be deviated (Air gap etc).
129
Cam Phase sensor/ Camshaft speed sensor:

Location: On crankcase near Oil cooler assembly; cam trigger is integrated with cam shaft.
A B
Refer illustrations –
[A] Cam phase Sensor

[B] Location of Cam phase sensor on Crankcase.
[C] Integrated Cam trigger on camshaft
The camshaft controls the engine intake and exhaust valves. It travels at half the engine speed. When
a piston travels in the direction of TDC the camshaft position determines whether it is in compression
or exhaust phase. This information cannot be generated by the crankshaft position in the starting
phase. During normal operation on the other hand the information can be generated by the
crankshaft sensor suffices to define the engine status. In other word it means that if the Camshaft
sensor will fail while the vehicle is being driven the ECU shall receive information on the engine status
from the crankshaft sensor.
The camshaft sensor utilizes the Hall effect for establishing the camshaft position. A tooth of
ferromagnetic is attached to the camshaft and rotates with it. When this tooth passes the
semiconductor wafer of the camshaft sensor, its magnetic field diverts the electrons in the
semiconductor wafer at right angle to the direction of the current flowing through the wafers. This
result in a brief voltage signal (Hall voltage) which informs the ECU that cylinder 1 has entered the
compression phase.
Dos & Don’ts for the Phase Sensor:
Do’s
 The Phase Sensor should be unpacked directly before installation.
 Sensor to be mounted by pushing it into place.
 Clean and grease O-Ring prior to installation with mineral oil-based grease.
 The first support of wire after connection: Max 250 mm. It should be on the sensor carrier.
 Sensor terminal pins should be free from water/moisture.
 Fix with only partially micro-capsuled screw M6.
 Tightening Torque specification should be 8 ± 0.5 Nm.
130
Don’ts
o Do not hammer the sensor while fitting.
o Do not bend sensor wire between the connection and the first support.
o Do not touch the sensor pins or the wiring harness pins with hand (to avoid ESD i.e. Electro static
discharge).
o None of the application guidelines should be deviated (Air gap etc).
o Sensor should not be kept near hot medium or objects with Temp > 160 ºC.
Temperature sensors:
Usage: Coolant temperature sensor

Location: on the water outlet/
thermostat housing, near
thermostat.
Usage: Fuel Temperature sensor
Location: on the fuel filter head.
Type: Negative Temperature coefficient type

(NTC)
In the cooling circuit to establish engine temperature by way of

the coolant temperature.
In the fuel return line to measure the fuel temperature. The fuel
temperature is used for density correction.
The sensors are equipped with a temperature dependent resistor with a Negative temperature
coefficient (NTC) which is part of voltage – divider circuit across which 5 V is applied. The voltage drop
across the resistor is inputted into the ECU through an analogue- to – digital converter (ADC) and is a
measure for the temperature. A characteristic curve is stored in ECU microcomputer, which defines
the temperature as a function of the given voltage.
Refer below chart and sketch for temperature sensor.
131
Dos & Don’ts for the Temperature Sensor:
Do’s
 During service-After removing temperature sensor, existing Aluminum washer is to be carefully

cut (without damaging the brass threading) and taken out.
 Replace the washer with Copper washer (MICO 2916 710 608).
Don’ts

o Do not exceed the maximum permissible tightening Torque of 18 Nm for copper washer and 25
Nm for aluminum washer.
132
• Hot Film Air Mass meter:
The HFM sensor combines two functions. It monitors

the airflow & the air intake temperature so that the
density correction is carried out and also the hot film
temperature is maintained. It is used for EGR
operation & smoke limitation.
Particularly during dynamic driving operation, precise

compliance with the correct A/F ratio is imperative in
order to comply with the exhaust – gas limits as
stipulated by the regulations. This makes it necessary
to use the sensor, which precisely register the air-
mass flow actually being drawn by the engine at a
particular moment. This load sensor’s measuring
accuracy must be completely independent of
pulsations, reverse flow, EGR, variable camshaft
control and changes in air intake temperature.
A hot film air mass meter was selected for being most
suitable for complying with the above stipulations.
The hot film principle is based on the transfer of heat
from heated sensor element to the air mass flow. A
micromechanical measuring system is utilized which
permits registration of the air-mass flow and detection of flow direction. Reverse flows are also
detected in case of strongly pulsating airflow.
The micromechanical sensor element is located in the plug- in sensor’s flow passage. The plug in
sensor is installed in the outlet of the air cleaner. The signal voltage curve as a function of the air mass
flow is divided into signal ranges for forward and reverse flow. In order to increase measuring
accuracy the measuring signal is referred to a reference voltage outputted by the engine
management. The characteristic curve has been designed so that during diagnosis in the workshop for
an open circuit conductor for instance, can be detected with the help of the engine management.
133
A temperature sensor is also incorporated for measuring the air

intake temperature (IAT)
Accelerator pedal sensor:
Location – in the accelerator pedal
Type – 6 wire, double track potentiometer
Function – informs ECU about driver’s pedal request.
Purpose – to transmit driver’s pedal request to ECU
In contrast to the conventional distributor or inline pumps with

CRD the driver’s acceleration input is no longer directly inputted
to injection pump by the Bowden cable. But the motion is
registered by an accelerator pedal sensor and is transmitted to
the ECU.
A voltage generated across the potentiometer in the

accelerator pedal sensor as a function of the accelerator pedal
setting. Using a programmed characteristic curve the pedal
positions then calculated from this voltage.
There are two tracks called APP1 & APP2. The ECU monitors
signals from both the tracks. Even if the relationship between
either changes it is registered as a defect.
Dos and Don’ts:

Do’s
 Tightening Torque of the retaining screws should not exceed 9 ± 1.5 Nm.
 Use only self-locking screws.
 After damage or in doubt of damage (e.g. dropped APM) the APM has to be separated and
scrapped.
Don’t
o Don’t drop s the sensor.
o Do not exceed the maximum permissible tightening Torque.
o Do not dip in any liquid.
Common Rail & pressure sensor:
Common rail is HFR (Hot Forged Rail) mounted on

Cylinder head near intake manifold. It is laser
welded rail, max pressure is 1400bars. It has one
electrical connector, which is Rail Pressure sensor
[see illustration]. No leak off in the rail.
Purpose– to decide on injector energizing time

Caution: The rail pressure sensor has to be
changed along with the rail.
134
Vehicle Speed Sensor (VSS):

Location- on the gear box output shaft
Type- magnetic reed type
Function - Monitors the vehicle speed. ECU based on this
information can deduce the gear in which vehicle is
driven.
Purpose- Gear recognition is useful in low speed
governing & cruise control
Brake Pedal Switch:

Location – in the brake pedal
Type – 4 wire, make-break switch
Function – informs ECU about position of brake pedal,
operates brake lamp/stop lamp
Purpose – help ECU to identify brake actuation for cruise
control
Clutch Pedal Switch:

Location – in the clutch pedal
Type – 4 wire, make-break switch
Function – Informs engine ECU about position of clutch
pedal .Also informs 4WD ECU about position of clutch
pedal.
Purpose – help engine ECU to identify clutch actuation for
cruise control
135
ECU
Assignment & method of operation:
The ECU evaluates the signal it receives from the external sensors & limits them to permissible voltage
level
From this input data, and from stored characteristic maps, the ECU microprocessors calculates the
injection times and instants of injection and convert these times to signal characteristic which are
adapted to the movements of engine piston & crankshaft. The specified accuracy and the engines high
dynamic demands high level of computing power.
The output signal from the ECU microprocessor’s is used to trigger driver stages, it also provides
adequate power for switching the actuators for rail pressure control and elements switch off. In
addition actuators for engine function are triggered (e.g. EGR actuator) as well as those for further
auxiliary functions such as blower relay, auxiliary heater relay, glow relay, air conditioner). The driver
stages are proof against short circuit and destruction due to brief electrical overloading. Errors of this
type and open circuit are reported to the microprocessor. Diagnosis functions in the injector driver
stages detect faulty signal characteristic, and in addition a number of the output signal are transferred
via interfaces for use in other systems in the vehicle. And within the framework of a special safety
concept, the ECU monitors the complete fuel injection system.
Injector triggering particularly places heavy demands on the driver stages. In the injector, the current
from the driver stage generates a magnetic force in the triggering element, which is applied to the
injector’s high-pressure system. In order to ensure very tight tolerances and high reproducibility of the
injected fuel quantity, these coils must be triggered with steep current flanks. This necessities high
voltages being made available in the ECU.
A current control circuit divides the energisation time (injection time) into a pickup current phase and
hold phase. It must operate so accurately that the injector guarantees reproducibility injection under
all stages. In addition it must reduce the power loss in the ECU & the injectors
Operating conditions
High demands are made on ECU regarding

- The surrounding ambient temperatures ( in normal cases from –40°C to +85° C)
- The resistance to fuels and lubricants etc.
- The resistance to humidity and
- Mechanical loading.
Very high demand is also made upon the electromagnetic compatibility and upon the radiation of HF
interference signals.
136
Design & Construction
The ECU has a metal housing. The sensors, the actuators and power supply are connected to the ECU
through a multi pole plug in connector. The power components that directly trigger the actuators are
integrated in the ECU in such a manner that they can efficiently dissipate their heat to the ECU
housing.
Operating state control
In order that the engine operates with optimum combustion in every operating state the ECU in each
case calculates the optimum injected fuel quantity. In the process a number of parameters have to be
taken into account
Start quantity
For starting, the injected fuel quantity is calculated as a function of the temperature and cranking
sped. The start quantity is injected from the moment the starting switch is turned to start till the
engine has reached a given minimum speed. The driver has no influence upon the start quantity
Drive Mode
When the vehicle is being driven normally .The injected fuel quantity is calculated from the
accelerator pedal setting (accelerator pedal sensor) and the engine speed. Calculation utilizes the
driving maps so that the driver inputs and the engine O/P power are optimally matched to each other.
Idle sped control
At idle, fuel consumption depends for the most part on engine efficiency and idle speed. Since a
considerable portion of vehicles fuel consumption in dense traffic conditions is attributable to this
operating state, it is obvious that the idle speed must be kept to a minimum. The idle speed though
must be set so that no matter what the operating conditions, it does not drop so far under load that
the engine runs roughly or even stops. This applies for instances when the electrical systems are
overloaded, when the AC is switched on, or when the power steering is in operation. In order to
regulate the desired idle speed the idle controller varies the injected fuel quantity until the actual
speed equals the desired idle speed. Here the selected gear and the engine temperature (coolant
temperature sensor) influence the desired idle speed and control characteristic. In addition the
external load moments, the internal friction moments must also be taken into account and
compensated by the idle speed control. These change minimally but steadily throughout the vehicle
service life, as well as being highly dependent upon temperature.
137
Smooth running Control
Due to mechanical tolerances and aging, there are differences in torque generated by the engine’s
individual cylinders. This leads to rough or irregular running, particularly at idle. The smooth running
(cylinder balancing) control measures the engine speed change every time a cylinder has fired and
compares them with each other. The injected fuel quantity for each cylinder is then adjusted in
accordance with the measured difference in engine speed between the individual cylinders so that
each cylinder makes the same contribution to the torque generated by the engine. The smooth
running control is only operative in the lower engine speed.
Controlling the injected fuel quantity limit --
There are a number of reasons why the fuel quantity desired by the driver must not be injected. These
include
- Excessive pollutant emissions

- Excessive soot emissions
- Mechanical overloading due to excessive torques or engines speed.
- Thermal overloading due to excessive coolant temperature.
The limit for the injected fuel quantity is formed from the a number of input variables e.g. intake air
mass, engine speed, coolant temperature
Active surge damping control –
When the accelerator pedal is abruptly pressed or released. It

causes the injected fuel quantity to change rapidly with the
result that there is also a rapid change in the torque
developed by the engine. These abrupt changes lead to
flexible engine mounts and the drive train generating bucking
oscillations which result in fluctuation of engine speed.
The active surge damper reduces these periodic speed

fluctuations by varying the injected fuel quantity at the same
frequency as the periodic fluctuations. Less fuel is injected
when the speed increases and more when it decreases. This
effectively damps the surge movement.
Engine switch off –
The diesel engine operates according to auto ignition

principal. This means that it can only be switched off by
cutting the fuel supply.
With the CRDe the ECU stipulates injected fuel quantity zero. (The system also features a number of
additional – redundant switch off paths.)
138
• Injectors –
Special injectors with hydraulic servo systems and electrical triggering element (Solenoid valves) are
used in order to achieve efficient start of injection and precise fuel injected fuel quantity. At the start
of the injection a high pickup current is applied to the injector so that the solenoid opens quickly. As
soon as the nozzle needle has traveled its complete stroke and the nozzle has opened completely.
The-energizing current is reduced to lower holding value. The injector opening time & rail pressure
now defines the injected fuel quantity. Injection is terminated when the solenoid valve is no longer
triggered and closes as a result.
Injector –
6 holes injector with 300 cu. mm.
throw flow for better atomization
and improved HC & CO emission.
Injector: Solenoid injector

Max Pressure: 1400 bar
Max No of injection: 3/ Cylinder
No of IQA test points: 3 + 1
High Pressure Connector: M12X1.5
Injector – Sectional view
EGR position -
Depending upon the engines operating point, the air /gas mass drawn into the cylinders can be
composed of up to 40% of the exhaust gas.
For ECU control the actual drawn in fresh air is measured at each operating point with the air mass set
point value. Using her signal generated by the control circuit, the EGR position opens so that exhaust
gases flow into the intake tract.
The ECU controls the movement of the modulator. The modulator controls the amount of vacuum
going to the EGR valve, thus varying the lift of the EGR. The variable lift of the EGR changes the
amount of exhaust gas going to the Inlet system.
Integrated diagnosis:
Sensor monitoring-
For sensor monitoring the integrated diagnosis facility checks whether they are being supplied by
power, and whether the O/P signals are plausible (within the permitted range e.g. temperature
between –40 to 150°C. Where possible the reduancy principle is applied for important signals. That is
in case of a malfunction, a switch is made to another similar signal.
139
Monitoring module –
In addition to the microcontroller the ECU also incorporates a monitoring module. The ECU and the
monitoring module monitor each other. If a malfunction is detected, either of them can switch off the
injection independent of the other.
Malfunction detection
Malfunction detection is only possible within the monitoring range of a given sensor.
A signal path is classified as faulty when an error is present for longer than a predefined period. In
such cases, the error is stored in ECU’s error memory together with details of the environmental
condition which prevailed when the error / malfunction occurred (e.g. coolant temperature, engine
speed etc.) For a large number of errors/ malfunction, it is possible for the healed status to be
established. Here the signal path must be identified as intact for a defined period of time.
Error Procedure-
If a sensors permitted output-signal is violated, a switch is made to a substitute value. This procedure
is applied for battery voltage
- Coolant, air, and lube temperature
- Atmospheric pressure
- Intake air quantity
In addition in case of non-plausible signals from the accelerator pedal sensor and/or brake as
substitute accelerator pedal signal is applied (unless there is a plausibility error.)
ECU Data processing
The actuators and the sensors are the interface between the vehicle and the ECU
Analogue input signals (from analogue sensors; quantity of the air drawn, engine & intake air
temperature, battery voltage etc are converted to digital value by an A/D converter in the ECU
microprocessor.
Digital input signal (e.g. On/Off switching signals or digital signals such as rotational speed pulse) can
be processed directly by the ECU
In order to reduce interference pulses the pulse shaped input signal from inductive sensor (crankshaft
speed sensor) which carry information on engine speed and reference mark are conditioned by a
special circuit in the ECU and converted to square wave form
Some signal conditioning can take place at the sensor end itself.
Signal conditioning
Protective circuitry is used to limit the incoming signals to a maximum voltage level. The effective
signal is freed almost completely of superimposed interference signals by means of filtering and is
then amplified to match it to the ECU voltage.
140
Engine will not start & • Clogged fuel filter/  Change fuel filter
emit black smoke fuel lines.  Check fuel supply line.
• Defective injectors  Refer diagnostic manual
Noisy engine & black • Injector coking.  Clean external coking

smoke. • CR System  Refer the diagnostic manual
Engine speed falls off. • Clogged fuel filter/  Change fuel filter
fuel lines  Check fuel supply line.
 Refer diagnostic manual.
Engine does not give full • Clogged fuel filter/  Change fuel filter
power. fuel lines  Check fuel supply line.
 Replace filters.
 Locate the kink/block in return pipe
and rectify.
• Defective injectors.  Refer diagnostic manual
Black smoke. • Defective injectors  Check injectors.

• CR system  Refer diagnostic.
Engine will not start • Weak battery  Check the battery specific gravity.
 Clean & tighten battery connections.
• Corroded or loose  Repair starter.
battery connection  Refer diagnostic manual.
• Faulty starter
• CR system
141
• Care of the System -
The fuel injection system depends on supply of clean diesel fuel for the proper functioning of the fuel
system.
To ensure that High Pressure Pump receives clean fuel all the times it is advisable that the fuel filter is
replaced at the specified intervals.
The fuel filter should be changed at every 20,000 KMs. If the operating conditions are poor then
reduce the change interval. The fuel filter is equipped with water separator. If the water level
indication comes on in the instrument panel, then the water should be immediately drained.
The internal components of the High Pressure Pump depend on the lubricating properties of diesel for
lubricating them. Hence, if water is present in the fuel then lubrication between the component break
down and there is seizure.
142
• In Car Repairs –
The In Car repairs which can be carried out are:
• Fuel filer Removal
• Fuel tank Removal
• Draining the water from the fuel filters.
• Common Rail System
• Injectors Removal
• HPP Removal
143
• FUEL FILTER – REPLACE
Fuel Filter
Element
4 3
Fuel Filter dismantling & assembly procedure

Fuel Filter Assembly
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.
 Always use genuine fuel filter assembly.

 Fuel filter to be replaced at every 20000kms or earlier if found choked.
144
• FUEL TANK & STRAINER – CLEAN
Fuel Tank mountings
Fuel Tank, Float unit & Fuel Pipe Fitting
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.
 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.
145
• WATER SEDIMENTS DRAIN - FUEL FILTER
Fuel Filter
Assembly
Fuel Filter water drain socket removal

Fuel Filter Assembly
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.
 Water sediments to be drain from Fuel filter first at 5000kms, 10000kms, and then
at every 20000kms.
146
• COMMON RAIL ASSEMBLY – R&R

• HP line nut at Injector end 04 14 mm 25 ± 03

• CR assembly mtg. bolts 02 12 mm 15 ± 02

Refer above illustrations. Refer above illustrations.
1. Remove NVH cover. 1. Refit CR assembly.

2. Remove high pressure pipe line clamps & 2. Replace new high pressure fuel lines on CR
Pipe lines connected on Common rail & all to all injectors.
injectors. 3. Replace new high pressure fuel line on HP
3. Remove high pressure fuel line from CR to pump to CR assy.
HP pump. 4. Reconnect fuel return line.
4. Remove Sensor wiring socket from CR 5. Reconnect socket on CR assy.
assembly. 6. Start engine & Check for fuel leak from
5. Remove fuel return line. system, if any. Check for engine
 High pressure fuel pipes to be replaced once it is removed.
147
• INJECTOR - R&R
HPP Pump end 01 14 mm 20 ± 02
HPP Rail end 05 14 mm 21 ± 02
HPP Injector end 04 14 mm 27 ± 02
Injector mounting clamp allen bolt 04 05 mm 25 ± 03
Injector assembly removal
Removal Step –
Section view –
Refer illustration shown. Injector Assembly
Following steps recommended while removing
Injector No. 1, 2 or 3-
(Here injector no.1 is the injector from Fan side)
1. Remove NVH cover & intercooler assembly.

2. Remove the clamp connected between two
injector pipe lines.
3. Remove wiring socket connected to the injector.
4. Remove HP fuel line connected on particular
injector & common rail.
5. Remove injector assembly. No. 1, 2 or 3.
Injector No.4 removal needs to do following

additional activities -
1. Remove Plenum appliqué & wiper motor along Injector:

with linkages. It is solenoid injector; Maximum operating
2. Remove wiring socket & High pressure fuel line pressure is 1400 bar. The high pressure
connected on injector No.4 connector on injector is of M12x1.5
3. Remove injector assembly No.4
148
• HIGH PRESSURE FUEL PUMP – R&R

 HP pump mtg. nut 03 11 mm 20 ± 02
 HP pump shaft nut 01 12 mm 25 ± 03
Vacuum
pump
HP Pump
HP Pump
Sprocket
Vacuum Pump
Drive Nut
Removal Steps –
1. Remove NVH cover. (if applicable)
2. Remove Intercooler assy. (if applicable)
3. Remove intake manifold hose for better
4. access.
5. Remove the vacuum pump assy, HP fuel
6. line & fuel hoses on fuel pump.
7. Remove the HP pump shaft lock nut and
8. washer.
9. Use MST (0305BAC0008ST) fix it with 2
10. mounting bolts on Front cover.
11. Use 04 mounting bolts to hold sprocket.
12. Loosen and remove HP fuel pump mounting nuts.
13. Start rotating MST centre bolt in clockwise direction so that HP pump can be pushed out slowly.
14. Remove HP fuel pump safely.
149
HP Pump Mounting – Genio mDI CRDe HP Pump – Genio mDI CRDe
1. Refit HP pump assembly. Ensure that HP pump Sprocket is intact and properly holds by MST.
2. Fix the HP pump by tightening its 3 mounting nuts.
3. Remove the MST by removing 04 nos. bolts holds the sprocket and 02 nos. bolts used to fix the
tool on front cover.
4. Replace new washer and HP pump shaft nut.
5. Torque tightens the shaft lock nut.
6. Refit the vacuum pump assembly.
7. Ensure that the vacuum drive shaft lug is aligned and Inserted properly into HP pump shaft lock
nut grove; Vacuum pump will not work in case it is not aligned properly.
8. Reconnect fuel hoses and HP pipe lines on pump.
10. Check & insure for no fuel leakage from the system.
 Special tool required to remove & refit HP pump in Genio mDi CRDe Engine.
 Special tool no. MST 0305BAC0008ST.
 Dismantling, Inspection & overhaul of the High Pressure Pump –
The HPP is non - serviceable.

Specifications –
Bosch CRI 1.1 Injector,
HPP Type: CP1H, 1400 Rail Pressure (Max)
ECU: EDC 17C55
150
Location Torque in Nm
High pressure pipe nut on Rail 27 ± 2 Nm
High pressure pipe nut on pump 20 ± 2 Nm
High Pressure Pipe to injector 27±2 Nm
Injector holder clamping 25±3 Nm
Rail mounting on intake manifold 25±3 Nm
151
Emission Control System
Contents…
• Description……………………………………………………………………………. 153
• In Car Repairs………………………………………………………………………. 158
152
• Description
The mDI CRDe engine meets the BS III emission norms. To control the NOx an Exhaust gas recirculation
is used. Overall, two systems are used.
• Exhaust Gas re circulation.
• Working Principle of the Exhaust Gas Recirculation

Vacuum
Modulator
Exhaust Air
Temperature
Sensor E
C
RPM sensor EGR
Engine
U
Load Sensor
Air flow
Vacuum
pump
During acceleration and in higher loads the engine generates high combustion temperatures. The high
combustion temperatures increase the NOx generation. The higher percentage of NOx generated in
the combustion chamber come out through the tail pipe spreads in the atmosphere.
To reduce the amount of NOx coming through the tail pipe the EGR system adds exhaust gases into
the fresh air that is going into the combustion chamber. Since the exhaust, gas is already burnt hence
when mixed with fresh air acts an inert gas. Thus when the exhaust gas mixed with fresh air enters the
combustion chamber. The role it does is that it reduces the amount of oxygen available for
combustion. The net effect is that it reduces the peak combustion temperatures. This results in lower
amount of NOx being generated.
To control the amount/percentage of exhaust gases to be circulated back to the combustion chamber
an ECU is used. The ECU monitors the coolant temperature, attitude, engine speed, and accelerator
pedal position. Based on the above parameters the ECU operates a switch that in turn controls the
amount of vacuum going to the EGR valve. The amount of vacuum applied controls the lift of the EGR
valve through vacuum modulator.
The inputs of the engine speed (from the Engine RPM Sensor); Throttle position (accelerator pedal
sensor) is fed in one map. Another map uses the throttle position and correlate in terms of the
153
acceleration. The third map uses the water temperature. The inputs from the 3 maps are added
together to give an input to the EGR pressure modulator.
At the same time it has a set point that if the water temperature is less than 25 ° C or more than
95°C. Then the EGR will not be operated.
The acceleration map ensures that if the rate of acceleration is above a certain level then the EGR will
not operate. This feature allows full engine power to be available during acceleration (say during
overtaking).
The Engine ECU controls the EGR. The vacuum connections are shown below.
Vacuum Hoses Connections - Layout
154
• Trouble Shooting -

Engine does not give full 1. Gas leak between EGR pipe  Change the gasket or the hose.
power. joints.  Change the pipe.
2. EGR pipe leak.  Check the EGR using the blink
3. EGR valve improper codes. Proceed appropriately.
functioning.  Ensure vacuum connections at
4. Vacuum hose crack, loose, vacuum modulator, reservoir,
fallen off and alternator.
Noisy engine & high 1. Cylinder head gasket  Replace the cylinder head gasket.
smoke defective.  Lap the valve seats or regrind.
2. Worn out or damaged valve
seats.  Tighten the injector pipe.
3. Leaking injector pipe/ HP
pipe.  Confirm & check
4. Leakage at EGR Valve flange -Gasket condition
face, exhaust manifold and - Bolt torque.
EGR pipe end.
Black smoke. 1. EGR valve stuck open  Check the EGR valve-physically.
Excessive oil 1. Cracked vacuum line hoses  Check the vacuum line from the
consumption Pump to the EGR valve - check
for leaks, crack. Replace cracked
2. Restriction in crankcase hoses.
breather.  Locate & remove restriction.
 Check the crankcase ventilation
3. Damaged oil separator & rectify.
4. Bend/kink in any of the oil  Replace the oil separator
return pipe’s/vacuum hoses.  Change the vacuum hoses.
 Remove the bend or kinks.
155
To meet the emission norms it is essential that the Fuel system, Air intake system & cooling system be
maintained as per the schedule .For details refer to the particular sections.
Generally it is not appreciated that if the engine is running below the optimum temperature (happens
when thermostat is removed then tailpipe emissions in particular the particulate increases (up to
30%). Similarly a wrong grade or poor quality of fuel increases the emissions. A blocked air cleaner or
restriction in intake system increases the emissions.
Oil separator system:
Check the hose connection at every 10,000 Kms for cracks, aging and leaks.
EGR:
On vehicles fitted with EGR system the following additional points check have to done during
scheduled maintenance.
• Check for any exhaust gas leakage through sealing faces, EGR pipe. Formation of any black
soot indicates leakage.
• Check the vacuum hoses for any leaks, cracks.
• Retighten all nuts and bolts as per the recommend torque.
If the pipes are removed then it is essential that while fitting back new gaskets is used. Do not open
the pipe from one end only; it will cause the pipe to twist. If the EGR pipe has to be removed, then
open from both the ends.
The EGR operation is controlling by Engine ECU. Hence it is prone to get damaged if spikes are
generated in the system. It is advised that the following precautions be taken.
♦ If any welding work is being carried out on the vehicle then the battery terminals needs to be
removed.
♦ Similarly, the practices of shorting the battery to check the battery have to be avoided. (It can
cause a spike.).
♦ The practice of changing battery with a running engine is also not acceptable. Again, the resultant
spike can damage the ECU beyond repairs.
EGR Valve
Remove the EGR valve and check it valve-sticking, deposition of carbon etc. If excess carbon deposits
and sticky valve noticed then it should be cleaned with a suitable solvent, so that the correct valve
seat is ensured.
After cleaning the valve blow air from the bottom side of the valve and check for any leakages.
To check for the functioning of the EGR valve apply vacuum on the vacuum connection of the EGR
valve. The lift of the valve at the required vacuum should be achieved.
156
EGR Pipe
Remove the EGR pipe and check for gas leakage, damages etc. Clean the gasket seating area from any
carbon deposits burrs etc. Spray ‘WD-40’ rust cleaning spray on the nut. To check the pipe for any
leakages, close one end of flange and from other end blow air at two bars. Dip the pipe in water and
observe if any leakage is observed. If any leaks are observed then the pipe has to be replaced. Do not
attempt to weld/ seal the leakage joint.
EGR Cooler
EGR cooler does not require any maintenance. During coolant level & leak check as well as refilling it is
recommended to check for any leak at the EGR cooler coolant inlet and outlet hose connections. Tight
the clamps and arrest the coolant leakages if any.
ECU:
It does not require any maintenance.
However, like any ECU care has to be taken that if any welding work is being carried out on the vehicle
then the battery terminals needs to be removed. Similarly, the practices of shorting the battery to
check the battery have to be avoided. (It can cause a spike.). The practice of changing battery with a
running engine is also not acceptable. Again, the resultant spike can damage the controller beyond
repairs.
Catalytic Convertor
It does not require any maintenance.
157
This section consistes of –
• EGR Valve assembly Removal
• EGR Pipe Removal
• EGR Cooler Removal
158
• EGR Valve Removal

 EGR valve assembly mtg. bolts 04 12 mm. 25 ± 03
Integral EGR Valve Removal

Refer illustration –
1. Remove NVH cover, Intercooler assembly.
2. Remove Vacuum hose and intake hose on EGR valve assembly.
3. Remove EGR Pipe connected on EGR valve housing.
4. Remove EGR valve housing mounting bolts.
 Ensure gasket lug position for correct orientation, refer illustration.
159
• EGR VALVE, EGR COOLER & EGR PIPE - R&R

EGR pipe mtg. bracket bolt. 01 12 mm. 25 ± 03
EGR pipe mtg. allen bolt (exh side) 02 05 mm. 25 ± 03
EGR pipe mtg. on valve body 02 12 mm. 25 ± 03
EGR valve body on intake manifold 04 12 mm 25 ± 03
EGR assembly Removal & Refitting EGR Cooler & Pipe (TC to EGR Valve) R&R
Removal Steps – EGR Pipe & Cooler Assy.

1. Remove NVH cover & intercooler assy. EGR Pipe
1. Remove intake hose on manifold.
2. Remove EGR pipe mtg. brackets.
3. Remove EGR Pipe assembly from
exhaust and intake manifold side.
4. Remove hoses on EGR cooler.
5. Remove EGR valve & cooler assembly.
6. Remove EGR gasket on intake manifold. EGR Cooler
Assembly Procedure – Refer illustration shown.

1. Refit new EGR gasket.
2. Refit EGR valve assembly on intake manifold.
3. Refit EGR cooler & Pipe along with new gaskets.
4. Refit EGR pipe mtg. brackets on engine.
5. Reconnect intake hose and EGR cooler hoses.
6. Refit intercooler & NVH barrier assembly.
7. Check & insure for no leak of exhaust gas from system.
 Use recommended rust free solution if EGR pipe mounting bolts are found jam.
 Replace gasket while assembling g EGR pipe (TC to EGR Valve).
 Check and top up the coolant level in radiator & reservoir.
 EGR Cooler is only applicable for BS-IV engines.
160
CLUTCH
Contents…
• Description……………………………………………………………………………. 162
• In Car Repairs………………………………………………………………………. 174
• Specification & Wear Limit…………………………………………………. 183
• Lubricants…..………………………………………………………………………… 184
161
• Description
The clutch disc is a single, dry type with cushion springs in the hub. The clutch disc’s friction material is
riveted to the hub.
The clutch cover is a diaphragm type with one-piece construction. A 240-mm clutch disc is used.
In the engaged position (when the clutch pedal is not pressed), the diaphragm spring of the clutch
cover assembly holds the clutch pressure plate against the clutch disc. This enables the engine torque
to be transmitted to the input shaft of the gearbox, without any slip / loss.
The clutch is hydraulically actuated with self-adjusting features. The complete actuation system
comprises of a clutch master cylinder with integral reservoir. The master cylinder is connected to the
clutch actuation or the slave cylinder by hydraulic pipe. The travel of the push rod results in linear
movement of the release bearing through a release fork pivoted on a ball in the clutch housing.
The clutch release bearing pushes the diaphragm spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load on the clutch plate. Steel spring straps riveted to the
pressure plate cover pulls the pressure plate away from the clutch disc. When the clamping load on
the clutch plate is relieved it slides on the splines of the input shaft away from the flywheel thus
disengaging the engine torque from the input shaft & enabling the gears to be changed.
162
Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will require a
road test to confirm that the problem exists. To find out the actual root cause of the problem the
clutch will have to be dismantled and the failed parts examined to determine the cause.
During road test, drive the vehicle in normal operating speeds. Shift the gears and observe the clutch
action. If chatter, grab, slip or improper release is experienced, remove & inspect the parts. However if
problem is noise or hard shift then the problem may not be in clutch only but also the transmission or
the driveline.
If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed (corresponding
to the gear). Keeping the accelerator fully pressed, slowly apply the brake- with your left feet. If the
engine stalls then the clutch is not slipping.
• Clutch Problem Causes –
Fluid contamination is the most frequent cause of clutch malfunction. Oil, water on the clutch contact
surface will cause faulty operation viz. Slip, grab, and judder.
During inspection check if any parts in the clutch are coated with oil or water splash from road.
Oil contamination indicates a leak at either rear main seal or transmission-input shaft. The oil leaks
from either of these areas will normally coat the housing interior or clutch cover or flywheel. Heat
buildup due to slippage between the clutch plate and the flywheel or the pressure plate can result into
the leaked oil literally getting baked. Visually this will result in a glazed residue varying from amber to
black.
Roads splash contamination will mean that the dirt water is entering the clutch housing either due to
lose bolt or torn rubber boot.
Clutch misalignment –
The clutch component i.e. the clutch plate, flywheel and the pressure plate have to be aligned with
the crankshaft and the transmission input shaft. Misalignment caused by run-outs/ warpage will cause
clutch to grab judder as well as improper release (also manifesting as hard gearshift).
163
Flywheel run out –
The flywheel run-out needs to be checked whenever misalignment is suspected. Flywheel run-out
should not exceed 0.10 mm.
To measure the run-out mount the base of the magnetic dial gauge on the block. Locate the dial
gauge’s needle on the outer surface of the flywheel.
Some of the common reasons for excessive run-out are:

 Heat warpage.
 Improper machining.
 Incorrect bolt tightening
 Foreign material on crankshaft flange or flywheel.
 Improper seating on crankshaft.
Clutch cover & Disc runout –
A warped cover or diaphragm spring will result in clutch grab and / or incomplete release of clutch
plate.
If the clutch alignment tool is not used then the misalignment of the clutch plate can cause distortion
of the cover and also disc damage.
164
The cover can also get misaligned due to improper tightening of the cover onto the flywheel. The only
way to avoid is that the bolts must be tightened alternatively (diagonal pattern) and evenly i.e. 2 to 3
thread a time only.
A noisy gearshift operation especially the 1st and 2nd gear can be due to clutch not getting disengaged
completely. To check it, jack up the rear axle. Lift the axle till both the wheels are rotating freely.
Press the clutch pedal completely and start the engine, the wheels should not be spinning. Now slowly
release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some
spinning is noticed then it indicates improper lift of the pressure plate. First check the bleeding and
the pedal travel then check for the pressure plate lift.
Clutch Housing Misalignment –
The clutch housing has to be aligned with the engine so that the input shaft is aligned with the
crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It
can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also
damage the spline of the input shaft and clutch hub’s well as the clutch splines
 Normally the clutch housing misalignment is a result of:

 Incorrect seating on the engine/transmission.
 Missing alignment dowel holes.
 Loose or missing mounting bolt.
 Mounting surfaces that are damaged/ not parallel.
To check the clutch housing misalignment bell housing run-out will also need to be checked.
165
Clutch slippage –
Observation Causes Remedial action
Disc facing worn out. 1. Normal wear.  Replace clutch disc

2. Clutch riding.  Replace clutch plate
3. Insufficient diaphragm  Replace clutch plate & cover
spring clamp load. assembly.
4. Faulty release  Replace , and bleed/
mechanism.
5. Vehicle being driven  Customer to be informed.
despite slipping clutch.
6. Bad driving practice of  Customer to be informed.
allowing the clutch to
slip far too long.
Clutch disc facing Leak at :  Replace seal & disc. Clean cover
contaminated with oil, 1. Crankshaft rear end oil assembly.
grease or clutch fluid. seal
 Replace seal & disc. Clean cover
2. Leak through the input assembly.
shaft
 Apply less grease. Replace clutch
3. Excess amount of grease disc. Clean cover assembly.
applied to the input
shaft splines
Clutch is running partially Release bearing carrier  Replace bearing / carrier.

disengaged. sticky.
Flywheel height incorrect. 1. Improperly machined

flywheel.  Replace flywheel in both case.
2. Excess machining done.
Wrong disc or pressure plate Use the correct parts  Replace the parts after comparison.
used.
Clutch disc/ cover or 1. Improper tightening or  Replace the parts and tighten as per
diaphragm spring warped. loosening procedure. sequence.
2. Rough handling of clutch  Replace the parts, ensure that the
plate or cover assembly rough handling is avoided
166
Flywheel side clutch facing Flywheel surface ,scored and  Reduce the scoring and nicks by
surface – torn/ nicked/ worn having light notch sand paper. Reduce if scoring
deeper.
Clutch disc facing burnt. 1. Frequent operation  Roughen the flywheel face with
Excessive glazing of the under high loads or hard sandpaper. Replace clutch plate &
flywheel & pressure plate. acceleration conditions cover assembly.
2. Frequent clutch riding by  The driver has to be alerted to avoid
the driver. repeat failure.
Clutch facing broken Improper storage- clutch  Replace.

plate dropped prior to
fitting.
Fouling marks on the torsion Improper fitment-  Rectify.

damper. assembled the wrong way
around.
167
Clutch grab/chatter –

Clutch disc facing Leak at :
contaminated with oil, 1. Crankshaft rear end oil  Replace seal & disc. Clean cover
grease or clutch fluid. seal assembly.
2. Leak through the input  Replace seal & disc. Clean cover
shaft assembly.
3. Excess amount of grease  Apply less grease. Replace clutch
applied to the input disc. Clean cover assembly.
shaft splines
Clutch disc / pressure plate 1. Incorrect or substandard  Replace disc and cover with the
warped. parts. correct parts.
2. Improper tightening or  Replace the parts and tighten as per
Disc facing show unusual loosening procedure. sequence.
wear
3. Rough handling of clutch  Replace the parts, ensure that the
plate or cover assembly rough handling is avoided.
Partial engagements of 1. Clutch pressure plate  Replace clutch cover & clutch plate.
clutch disc (One side worn – position setting incorrect
opposite side glazed and or modified
lightly worn.) 2. Clutch cover, spring or  Replace clutch cover & clutch plate.
release fingers bent or
distorted due to rough
handling or improper
assembly.
3. Clutch disc damaged or  Replace clutch plate.
distorted.
4. Clutch misalignment.  Check alignment and runout of
flywheel disc or cover.
 Replace the clutch plate & cover
assy. (if required. Correct the
alignment)
No fault found with clutch Problem related to  Further diagnosis required. Check
components. suspension or driveline engine & transmission mounting
components. insulators. U Joint, tyres, body
attaching parts.
Clutch master cylinder or Piston/ bore damaged or  Overhaul the master & slave
slave cylinder piston corroded cylinder.
jammed/ scuffing.
Tangential strap connecting 1. Incorrect driving practice  Advise the customer of the
the pressure plate to the  Mostly due to tow consequences.
168
diaphragm cover broken. starting in 1st or 2nd gear
Or
 Incorrect gear selection
Withdrawal fork worn out Wear of the fork at pivot end  Replace the fork.
or the release bearing end
169
Improper clutch release –

Clutch disc warped. New disc not checked before  Check the new disc’s runout &
installation replace it.
Clutch plate is binding on the 1. Clutch disc hub splines  Replace the clutch plate.
input shaft’s splines. damaged during
installation.
2. Input shaft splines rough  Replace input shaft is severely
or damaged. damaged.
3. Corrosion or rust  Replace the clutch plate. Replace
formation on splines of the input shaft if the scaling can
disc and input shaft. not be removed.
Clutch disc-facing sticks to Vacuum may form in pockets  Drill 1/16 inch diameter hole
flywheel. over rivet head. Occurs as through rivets and scuff sand the
clutch cools down after use. clutch disc facing .
Clutch will not disengage 1. Low fluid in the clutch  Top off the fluid and check for
properly. master cylinder. leaks.
2. Air in the hydraulic  Bleed & refill the system.
system
3. Clutch cover loose.  Tighten the bolts.
4. Wrong clutch disc.  Replace disc.
5. Clutch cover diaphragm  Replace the cover assembly.
spring bent / warped
during transmission
installation.  Fit the clutch plate correctly the
6. Clutch disc fitted hub should be facing the pressure
backwards. plate side & the flywheel side mark
towards the flywheel
Bush worn out / damaged Vibration / misalignment  Fit new bearings & check for
Clutch misalignment misalignments.
Hard gear shift -

Brake fluid less and or 1. Leaks  Replace fluid.
contaminated 2. Reservoir strainer  Stop leaks and avoid
missing contamination.
Excessive clutch pedal free Wrong adjustment or lock Adjust
plays. nut loosening
Clutch plate warpage 1. Warpage due to handling Replace
or assembly.
2. Warpage due to
misalignment.
170
• Care of the System –
While topping up use the recommended fluid conforming to DOT 3 specifications only. Avoid mixing
different brands.
The clutch fluid is hygroscopic fluids hence tend to collect humidity. The humidity along with the brake
fluid can cause acidic reaction & seizure of the master & slave cylinders. The clutch fluid should be
replaced every 30,000 km or one in a year, whichever is earlier. The master & clutch cylinder seals to
be replace every 50,000 Kms.
Refer procedures given below while doing scheduled maintenance of the Clutch System -
• CLUTCH FLUID LEVEL & LEAK – INSPECT
• CLUTCH FLUID – REPLACE
171
 CLUTCH FLUID LEVEL & LEAK - INSPECT
Clutch Fluid – DOT3 standard / SAE J1703 / IS 8654
MAX MAX
MIN
MIN
Schematic - Clutch System
CLUTCH FLUID – LEVEL & LEAK - INSPECT

Refer above illustration –
• Check for Clutch Fluid Level up ‘Max’ mark on the brake/clutch fluid reservoir.
• Check for 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.
 Clutch slave cylinder inlet banjo.
 Clutch slave cylinder bleed screw.
• The clutch fluid container should not be opened with dirty hands to check fluid level.
• Avoid direct water spray while washing engine compartment.
 Park the vehicle on level ground/2 post lift /4 post lift.

 Always use recommended fluids only.
 Do not mix different brand fluids.
 Clutch fluid level to be inspected at every 5000kms.
 Mahindra recommends CASTROL UNIVERSAL Fluid “CUBF”/
TVS Girling DOT 3.
172
 CLUTCH FLUID – REPLACE
Clutch Fluid – DOT3 standard / SAE J1703 / IS 8654
1
MAX
MIN
Schematic - Clutch System
CLUTCH FLUID – REPLACE

1. Remove the dust cap of the bleeder screw.

2. If the bleeding operation is done without connecting a tube and in the open air then the
chance of air remaining trapped is high.
3. Connect bleeding tube, to bleeding screw on slave cylinder.
4. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch fluid.
5. Fill the Reservoir clutch master cylinder up to the top level with recommended clutch fluid.
6. Operate clutch pedal 3 or 4 times slowly to the full stroke.
7. 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.
8. Repeat the exercise till no air bubbles appears in the bottle.
9. During this operation ensure fluid level in reservoir.
10. Tighten the bleed screw properly.
11. Remove bleeding tube and place the dust cap on bleed screw.
12. Check the fluid level in container and be top up to the ‘MAX’ level.[1]
13. The clutch fluid container should not be opened with dirty hands to check fluid level.
14. Avoid direct water spray while washing engine compartment.

 Use recommended fluids & don’t mix different brand fluids.
 Clutch fluid to be replaced at every 30000kms.
 Mahindra recommends CASTROL UNIVERSAL Fluid “CUBF”.
173
• Adjustment of clutch pedal height
• Clutch bleeding.
Adjustment of clutch pedal height –
Loosen the lock nut of master cylinder’s push rod

fork.
Slide back the dust cover.
Rotate the master cylinder push rod till desired

height of pedal is achieved.
Tighten the lock nut of push rod fork.
Screw in pedal stopper bolt completely.
Press pedal fully till the pedal bottoms on the floor.
Now screw out the pedal stopper bolt till it touches
the pedal lever, release pedal.
Screw out the bolt further by one turn. Tighten the
locknut.
Recheck pedal height.
Bleeding the clutch system –
Clean the external areas of the clutch slave cylinder

and remove the dust cap of the bleeder screw.
If the bleeding operation is done by without

connecting by a tube and in the open air then the
chance of air remaining trapped is high.
Connect bleeding tube, to bleeding screw on slave

cylinder.
Ensure that the other end of the tube is fully

immersed in the bottle having clean clutch /brake
fluid.
Fill the Reservoir clutch master cylinder up to the top
174
level with recommended clutch fluid.
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.
Repeat the exercise till no air bubbles appears in the
bottle.
During this operation ensure fluid level in reservoir.
Tighten the bleed screw properly.
Remove bleeding tube and place the dust cap o bleed

screw.
Check the fluid level in container and need be top up

to the ‘max’ level.
Clutch Actuation Mechanism –
The clutch actuation is hydraulic actuation. The clutch pedal actuates a master cylinder. The hydraulic
fluid is transmitted to the slave cylinder through Bundy tubes.
The slave cylinder actuates a fork, which is pivoted on a ball pivot. The other end of the fork; a release
bearing on a carrier actuates the diaphragm springs.
• Clutch Master cylinder overhaul

• Slave cylinder overhaul.
• Slave cylinder and Concentric bearing Overhaul
175
Clutch Master Cylinder overhaul –
Remove the outlet pipe connection.
Remove the clevis pin lock & the clevis pin.
Remove the clutch push rod fork & the clutch pedal.
Remove the master cylinder from the firewall.
1. Pull back the dust cover.
2. Remove circlip.
3. Remove the push rod assembly with

retainer washer.
4. Remove the piston assembly by gently

tapping the Clutch Master Cylinder body
on a wooden block.
176
Using a screwdriver, lift the leaf spring retainer.

Remove spring assembly from plunger.
Take care, while lifting the spring otherwise the spring

and the stem will fall off.
Compress spring to free valve stem from eccentrically

positioned hole in the end face of spring retainer. This
will separate spring retainer from valve stem.
Remove spring, valve spacer and spring washer from

the valve stem.
(While assembling hold the spacer between fingers
such that the valve stems hangs down vertically. Pull
down the stem downwards as far as possible. Observe
if the valve stem has moved freely upwards. If
movement is not free replace valve spacer.)
Remove the valve seal from the valve stem.
The bore and the plunger should be checked for

scoring, scuffing uneven wear marks, corrosion and
excessive clearance between plunger & body
Check the condition of dust cover for cut,
deterioration if damaged replace.
The assembly procedure is the reverse of the
dismantling procedure.
While fitting the plunger lubricate it with brake fluid.
177
Slave cylinder overhaul –
Remove the Bundy pipe from the inlet port of slave

cylinder.
Remove the slave cylinder from the mounting bracket.
1. Remove dust cover.
2. Remove circlip.
3. Remove plunger with gland seal and plunger spring from body by lightly tapping it on wooden
block.
4. Remove gland seal from plunger.
178
The bore and the plunger should be checked for

scoring, scuffing uneven wear marks, corrosion and
excessive clearance between plunger & body
Check the condition of dust cover for cut,
deterioration if damaged replace.
The assembly procedure is the reverse of the
dismantling procedure.
While fitting the plunger lubricate it with brake fluid.
Make sure that the push rod end is firmly located at

the fork.
Clutch overhaul –
Block the front wheels, so that the vehicle does not

move forward.
Disconnect the negative cable of the battery.
Remove the electrical connections to the starter

motor.
Remove the starter motor.
Remove the clutch slave cylinder from the gearbox

mounting.
Remove the propeller shaft from the gearbox end.

Do not allow the propeller shaft to hang. Support it.
Remove the speedometer cable from the gearbox

end.
Remove the electrical connection for the reverse
lamp switch.
Support the engine suitably at rear.
179
Remove the gearshift lever grommet.

Remove the gearbox lever upper half.
Support the gearbox using a suitable stand.

Remove the gearbox mounting insulators.
Remove the clutch housing mounting screws to the
engine rear face & the ladder frame.
Move the gearbox away from the engine.
Remove the clutch release bearing with sleeve.
Remove the clutch fork.
If the original cover will be reinstalled then mark

position of cover on the flywheel for assembly
reference. Use paint as a marker for this.
If the cover assembly may be reused then loosen the
cover bolts evenly and in tightening sequence to
relive the spring tension equally.
The bolts should be loosened few threads at a time –
so that the warping is avoided.
If the cover assembly is not going to be reused then
this precaution is not essential.
If the pilot bearing has to be removed then the
flywheel has to be removed and then the bearing
removed.
The assembly sequence is the reverse of the dismantling (except the precautions mentioned.)
Inspection:
All the components should be inspected for wear. Any components, which are beyond the wear limits,
have to be replaced.
Over & above the wear limits: The following points also need to be ensured.
Flywheel run-out --
The flywheel run-out needs to be checked whenever misalignment is suspected. Flywheel run-out
should not exceed 0.10 mm
To measure the run-out; mount the base of the magnetic dial gauge on the block. Locate the dial
gauge’s needle on the outer surface of the flywheel.
Some of the common reasons for excessive run-out are:

 Heat warpage.
 Improper machining.
 Incorrect bolt tightening
180
 Foreign material on crankshaft flange or flywheel.

 Improper seating on crankshaft.
If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it
back ensure that:
 No dirt and grease present on the mounting face (it can cause cocking & run out)
 The flywheel bolts have been replaced.
 Torque tightened as per sequence and also the angular tightening as per the specification is done.
Absence of any of these requirements may result in bolt loosening causing flywheel runout.
Clutch cover & Disc runout --
Check the clutch disc run-out before fitting. It should be within the specifications. If it is more than the
specification- use a different clutch plate.
A warped cover or diaphragm spring will result in clutch grab and / or incomplete release of clutch
plate.
If the clutch alignment tool is not used then the misalignment of the clutch plate can cause distortion
of the cover and also disc damage.
The cover can also get misaligned due to improper tightening of the cover onto the flywheel. The only
way to avoid is that the bolts must be tightened alternatively (diagonal pattern) and evenly i.e. 2 to 3
thread a time only.
Clutch Housing Misalignment –
The clutch housing has to be aligned with the engine so that the input shaft is aligned with the
crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It
can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also
damage the splines of the input shaft and clutch hub’s well as the clutch splines
 Normally the clutch housing misalignment is a result of:

 Incorrect seating on the engine/transmission.
 Missing alignment dowel holes.
 Loose or missing mounting bolt.
 Mounting surfaces that are damaged/ not parallel.
Before fitting the clutch housing ensure that no dirt, debris or foreign parts are trapped between the
mating surface of the transmission & the clutch housing.
181
Flywheel --
If the flywheel is found to be having minor scoring then it can be resurfaced. However the maximum
allowed cut is 0.076 mm. If scoring is deeper than 0.0076 than the flywheel has to be changed.
(Excessive material removal will cause the flywheel to either crack/ warpage after installation/ drop in
clamping load and will affect the proper clutch release as the travel of release bearing gets affected.)
If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it
back ensure that:
 No dirt and grease present on the mounting face (it can cause cocking & run out)
 The flywheel bolts have been replaced.
 Torque tightened as per sequence and also the angular tightening as per the specification is done.
Absence of any of these requirements may result in bolt loosening causing flywheel runout.
Starter/ flywheel ring replacement: Unless the provision of properly heating & fitting is available. It is
not recommended to replace the starter ring. It is worthwhile to replace the ring along with the
flywheel.
Caution: If the starter ring is only going to be replaced then:-
• Do not use a gas flame to cut. It can cause local overheating of flywheel.
• The ring gear has to be heated in an oven to get uniform expansion. (Nearly 191°C)
• Do not uses flame to heat the ring – it can cause annealing of the ring teeth and premature failure.
182
• Specifications & Wear Limits –

Clutch control type- Hydraulic- self adjusting
Pressure plate Diaphragm
Clutch Disc Progressive
Outer Dia (mm) 240 ±1
Inner Dia ( mm) 160 ± 1
Disc Thickness ( mm) 8.0 mm (free)

Clutch disc run out --
Minimum thickness from 1 mm
outer face to rivet head.
Clutch pedal Suspended Type

Clutch pedal Ratio 7.12
Clutch pedal free play ( 10 to 20 mm

including push rod play at
pedal top)
183
Master Cylinder 19.05 mm

Bore diameter
Slave Cylinder 23.81 mm

Inner diameter
Clearance between 0.13 mm

The piston & the bore
( Both cylinders)
Flywheel Standard Service

Limit
Flatness ≤ 0.05 0.1
Runout ≤ 0.05 0.1
Flywheel
Width from Mounting face to 72 mm
clutch face
Clutch release point from
pedal full stroke end position 25 mm from Bottom position
Pressure plate finger height ( 47.6 ± 1.0 mm
mm)
Diaphragm spring tip non 0.8 mm ( finger to finger)

alignment.( Max)
Diaphragm spring finger wear Max depth 0.5 mm

Max width 5 mm
184
Location Torque Value
Pressure plate bolts 23.5 ± 3.5 Nm (17 ± 3 lbf-ft)

Hydraulic clutch Bundy tube connections pipes 15 ± 1Nm (11 ± 1 lbf-ft)
Clutch master cylinder mounting nut 18.5 ± 3.5 Nm (14 ± 3lbf-ft)
Clutch slave cylinder bolts 37.5 ± 2.5Nm (28 ± 2lbf-ft)
Flywheel Bolts 95 ± 5Nm ( 70 ± 4 lbf-ft)
Clutch pedal pivot bolt and nut 27.5 ± 2.5 Nm ( 20 ± 2 Lb-ft)
• Lubricants Recommended –
Specification: DOT 3
Castrol/ Girling Brake Fluid
Hindustan Petroleum: HP Super Duty Brake Fluid
Indian Oil: Servo Brake fluid Super HD
185
TRANSMISSION
(NGT 520 – TRANSMISSION)
Contents…
• Description…………………………………………………………………. 187
• Trouble Shooting………………………………………………………….. 189
• Care of the Transmission………………………………………………… 191
• In Car Repairs……………………………………………………………… 192
• Transmission Dismantling………………………………………………….. 202
• Transmission Component Inspection……………………………………. 213
• Sub-assemblies………………………………………………………………. 215
• Assembly Inspection………………………………………………….. 235
• Specification……………………………………………………………….. 237
• Tightening Torques……………………………………………………….. 238
• Sealant Recommendation……………………………………………….. 238
• Special Tools……………………..………………………………………… 239
186
• Description –
It is a 5-speed gearbox. All the forward speed is synchromesh type. The reverse gear is having sliding
mesh type.
The gear selection is by a direct shift lever tongue operating in between shift rail gate. The accidental
operation of two gears is avoided by an interlocking mechanism. To avoid vibrations passing on to the
shift lever, the shift lever is a two-piece with rubber isolation provided on to the top half.
The gearbox housing is tunnel type Cast iron with an intermediate plate. The Gearbox is mounted
directly on the engine through the integral clutch housing and supported at bottom below the rear
housing. The output shaft is fitted with companion flange which is bolted to propeller shaft in case of
2 wheel drive. If vehicle is equipped with 4 wheels drive the output shaft is splined and is mated to the
transfer case.
Refer illustrations of –
1. NGT520 transmission cross sectional view of 2WD.

2. NGT520 transmission cross sectional view 4WD.
3. Synchroniser pack assembly cross section view used in NGT 520 Transmission.
CLUTCH HOUSING INTERMEDIATE

PLATE SHIFT LEVER
MAIN DRIVE SHAFT SYNCHRO PACK 3 & RD
RELEASE BEARING
SYNCHRO
4TH PACK 3RD &
SLEEVE 4TH
BREATHER SYNCHRO
REAR HSG. ASSY.
FRONT PACK 1ST & 2ND
HOUSING COMPANION
FLANGE
5TH REVERSE
COUNTER SHAFT SYNCHRO
SUB-SHAFT
PACK 1ST &
NGT 520 TM (2WD) Cross-sectional View
187
CLUTCH HOUSING
SHIFT LEVER
MAIN DRIVE SHAFT
SYNCHRO
RELEASE
REAR HSG.
PACK 1ST &
BEARING
ASSY
BREATHER INTERMEDIATE SPLINED
FRONT HSG. PLATE OUTPUT
ASSY SHAFT
SYNCHRO PACK 3RD

COUNTER SHAFT 5TH REVERSE
& 4TH
SUB-SHAFT
NGT 520 TM (4WD) Cross-sectional View
Synchronizer Pack Assembly Cross Section View
188
• Service Diagnosis / Trouble Shooting –
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an
incorrect lubricant level check.
Leaks can occur at the mating surface of the gear case, intermediate plate and adapter or extension
housing or from the front/rear seals. A suspected leak could also be result of an overfill condition.
Leaks at the rear of the extension or adapter housing will be from the housing oil seal. Leaks at
component mating surface will probably be the result of inadequate sealer, gaps in sealer, incorrect
bolt tightening, or the use of a non-recommended sealer.
A leak at the front of the transmission will be from either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe,
it may also contaminate the clutch disc causing slip, grab and chatter.
A correct lubricant level check can be made only when the vehicle is level, use a two post or a four
post hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These
recommendations will ensure that an accurate check and avoid an under fill or overfill conditions.
Hard Shifting
Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants,
component damage, and incorrect clutch adjustment or by a damaged clutch pressure plate or disc; or
worn out brass synchro ring.
Substantial lubricant leak can result in gear, shift rail, synchro and bearing damage. If a leak goes
undetected for an extended period the first indications of a problem are usually hard shifting and
noise.
Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear, internal bind and hard shifting.
Improper clutch release is one of the most frequent causes of hard shifting. Incorrect adjustment of a
worn damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced
then gear clash during shifts can be resulted. Incomplete travel of the clutch pedal due to restrictions
at the end of stroke (upturned carpet, extra carpet or cover or bend clutch linkage can also cause
improper clutch release and hard shift.)
Worn or damaged synchro rings can cause gear clash when shifting any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most
conditions this will decline as the rings wear in.
Transmission noise
Most manual transmissions make some noise during normal operation. Rotating gears can generate
slight whine that may only be audible at extreme speeds.
189
Severe obviously audible transmission noise is generally the result of a lubricant problem. Insufficient,
improper or contaminated lubricant can promote rapid wear of gears, synchros, shift rail, forks and
bearing’s. The overheating caused by a lubricant problem can also lead to gear breakage.
Summarizing the common faults and their cause:
PROBLEM POSSIBLE CAUSES CORRECTION

Gear Whine • Low oil level  Top up oil.
• Worn teeth gears  Replace gears
• Worn bearings  Replace bearings.
Knocking or ticking • Chipped gear teeth  Replace gears.

• Foreign matter inside  Remove the foreign matter
transmission. and locate how the foreign
matter came inside e.g.
missing breather and rectify
that also to avoid recurrence.
 Replace the bearings.
• Defective bearings.
Jumping out of gear • Defective detent springs.  Replace the detent springs.
• Worn out grooves in shift rail.  Replace the shift rails.
• Shaft misalignment.  Check & Correct it.
• Worn dog teeth in gear  Replace the gears
• Worn out fork/ fork pads  Replace the fork/ pads
• Worn out synchronizer body.  Replace the body
• Gear lever fouling.  Check & correct.
• Bottom lever slot worn out.  Replace bottom lever.
Unable to select gear • Clutch defective  Rectify the clutch/ clutch

withdrawal mechanism
• Worn out selector mechanism.  Rectify the gear selector
mechanism.
• Worn out brass synchro ring.  Replace synchro ring.
• Gear clutch teeth damaged.  Replace gear.
Hard gear shifting • Clutch defective  Rectify the clutch/ clutch

withdrawal mechanism
• Improper or contaminated  Replace the lubricant with the
lubricants specified lubricant.
• Worn out brass synchro ring.  Replace synchro ring.
• Gear clutch teeth damaged.  Replace gear.
NOTE:
• Transmission assembly steps given below consist of Problems, Causes and Precautions while
assembling of sub components and main assembly.
• For more details on various problems and probable causes refer the assembly procedure section
prescribed in this manual.
190
• Care of the Transmission –

Use lubricant meeting oils specification of API GL4 and viscosity 80W90 Synchro. Recommended brand
name is MAXIMILE GO 80W90 Synchro. Recommended fluid replacement interval first is 10000 kms,
then every 30000 kms. The fluid capacity/ quantity in NGT520 Transmission are 2 Liters.
TRANSMISSION OIL – REPLACEMENT PROCEDURE
NGT 520 - Transmission
Transmission Oil – Replace (Refer above illustration)

1. Remove the Filler plug.
2. Put the oil collection tray under transmission, Remove the drain plug. Allow the oil to
drain out completely.
3. Clean the metal particles if any deposited on the drain plug. 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 and torque to 27.5±2.5 Nm.
5. Check Oil leakage / seepage at –
• Transmission Housing Joints.
• Transmission Oil drain plug.
CAUTION: While replacing the transmission fluid ensure that –
• Vehicle is parked on level ground/ 2 post/ 4 post lift.

• If the activity is done on a 2 post lift and vehicle is fitted with LSPV, ensure that
the LSPV spring is disconnected before lifting the vehicle & re-connect the LSPV
spring & ensure that the setting height is correct after job completion.
• The lubricant level should be at the lower edge of the filler plug.
• The filler plug and drain plug on NGT 520 TM to be tightened to 27.5 + 2.5 Nm.
191
Rear Oil Seal Replacement –
• Remove the Rear propeller shaft from

companion flange*
( Only rear propeller shaft in case of 2 wheel

drive vehicle)
• Refer section ‘ removal and installation of

propeller shaft’
• Remove the Speed sensor* from Transmission assembly (*optional)

• Remove the Locking nut from companion flange assembly. Hold the companion flange while
removing nut.
• Remove washer form companion flange.
• Remove the companion flange from

Transmission assembly.
• Use flange puller in case it found jam.
192
• Remove dust cover.

• Remove rear oil seal using tool.
• Always replace with a new seal once it has been removed.
Installation –
• Before installation apply multi-purpose grease to lip of oil seal.

• Install new seal, press until it stops.
• Refit propeller shaft assembly.
193
• Gear Position/ Gear Neutral Switch Check -

Micro hybrid vehicles are equipped with ‘STOP START’ system. The Gear neutral Switch is located on
the Adaptor Pivot Plate. Refer illustration below.
• Check continuity, refer below chart.
Switch Gear Position Continuity

Reverse Yes
Reverse lamp switch
Except Reverse No
Neutral Yes
Neutral Position Switch
Except Neutral No
NOTE:
Neutral switch should be fitted with 6 mm gap with sensor; Sensor is fitted on bottom gear lever.
194
• Transmission Rear Insulator Removal –
NGT 520 Transmission

(2WD)
Rear Insulator
Cross Member below

transmission
CAUTION:
• Before separating the transmission from the engine, remove the crankshaft position sensor
(OBD) from the clutch housing.
• Support transmission while removing it from vehicle.
• Remove battery –ve terminal.
NOTE:
• To prevent oil spills, drain transmission oil before removing transmission.
• Ensure and take care of rear oil seal while removing propeller shaft.
• Lift vehicle on four post.
• Remove battery terminal.
• Remove Clutch Slave Cylinder from clutch

housing.
195
• Remove Gear Neutral switch connector*

from transmission.
• Remove reverse light switch connector on

TM assembly.
Refer illustration for locations of Reverse light

switch on NGT 520 Transmission.
• Disconnect and remove speedo cable from

speedo sleeve fitted on Transmission.
• Remove starter motor from transmission.
• Remove Rear propeller shaft.
• Remove gear knob and shift lever- upper part.

• Remove insulator below TM and the Cross member below the TM assembly.
CAUTION:
• Support to the TM assembly bottom side for safety purpose and to avoid TM damage.
196
• Support engine by placing a jack under oil pan; before removing Bell housing mounting bolts.
• Do not place jack under oil pan drain plug.
• Remove bell housing mounting bolts and separate transmission from engine.
• If vehicle is equipped with 4 wheel drive, ensure to –
• Disconnect and remove four wheel drive

Shift link.
• Put tray below the transfer case, remove

drain plug to drain the Transfer Case oil.
197
• Disconnect and remove the speedometer

cable connector on Transfer case.
• Disconnect and remove the front propeller

shaft.
• Remove the transfer case insulator by

removing its mounting bolt.
Put spanner through cross member hole to

access the mounting bolt of insulator.
CAUTION:
Support to the TM assembly bottom side for

safety purpose and to avoid TM damage.
198
• Transmission Case Components –
• Transmission Gear Components –

• Main Drive Gear –
199
• Main Shaft Drive Gear & Synchronizer–
• Counter Lay Shaft Gear & Synchronizer –
200
• Shift Control Components -
PLUNGER
POPPET PLUG
• Selection Biasing and Shift Lever Components –
201
• Transmission Components Disassembly –
NGT 520 2WD Assembly NGT 520 4WD Assembly
SCHEMATIC OF NGT 520 TM DISASSEMBLY

• Remove Clutch release bearing and fork.
202
• Remove clutch housing from transmission

assembly.
NOTE:
• Use mallet for slight tapping on bell housing
while removing from transmission.
• Remove the bellow and bottom lever

mounting bolts.
• Lever and locating pin removal.
203
• Use a lengthy screw driver and put gear in

neutral position for ease of removal of gear
components.
• Remove the Speedo gear along with adaptor.
• Remove Companion flange lock nut and

washer.
• Remove the companion flange from

Transmission end.
204
Rear housing Removal -
CAUTION:
• Rear housing should be in straight position
while removing.
• To avoid oil spillage, check and drain
remaining oil residuals from housing.
• Be careful not to damage of rear oil seal.
Front housing removal -
CAUTION:
• Remove the counter shaft front bearing
spacer.
Remove Circlip, Bellevelle washer, Snap ring
and Adjuster shim from end of MD Gear
assembly.
• Remove front release brg. Sleeve.
• Use brass hammer while removing the front
housing from intermediate plate.
205
• Remove 5th drive gear bearing using puller. Remove Shim and Spacer.
• Remove 5th gear driving gear by removing roller bearing, using Special tool.
CAUTION:
• Move sub shaft in forward direction.

• Reverse gear fork to be taken forward and
remove Circlip and bearing using puller.
• Remove 5th driven gear with bearing.
206
Remove 5th and Reverse hub assembly -
CAUTION:
• Be careful not to lose pin, shifting inserts.
Remove poppet plug fitted on intermediate plate and shaft rail assembly of 5th and reverse.
CAUTION:
• Be careful not to lose ball & spring while removing shaft and rail assembly.
NOTE:
• It is differ as in 2WD and 4WD.
• Output shaft in 4WD provided with lock nut where as in 2WD it is plane OD.
• Output shaft in 4WD is having splines throughout the shaft where as in 2WD it is fitted with
companion flange.
207
Removal of Shift Rail and Fork assembly -
CAUTION:
• Remove insert pin using dolly.
• Remove fork shaft by hand.
• Remove insert pin on 1st/2nd shift rail.
• Remove fork shaft by hand, use mallet if required.
• Remove fork on 3rd/4th and 1st/2nd
NOTE:
• 4WD output shaft having splines throughout the shaft end, whereas 2WD output shaft is having
Companion flange and nut fitment arrangement at the shaft end.
• Remove lock nut on output shaft* in case 4WD transmission.
NOTE:
• Use special tool, lock the free movement of assembly and remove nut.
208
• Take out reverse gear from output shaft
 Sub-Plate and Drive Shaft Removal –

• Remove sub plate fitted on intermediate plate assembly.
(It is located on output shaft side).
• Remove circlip on output shaft main bearing.
209
 Separate drive shaft from intermediate plate -
NOTE:
• Use mallet to remove the main drive shaft
from intermediate plate.
• Remove main drive gear assembly.
• Remove counter shaft bearing and cone from

intermediate plate. Use puller, refer
illustration.
• Remove main shaft main bearing using puller.

MD Gear dismantling –
• Remove synchro ring.
• Remove circlip and bearing using tool.
• Remove roller bearing by hand.
210
 Main Shaft Drive Gear & Synchronizer dismantling –
• Separate Counter shaft from Intermediate

plate.
• Counter shaft front bearing can be removed by

using bearing puller.
211
• Counter shaft rear bearing can be removed by

• Remove the circlip.
• Remove the Hub assembly.
CAUTION:
• Be careful not to lose synchro key.
212
• Transmission Components Inspection –

1. Shift Control Rod and Fork Inspection:
• Check contact and sliding surfaces of Shift Rod and Fork for wear, scratches and damage if any.
2. Gear Components Inspection:
• Check gear shafts for cracks, wear and

bend if any.
• Check gears for excessive wear, cracks,

tooth breakage and chips if any.
213
3. Synchronizers:
• Check splines portion of coupling sleeves,

synchronizer hubs, and gears for wear,
chips, and cracks.
• Check shifting synchro key for wear and
deformation.
• Check synchro key C-spring for
deformation.
4. Bearings:
• Ensure that all bearings are roll freely.

They are free from noise, cracks, wear
and pitting.
214
• Transmission Components Assembly –

• Assembly of the Transmission is the reverse of its disassembly. While assembling following care
should be taken.
CAUTION:
• Ensure that front housing, intermediate plate and all components are free from dirt, dust before
assembling.
• Transmission bearings life will reduce in case use of unclean gear components used.
 Assembling Synchronizers (Strut type) -
• Ensure fitment of both sides.

• Check all three key for proper fitment.
• Ensure free movement of hub & sleeve.
• Ensure proper C-spring fitment.
 MD Gear Sub assembly -
• Ensure circlip groove on the bearing to be on

the top side. Refer illustration.
• Circlip to be assembled after bearing fitment.
NOTE:
• In case circlip is missing/ not fitted properly;
excessive play in MD gear will be observed
which can lead to gear slippage.
 Counter Shaft Sub assembly -
• Ensure direction of inner race as shown in

illustration.
• Press bearing as shown in illustration.
215
CAUTION:
• Press bearing to the full depth.
• Maintain run out of counter & sub-shaft within 0.05 mm. (extended countershaft with subshaft)
• Mark counter & sub-shaft with marker on spline end for matching at which the run out is within
specification.
NOTE:
• If run out in counter sub-shaft pairing is not maintained then 5th gear slippage can take place.
 Intermediate Plate assembly -
Bearing installation in intermediate plate-

• Main shaft ball bearing installation in intermediate plate.
CAUTION:
• Ensure counter shaft bearing is pressed such that bearing should be flushing with the rear face of
the plate.
• Ensure torque on M10 bolts for idler shaft. Torque value 43 ± 7 Nm.
NOTE:
• In case Idler shaft is not fitted properly or not torque as per recommended value, the 5th gear
failure issue may come, or 1st gear teeth will foul with idler shaft.
• Insufficient bearing pressing can restrict lever to and fro movement/ gear slippage may occur.
• Over torque or under torque to the idler shaft bolt may lead to reverse gear failure due to
support loosening.
 Front housing sub assembly -
• Ensure that rail end caps are fitted.

• Ensure that dowel slot is inside while entering into front housing.
• Ensure that dowel is pressed fully.
• Place the filler plug.
• Ensure that rail and cap flushed with housing cap.
216
NOTE:
• If end cap not fully pressed then dust can go inside the tm before clutch housing fitment.
 Bearing Retainer/ Clutch Release Bearing Sleeve Sub Assembly -
• Ensure that oil seal direction is correct before

assembly.
• Ensure proper pressing and fitment of oil seal.
NOTE:
• In case oil seal not fitted properly or gets
damage while fitting, the oil leak complaint
may come.
• Apply oil on seal lip for initial lubrication
purpose.
5th Reverse Hub Sub assembly (Double DOP) –

Do entire assembly of 5th/Rev hub on press fitted hub along with sub shaft or do separate sub
assembly of 5th/Rev hub & then press it on sub shaft.
CAUTION:
In case assembly is not proper, hard shifting or reverse gear failure may occurs.
• Match the sleeve in hub with respective

direction. (Plain side of sleeve & grooved side
of hub on upper side.
• Insert three struts. Small length on rev side &

big length on 5th side.
217
• Insert the C-SPRING covering all three struts.
• Place the BELLE VELLE WASHER in hub with

tapper angle down side.
• Place the PROTECTOR & fix the circlip by

hammering using dolly.
• Rotate entire assembly on opposite side i.e.

5th side & fix the C-SPRING.
218
• Check the entire assembly for the fitment.
• Use Double DOP hub having groove on OD.
NOTE:
• In case synchro key is missing or fitted in wrong direction, no shifting will takes place or synchro
will damage in running.
• If sleeve is fitted in opposite direction, no shifting will takes place.
• In case C-spring missing or if it is not covering one key, crash shifting occurs.
• If belle velle washer is missing gear box noise may come.
• Gear box will jammed in case of circlip is missing.
 Speedo Sleeve Sub Assembly –
CAUTION:
• Ensure proper direction of oil seal during assembly.
• Ensure proper pressing of oil seal.
NOTE:
• In case oil seal is not pressed properly or damages while assembling, oil leak issue may occur.
219
 Rear Housing Sub Assembly –
• Tighten the drain plug with nut runner & torque with wrench - (27.5 ± 2.5 Nm)
• Use freudenkeg seal (brown colour) for sub assembly & locate it on floating dolly for pressing.
• Check and ensure circlip for proper fitment.
CAUTION:
• Ensure proper direction of oil seal.
• Ensure bearing for fully pressed.
• Ensure oil deflector below the outer race of
cylindrical roller bearing.
• Ensure dowel for pivot fitment.
NOTE:
• Oil leakage takes place in case oil seal is missing or seal lip is damaged or cut.
• Over torque to the drain plug lead to crack on rear housing drain plug side and oil leak start.
• Under torque to the drain plug lead to drain plug falling off and oil leaks.
• If circlip is missing or not fitted properly, 5th driven gear & outer race will come out and get
damage.
• Gear box noise may come in case bearing outer race is missing.
 Output Shaft Sub assembly -
• Put output shaft spline side into fixture.

• Fit the needle cage, put the oil drops and fit
the 3rd gear. Fit the brass ring over it.
• Fit the hub into the spline. Ensure the
direction of hub, refer illustration.
220
• Put the BELLE VELLE washer and fix the circlip

on it.
• Use oil on cone of brass ring.
• Check snap ring for its proper sealing using
the gauge provided. Paint mark on the shaft
after checking.
NOTE:
• If 3rd gear circlip is not fitted properly, circlip
will come out resulting in lever too & fro
movement and 3rd gear slippage.
NOTE:
• In case of 4 WD, the output shaft will have internal threading.
• Ensure end play of 0.175 - 0.375 mm in 1st, 2nd and 3rd gear; in case wrong shims put or shims
missing, 1st/2nd or 3rd/4th gear slippage may occur.
• Ensure brass ring placement on each 1st, 2nd and 3rd gear.
• Ensure proper direction of bearing. (Snap ring groove should be above, away from 1st gear)
 MAIN ASSEMBLY -
 Power Train Assembly -

• Put MD Gear into fixture.
• Place the pilot bearing in MD Gear / Input
Gear.
• Apply grease to the pilot bearing.
• Insert 4th gear brass ring on MD Gear.
• Ensure that MD Gear and output shaft are

free.
• Put counter gear sub assembly on fixture.
221
 Adaptor Plate/ Intermediate Plate and Bearing Retainer Plate Fitment -
CAUTION:
• Ensure that the pilot bearing is fitted.
• Put locator on counter gear and then fit the
intermediate plate by tapping on plate.
• Ensure that the bearing is flushes with the
rear face of the adaptor plate.
• Ensure that the snap ring fitment before
placing the bearing retainer plate.
CAUTION:
• Apply ANABOND 111 sealant on M8 bolts.
• Torque value for retainer plate bolt is 31 ± 4
Nm.
NOTE:
• Ensure fitment & torque tighten of 4WD lock nut over reverse driven gear @ 60 ± 10 Nm. (Ensure
spacer sleeve fitment in 2wd models)
• Ensure circlip fitment under 5th driven gear in 4wd models
• Ensure crimping of nut with hammer & dolly.
• If snap ring is not fitted or bolts are not torque properly, crash shifting may occurs.
 SRSF Fitment -
CAUTION:
• Ensure that Reverse driven gear is placed

before 1st/2nd rail is inserted.
• Put the grease before 3rd/4th interlock plunger
is placed.
222
• Fix the fork and insert 1st /2nd rail.

• Fix the ball and insert 3rd/4th rail.
• Press the 1st/2nd split pin. Ensure that 1st/2nd
split pin is not fouling with 3rd/4th rail.
• Ensure that 1st & 2nd split pin flushes with fork
boss.
• Ensure that both pins are pressed.
• Insert the plunger.
• Insert 5th & Reverse fork along with 5th &
Reverse synchro assembly and Reverse sliding
gear.
• Ensure ball and spring insert after 5th/Reverse
rail assembly.
223
CAUTION:
• Tighten the vibra-seal 516 pre coated puppet plugs & torque (25 ± 5 Nm) with use of angle nut
runner.
• In case of 4WD Transmission, put nut above reverse driven gear and torque tighten it.
• In case of 4WD Transmission, put snap ring above 5th gear and circlip below 5th driven gear.
NOTE:
• Shifting will not happen in case split pin not pressed.
• Crash shifting will occur if split pin is fouling.
• In case of ball & spring missing the shifting will be effortless and gear slippage issue may occur.
• In case of brass ring in 5th/reveres synchro assembly is missing, 5th crash shifting may occur.
• In case of no torque/ less torque to puppet plugs may lead to gear slippage; and high torque may
lead to thread slippage and then gear slippage.
• Puppet plug sealant application missing will lead to fluid leakage through poppet plug.
• In case 1st/2nd pin fouling with 3rd/4th hard shifting may occur.
• In case pin is partial pressed or missed out or pin direction is wrong, gear slippage will occur
and/ or gear will not shift or double gear engagement will occur.
• If fork is tight in rail, gear shifting will not happen.
• Use mallet to check and ensure that double

shifting is not taking place.
NOTE:
• If there is no gap at the rail end, it may foul
and hard gear shifting may happen.
• Apply sealant LOCTITE – 574 on front

housing face.
224
 5th Gear Pair Assembly -
• Put roller bearing on 5th driven gear.

Ensure cone is on bottom side.
• Ensure fitment of brass ring below 5th
driving gear.
• Match the 5th gear couple and press it.
• Ensure output shaft sleeve is not rotating
freely after pressing 5th driven gear.
• Ensure placing of spacer on 5th driving
gear and sub shaft.
NOTE:
• Use 5th driving gear without worm for 4WD Transmission.
• Ensure circlip fitment on gear in case of 4WD Transmission.
• If 4WD circlip is not used then it may lead to gear slippage/ seizure.
 Front Housing Tunnel Insertion -
• Ensure that loctite-574 is applied on front

housing face.
• Ensure ball and spring insertion in the
detent holes.
• Ensure torque tighten both the poppet
plugs.
• Ensure intermediate plate is located in
place.
• Put the assembly in front housing; tap the
intermediate plate if required.
225
NOTE:
• If sealant not applied properly Oil leakage
issue may come.
• Gear shifting problem-Synchro ring
damaged during insertion/improper
insertion.
 Rear Housing Shimming – (In case Housing is being replaced with new)
• Tighten 2 bolts to clamp front housing

and plate.
• Ensure that the front housing bottom face
is resting properly on the locating faces.
Use filler gauge of 0.05 mm to confirm no
gap. Gauge should not pass.
• After shimming put the ball bearing on
sub shaft & press with impactor dolly.
Shim selection procedure:

Dimension B= Intermediate plate face to Sub
shaft collar face.
Dimension A= Rear Housing face to lower
face of bearing bore.
Shim size =A - B -( 0 to 0.120 mm)
NOTE:
• Gear slippage will take place if Shim/spacer or both are missing.
• Gears jam/ not engage /bearing seizure will take place if Shim selection is not proper.
• If rear housing with bracket not used then wire routing on vehicle can't be done.
 Rear Housing Insertion on Main Assembly -
CAUTION:
• Ensure torque on M10 bolts - 8 numbers. - 55 ± 5 Nm.
• Ensure one number M10 bolt with hole.
• Use sealant FEVICOL- 171 on external thread of the Speedo sleeve.
• Apply torque on Speedo sleeve - 39 ± 4 Nm.
226
NOTE:
• Apply sealant Loctite-574 on rear housing.
• Ensure that shim is fitted on sub shaft.
• Put dolly on the splines of output shaft for

rear housing insertion & check for 5th
driven circlip fitted.
• Put the rear housing and tighteen the mounting bolts.
227
• Fit the rear housing and 8 nos. mounting

bolts.
• Tighten filler plug and drain plug.
• Assemble Speedo sleeve and Speedo
gear.
• Insert ball and spring in detent hole.
Ensure both ball and springs are inserted.
• Tighten the vibra seal 516 pre coated
puppet plug & torque @ (25 ± 5 Nm) with
use of Angle Nut Runner.
• Fit the dust shield on the rear housing
with 4 bolts.
• Torque the dust shield bolts with angle
nut runner at 25 ± 5 Nm .
• Fit companion flange on the output shaft
splines.
NOTE:
• Put the plane washer before fitting
companion flange nut.
• Apply Sealant (Anabond 111) on output
shaft spline/ nut ID.
• Torque the companion flange nut to -
191 ± 21 Nm.
• Remove the dolly after fitment of Rear housing assembly.

• Put the washer and Lock nut on output shaft.
228
NOTE:
• Apply Sealant (Anabond 111) on output
shaft thread/ nut ID; before fixing it on
shaft.
 Bearing Retainer / Clutch Release Bearing Sleeve Fitment -
• Ensure shim of MD gear fitment and snap

ring fitment on MD gear bearing.
• Ensure grease application on oil seal in
bearing retainer.
• Place belleville washer on the bearing
retainer before insertion on the MD gear.
• Place the counter shaft spacer before

retainer fitment.
• Use oil seal locator for retainer insertion
on the MD gear spline.
• Torque the m8 bolts to 24 ± 4 Nm.
229
NOTE:
• Apply the Loctite 243 on small side of stud before stud fitment.
• Use new front end Retainer which has groove on OD & suffix ‘O’ ring. Refer sketch.
• If snap ring or spacer is not fitted then gear slippage will take place.
• If M.D gear shim is not fitted then 4th to 2nd crash shifting will take place.
• If torque or tightening of retainer bolts is not done then Oil leakage will take place.
 Adaptor Pivot Assembly / Lever Sub Assembly -
• Adaptor pivot dowel fitment.
NOTE:
• Apply silicon sealant on pivot before inserting dowel. Inadequate sealant application on the
pivot will cause oil leakage.
• In case dowel pin is missing, no proper alignment of lever sub assembly.
230
• After adaptor dowel fitment, put the

adaptor pivot on fixture/ assembly table.
NOTE:
• If pivot not entering s/a fixture fully then
check whether the pivot pin is inserted
fully.
• Torque 3 M8 Bolts. - 24 ± 4 Nm.
• Assemble the gear bottom lever into the

Transmission assembly.
NOTE:
• The TM bottom lever assembly differs
from vehicle to vehicle as the NGT 520
Transmission is used for Xylo mDICRDe,
Scorpio M2Di, and in Bolero variants.
• Bottom lever shown in Illustration
belongs to Scorpio M2Di model.
231
• Assemble the correct gear bottom lever into the adaptor pivot assembly. Refer illustrations -
• Assemble the nylon bush, spring and retension plate. Refer illustartions.
NOTE:
• Ensure bush fittment. In case bush is missing, improper shifting or lever rattling may occur.
• After placing retension plate, press it and

then install the plunger and spring.
• Plunger and Spring fittmnet.
232
NOTE:
• In case plunger or spring is missing, biasing will not takes place.
• In case wrong spring used the biasing force will not ok.
• Side cover plate fittment. Ensure proper bolt fittment and torquing.
NOTE:
• In case bolt is missing or not torqued properly, the incorrect biasing may occur.
• Torque the side cover bolts to the torque
value 8 ± 2 Nm.
• Lever Fittment -
• Apply inadequate sealant on the adaptor

pivot bottom side mating face.
Refer illustration.
• Put the rubber below over bottom lever
and adaptor pivot.
233
• After fitment of Bottom lever assembly into the Transmission, torque the adaptor pivot to 24
± 4 Nm torque.
• Ensure proper location of pivot assy. with

help of dowel. - Pivot pin facing
downwards.
• Fit pivot pin with pivot insertion &
pressing impactor dolly.
• Apply silicon sealant on pivot.
• Fit pivot by tapping it.
• Use new Rubber grommet along with new

metal clip.
• Keep the clips of the metal tie clip
towards 5th/rev gear side.
234
• Apply sealant (Anabond 413/ Loctite 648)

on breather cap.
 Adapter Pivot & Gear Neutral Switch Fitment -
• Place the sensor on retainer plate.

• Put two lugs of sensor on plate hole and
press it.
• Fit two bolts of M8 40 on sensor lugs and
fit one bolt of M8 20 on plate. Torque
them 29 ± 2 Nm.
• Put 6 mm gauge between Magnet and

sensor while fitting to ensure gap (6 mm)
between them.
• Fit the Allen screw with help of screw
driver; apply 2.5 ± 0.5 Nm torque.
• Fit the grommet on pivot.
 Assembly Inspection -
Make sure that the following check points to be carried out after completion of Transmission
assembly and before fitting it on vehicle –
• Check for presence of railed caps.

• Check for presence of breather.
• Check for static shifting.
• Check for biasing.
• Check for presence of countershaft spacer.
235
• Check for presence of one number M10 flange bolt with hole.
• Check for reverse lamp switch lead damage.
• Check for drain plug torque (check if it is loose by hand)
• Check for presence of filler plug.
• Check for free rotation of MD Gear.
Recommendation –
Mahindra & Mahindra recommends that after the fitment of Transmission assembly on vehicle,
check all the parameters ensure all the fitments are completed and do vehicle drives test to check
Transmission behaviour as well as vehicle performance.
NOTE:
Vehicle to be run in neutral condition for 5 to 10 min for proper churning or lubrication of oil.
236
• Specification –
Type Mechanical
Description NGT 520
Gears 5 Forward and one reverse gear
Gear shift Direct shift with rubberized lever
Gears Helical- toothed
1 3 5 Gear Engagement Block synchro ring type synchronizer

on 1,2,3,4 & 5th
2 4 R
Gear Ratio
1st 3.778
2nd 2.087
3rd 1.379
4th 0.789
5th 3.524
Reverse
Oil grade/ quantity 80 W90; GL 4
Oil Capacity: 2.0 litres.
Counter shaft bearing One ball bearing/ one Cylindrical roller.

Input Torque capacity 20 Kg-m.
Weight 68 Kg
Kg
Play Limit (mm) Service limit(mm)
1st 0.175 0.375
2nd 0.175 0.375
3rd 0.175 0.375
4th 0.175 0.375
5th 0.18 0.3
Fork to groove clearances/ 0.1 to 0.4 mm
237
• Tightening Torques –
Description Torque in Nm (lbf-ft)

Plug - Shift Rail Poppet Spring 25 ± 5 Nm ( 18 ± 4 lbf – ft )
Flange Bolt / Nut – Clutch Hsg. To Main Hsg. 43 ± 7 Nm ( 32 ± 3 lbf – ft )
Flange Bolt – Front Intermediate & Rear Hsg. 55 ± 5 Nm ( 40 ± 4 lbf – ft )
Drain plug 27.5 ± 2.5 Nm ( 20 ± 2 lbf-ft)
Filler plug 27.5 ± 2.5 Nm ( 20 ± 2 lbf-ft)
Reverse light switch 30 ± 5 Nm ( 18± 4 lbf – ft )
Bolt – Clutch Release Bearing Support Sleeve 24 ± 4 Nm ( 18 ± 3 lbf – ft )
Bolt - Idler Shaft 43 ± 7 Nm ( 32 ± 3 lbf – ft )
Bolt - Bearing Retainer Plate 31 ± 4 Nm ( 23 ± 3 lbf – ft )
Lever Retention Bolt 24 ± 4 Nm ( 18 ± 3 lbf – ft )
Companion Flange Nut 191 ± 21 Nm ( 140 ± 15 lbf – ft )
Speedometer Sleeve 39 ± 4 Nm ( 29 ± 3 lbf – ft )
Bolt – Gear Box to Transfer case 55 ± 5 Nm ( 40 ± 4 lbf-ft)
Nut – Reverse Driven Gear 60 ± 10 Nm ( 44 ± 7 lbf-ft)
*also refer the torque values mentioned during the Transmission assembly and sub-assemblies where
ever applicable.
• Sealant Recommendation –
Sr. No. Location Sealant / Thread Locks Applicability

1 Ft. Hsg. & Intermediate Plate Loctite 574 
2 Intermediate Plate & Rear Hsg. Loctite 574 
3 Clutch Hsg. & Front Hsg. Loctite 510 

Anabond 413
4 Breather 
( Retaining Grade )
RTV Sealant Metlock 920
5 Pivot locking Option 1 – Rhodorseal 
Option 2 – Pidiseal 3P
Between Clutch Hsg. & OD of Ft.
6 Loctite 510 
Bearing Retainer
Clutch Release Bearing support
7 Loctite 510 
sleeve
8 Poppet Plug M 12X1.25 Loctite 542 
238
• Special Tools –
Description/ Part No./ Sketch Usage View
Dolly to press countershaft roller

bearing
0703AD0900H002
Dolly to press countershaft roller

bearing
0703AD0900H001
239
Dolly for pressing bearing on

output shaft
0703AD0900H011
Intermediate plate bearing pressing

dolly.
0703AD0900H005
Dolly for pressing ball bearing in

rear housing.
0703AD0900H015
240
Fixture to press bearing on output

shaft.
0703AD0900H007
Assembly fixture.
0703AD0900H004
241
PROPELLER SHAFT
Contents…
• Description……………………………………………………………………………. 243
• In Car Repairs………………………………………………………………………. 246
• Specifications & Wear Limits………………………………………………. 255
242
• Description
The function of the propeller shaft is to transmit power from one point to another. The shaft
is designed to transmit torque from transmission / transfer case to the axle.
The propeller shaft has to operate through constantly changing length while transmitting
torque. The axle rides suspended by spring in floating motion. The propeller shaft must be
able to change the transmission angle when going through the various road surfaces. This is
done through Universal joints which permit the propeller shaft top operates at different
angles. The slip joint or the yokes allow the contraction or expansion of the propeller shaft
thus allowing the length to change.
The propeller shaft is built with the yoke lugs in line with each other, which is called phasing.
This design produces the smoothest running condition. An out of phase shaft can cause a
vibration.
243
• Trouble shooting –
Tyres that are out of round or wheels that are out of balance cause a low frequency vibration.
Brake drums that are unbalanced cause a harsh low frequency vibration.
Driveline vibrations can also result from loose or damaged engine mountings.
Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller
shaft does not cause a vibration that is present only in a narrow speed range.
Drive condition Possible cause Correction

Propeller shaft • Undercoating or other  Clean exterior of shaft &
foreign on the shaft. wash with solvent.
• Loose companion flange  Tighten the mounting bolts.
mounting bolts.  Replace the joint/yoke.
• Worn out yoke/slip joint.  Check runout- replace shaft.
• Excessive runout.  Correct angularity.
• Incorrect drive line  Replace the UJ.
angularity.  Replace the propeller shaft.
• Worn UJ bearings.  Replace the rear springs.
• Propeller shaft damaged  Reindex the propeller shaft
or bent. by 180°, test and correct as
• Broken rear springs. required.
• Excessive runout or  Reindex the propeller shaft
unbalanced condition. by 180°, test and correct as
• Excessive pinion shaft required
runout.
Universal Joint Noise • UJ worn out  Replace the UJ
244
• PROPELLER SHAFT SLIDING JOINT - LUBRICATE

Grease Grade –MAXIMILE LCG, NLGI 2/3
Split Type Propeller Shaft
Refer below illustrations for grease pin locations on Sliding Joint.
Differential Oil – Replace (Refer illustration/ sample sketch shown)

1. Inspect the Sliding yoke for Grease & play; fill the grease through the grease nipple with
pressurized gun. Refer illustrations, grease nipples are shown by arrow marks.
2. Inspect the Universal Joint for play.
3. Check & torque tight the Companion Flange Nuts at both Transmission as well as Axle end
with – 23.5 ±3.5 Nm.
 Park the vehicle on level ground/2 post lift /4 post lift

 Always use recommended grease only.
 Propeller shaft sliding joint to be lubricated at every 10000kms.
 Before undercoating a vehicle with any under body protection; the propeller shaft
and the UJs should be covered. This will prevent the undercoating from causing an unbalanced
condition and vibration.
245
• In Car Repairs
 Removal of Propeller Shaft
 Disassembly of Centre Bearing
 Disassembly & Repair of UJ
 Inspection & Lubrication of Shaft & Components
 Check Unbalance
 Check Shaft Run-out
246
• REMOVAL OF PROPELLER SHAFT
Pre Removal Activities –

• Set the brakes and block the wheels.
• Mark the slip yoke assembly and tube shaft with a marking stick or paint to assure proper
alignment when reassembled.
Loosen and remove the pinion end companion

flange mounting bolts.
Loosen and remove the transmission end

companion flange mounting bolts.
Unscrew bearing strap retaining bolts at pinion

yoke.
Remove the Propeller shaft along with the centre

bearing assembly.
247
• DISASSEMBLY OF CENTRE BEARING –
Unstack clamping strap and remove centre

bearing bracket.
To remove the old seal, hold the yoke assembly

firmly in a vise. Using a large chisel, drive the seal
off the yoke.
NOTE:
• The unitized one piece seal used on drive

shafts is not intended to be removed in
service. To separate the tube shaft from
the slip yoke, pull the tube out of the slip
yoke, leaving the seal in place.
• Removal of the unitized seal causes

damage to the seal lip where it contacts
the slip yoke.
248
CAUTION:
• A significant amount of force is required to
remove and reinstall the tube shaft through
the seal.
Slide off rubber housing from centre bearing

assembly.
Remove rear spacer ring.
NOTE:
• Tight the locknut with washer with torque ranges of 11to 13 Kg.m.
• When the shaft is being fitted on to the vehicle, first keep the centre bearing loose, tighten at
the axle end, after that tighten the centre bearing mounting bolts.
249
• DISASSEMBLY OF UNIVERSAL JOINT:
Universal Joint Repair -

Lift the vehicle, Follow recommended procedure.
Put aligning marks on the flange, UJ and propeller

shaft before removal.
Do not use a punch to mark impression.
Remove the mounting bolts at the pinion end
Remove the mounting bolts at the gearbox end.
NOTE:
It is important to protect the machined, external surface of the yoke from damage after propeller
shaft removal. Any damage in the machined surface will lead to damage of the seal and cause a leak.
250
Remove the circlips holding the UJ in place.
If the bearing assembly will not pull out by hand

after pressing, tap the base of the lug near the
bearing assembly to dislodge it.
Applying the socket wrench on the outside of the

propeller shaft flange, force out one end of UJ using
a vice as shown.
• To remove the opposite bearing assembly, turn the yoke over and straighten the cross in the
open cross hole. Then carefully press on the end of the cross so the remaining bearing
assembly moves straight out of the bearing cross hole.
• Repeat this procedure on the remaining bearing assemblies to remove the cross from the
yoke.
While assembling- insert both ends then hold &

press fit them with special tool.
251
• INSPECTION & LUBRICATION
INSPECTION OF CENTRE BEARING

• Clean all parts thoroughly.
Note: Do not apply solvent in bearing assembly and rubber housing.
Check the following -

• Condition of splines and threads on shaft.
• Condition of splines and holes on coupling flange.
• Condition of rubber housing. Replace with new one if necessary.
• Condition of centre bearing bracket bearing surface and mounting holes.
• Condition of clamping strap for any damage specially at crimping portion.

• Free and smooth rotation of bearing unit in centre bearing assembly.
• The bearing should have negligible radial play.
• Condition of dust seals in centre bearing assembly.
• If any of the above defects are noticed in the centre bearing assembly, complete centre
bearing assembly should be replaced.
• Condition of dust caps on propeller shaft and coupling flange. These are tack welded to
respective components.
• Check both spacer rings for wear score marks. If found defective replace with NEW one.
PRELUBE OR LUBE FOR LIFE DESIGNS

•
Universal joint crosses and bearings are prelube or lube for life designs and have no lube
fittings.
• Special seals are used to contain the lubricant in the cross bearings in this design.
• Replacement of the cross and bearing kit is recommended rather than re-lubrication.
LUBRICATION FOR SLIP SPLINES
• Apply grease gun pressure to the tube fitting until lubricant appears at the pressure relief hole
in the plug at the slip yoke end of the spline
• Now cover the pressure relief hole with your finger and continue to apply pressure until
grease appears at the slip yoke seal
CAUTION: In cold temperatures be sure to drive the vehicle immediately after lubricating. This
activates the slip spline and removes the excessive lubricant. Failure to do so could
Cause the excess lubricant to stiffen in the cold weather and force the plug out. The end of the spline
would then be open to collect contaminants and cause the spline to wear and/or seize.
LUBE FOR LIFE CENTRE BEARING:

Centre bearing is packed with grease for life. No filling of bearing with grease is recommended.
252
• CHECK UNBALANCE –
If the propellers shaft unbalance is suspected then it can be verified by the following
procedure. Removing & rendering the propeller shaft by 180° may eliminate some vibrations.
NOTE:
•Clean all the foreign material from propeller shaft and the universal joint.
•Inspect the propeller shaft for missing balance weight, broken welds and bent areas.
•If the propeller shaft is bent then it must be replaced.
•Ensure that the propeller shaft is not worn, are properly installed and are correctly
aligned with the propeller shaft.
• Check the companion flange mounting bolts.
Raise the vehicle.
Remove the wheel & tyres.
Install the wheel nuts to lock the brake drum.
Mark & number the shaft 6 inches from pinion
end at four positions 90° apart.
Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which
the vibration occurs.
Install a screw clamp at position “1”
Start the engine and recheck for vibrations. If there is little or no change in vibrations then
move the clamp or of the other 3 positions.
If there is no difference in vibration at the other position then the vibration is not due to the
propeller shaft imbalance.
253
If the vibration decreases, install a second clamp

and repeat the test.
If the clamps cause an additional imbalance,

separate the clamp (¼ inch above & below the
mark.). Repeat the vibration test.
Increase the distance between the clamps until the

vibration is at the lowest level.
At this position bend the slack end of the clamp so that it does not loosen.
Install the wheel & tyres. Lower the vehicle.
If the amount of the vibration remains unacceptable then repeat the exercise at the Gearbox
end.
254
• CHECK SHAFT RUN-OUT –
Remove dirt, rust, paint & undercoating from the propeller shaft surface.
The dial indicator must be installed perpendicular

to the shaft surface.
Measure the run out at the center and at the ends

– 75 mm away from the weld.
Replace the propeller shaft if the run out is beyond the specified limit.
255
• Specification & Wear Limits –
Description 2WD
Length (Joint to Joint) x O.D x thickness in mm 1580.0 X 75.0 X 1.60
Fully Expanded length 1630.8
Run-out 0.4 mm MAX TIR at centre & 75
mm away from the yoke weld
• Tightening Torque –
Location Torque Nm (lbf-ft)

Companion Flange nuts at Transmission & Axle end 52.5 + 7.5Nm(38 lb-ft)
Split propeller shaft bearing fitment 88.5 + 16.5Nm(65 lb-ft)
256
REAR AXLE
Contents…
• Description…………………………………………………………………. 257
• Care of the Axle………..……..…………………………………………… 262
• In Car Repairs……………………………………………………………… 269
• Axle Component Dismantling..…..…………………………………. 273
• Axle Component Inspection………………………………………… 277
• Sub-assemblies………………………………………………………… 284
• Specification……………………………………………………………….. 296
• Special Tools……………………..………………………………………… 303
257
• Description –
The rear axle is of hypoid, semi-floating using shim adjustment to obtain bearing pre-loads. The
differential case with Crown wheel and the drive pinion are mounted in opposed taper roller bearing
in one-piece rear axle carrier.
GENIO – SEMI FLOATING BANJO TYPE REAR AXLE COMPONENTS
The rear axle pinion receives its power from the engine through the Transmission and driveshaft. The
drive pinion rotates the differential case through the engagement with the crown wheel, which is
bolted, to the differential case flange. Inside the differential cages are two differential pinions
mounted on the differential pinion shaft which is locked to the housing. These gears are engaged with
the side gears, to which the axle shafts are splined. Therefore as the differential housing turns, it
rotates the axle shaft and the rear wheel. When it is necessary for one wheel to rotate faster than the
other is, the faster turning gear causes the pinion to roll on slower turning gear to allow differential
action between the two axle shafts.
The axle shafts are held in the housing by the bearings and the retainers at the housing outer end.
Axle shaft endplay is adjustable. The hub bearings are not pre-packaged for life. Wheel end bearings
recommended to be greased after an interval of 40,000 kms.
NOTE: All operations other than the removal of the axle shafts and the replacement of the wheel
bearing oil seal should be carried out with the axle removed from the vehicle.
258
Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres
and other parts of the Vehicle. For this reason be sure that the cause of the trouble is in the rear axle
before adjusting, repairing or replacing any of the axle parts.
• Rear Axle Noise Diagnosis –
Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures.
Slight axle noise heard only at certain speed or under particular conditions must be considered
normal. Axle noise tends to peak or be more pronounced at particular speeds and the noise is in now
way a sign of the trouble in the vehicle.
Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to
isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to
eliminate a slight noise may baffle even the most experienced mechanic/ technician.
Axle noise fall into two basic categories: gear noise and/ or bearing noise.
 Axle Noise - Gear Noise

 Bearing Noise
 Others Noise
The most important characteristic of the gear noise is that it is usually sensitive to accelerator
position. E.g. noise audible under drive condition will often disappear under coast condition (i.e.
driving in neutral with the clutch released and engine running) at the same vehicle speed and vice
versa.
Axle gear noise whine will always occur at the same road speed and throttle setting i.e. drive or coast
(i.e. driving in neutral with the clutch released and engine running). Gear whine is usually a fairly high
pitched pure tone as opposed to a low-pitched rumble caused by a spalled bearing.
Some noises, which can be confused with axle gear whine, are: -
…. Whine from an engine component; this will always occur at the same engine speed irrespective of
which transmission gear is used
…. Whine from an indirect Transmission gear (e.g. 5th gear on some vehicles produces a whine
comparable with axle whine) however this will disappear when the direct transmission ratio is
selected.
…. Whine from tyres or wind noise from a rack or aerial. These noise generally occur over a very broad
speed range and do not change with driving mode i.e. drive or coast (i.e. driving in neutral with the
clutch released and engine running)
259
 Remember -
Before diagnosing the whine as axle gear noise, ensure that the whine:
• Occurs in direct transmission ratio (4th gear)

• Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the
clutch released and engine running)
• Always occur at the same road speed and not engine speed, Occurs over a limited vehicle
speed. (This can vary over a wide band should the axle be in extremely bad condition.)
Bearing Noise –
Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide
speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in
pitch as speed increases and is not directly affected by changing from drive to coast (i.e. driving in
neutral with the clutch released and engine running) and visa versa.
(a) Rear wheel bearing noise tends to be low pitched grumble, which can normally be detected
and confirmed when driving on a smooth road at constant speed, with the noise most audible
while swerving sharply from left to right. If the noise increases or a decrease as the car is
swerved, it is probable that a wheel bearing is faulty. Driving close to a wall or a curb at a
suitable speed can carry out a further check for wheel bearing noise.
(b) Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not
affected by the swerve check referred to previously.
(c) Pinion bearing noise is normally at a higher pitch than wheel or differential bearings and is
often slightly sensitive to throttle position, although not to the same extent as gear noise.
Other:
1. A further condition, which can exist, is due to a worn bearing that allows the gear set to move
out of its correct mesh cause gear noise. This condition is usually throttle sensitive, with the
noise frequently disappearing on a “drive” condition. Any amount of or endplay in either the
pinion bearings or differential carrier bearings are detrimental to the gears and bearings and
will cause axle noise.
2. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a
ticking or light knocking noise over a restricted range of throttle position. The frequency of the
noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring
gear. The severity of the noise indicates the size of the defect. A light “tick “is seldom
detrimental and usually occurs in new axle and will normally disappear once the axle has been
run in.
3. Louder noise usually indicates a more serious defect and a knock occurring in an axle which
was previously free from this type of noise must always be investigated.
 Refer below chart for more concerns and possible causes on Rear Axle –
260
 Summarizing the common faults and their cause:

PROBLEM POSSIBLE CAUSES
• Noise in all driving modes  Road and tires, wheel bearings
• Noise changes with type of road  Road and tires
surface/ Noise tone lowers with
vehicle speed
• Noise louder on turns  Differential pinion and side gears, axle wheel bearings
• Noise in all driving modes  Ring and pinion gears improperly adjusted
 Pinion bearing loose.
 Worn pinion shaft bearing
 Pinion and ring gear too tight
 Wrong lubricant being used
• Axle noisy on coast  Excessive back lash in drive ring gear and pinion.
 End play in pinion shaft
 Improper contact.
• Metallic noise on change of speed  Worn differential shaft or thrust washers; worn U-joints.
or direction of power flow.
• Wheel noise  Wheel loose; faulty or bad wheel bearing
• Axle gear noise  Insufficient lubricant, incorrect backlash, improper tooth
contact worn/damaged gears
• Axle noise  Insufficient lubricant, improper ring gear and drive
pinion gear adjustment, unmatched ring gear and drive
pinion gear, worn teeth on ring gear or drive pinion
gear, Loose drive pinion gear shaft bearings, loose
differential bearings, misaligned ring and pinion gear,
loose differential bearing cap screws, worn bearings.
• Vibration  Damaged drive shaft, missing drive shaft balance
weight, worn or out-of-balance wheels, loose wheel
nuts, worn U-joints, loose spring U-bolts, loose/broken
spring, damaged axle shaft bearings, loose pinion gear
nut, excessive pinion yoke run out, bent axle shaft.
• Differential gears scored  Insufficient lubrication, improper grade of lubricant,
lubricant contamination, excessive spinning of wheels.
• Gear teeth broken  Overloading, erratic clutch operating, wheel spinning,
improper adjustment.
• Loss of lubricant  Lubricant level too high, worn axle shaft seals, cracked
differential housing, worn drive pinion gear shaft seal,
scored and worn yoke, axle cover not properly sealed,
plugged vent or vent tube.
• Axle overheating  Lubricant level too low, incorrect grade of lubricant,
contaminated lubricant, bearing preload too high,
excessive gear wear, insufficient ring gear backlash.
• Back lash  Worn differential pinion gear washers
 Excessive back lash in bevel gear and pinion
 Worn universal joints
261
This section includes of –
• Differential Oil – Replace
• Rear Wheel Bearing Lubricate
• Axle Shaft - Removal
• Axle Shaft Seals - Removal
262
• Differential Oil (Rear) – Replace
Differential Oil – MAXIMILE DO EXL

Capacity – 2.1 Lit.
Banjo Axle - Schematic
Filler Plug
Drain Plug
Differential Oil – Replace

1. Remove the Filler plug.

2. Remove the drain plug. Allow the oil to drain out completely.
3. Clean the metal particles if any deposited on the drain plug. Assemble & torque tight the
drain plug with new washer.
4. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new
washer and torque tight.
5. Check Oil leakage / seepage at –
• Differential covers joint face
• Differential Oil drain plug.

before lifting the vehicle & re-connect the LSPV spring & ensure that the setting
height is correct after job complete.
 Always use recommended oils only.
 Differential oil to be replaced first at 10000kms and then at every 40000kms.
263
• Axle Shaft Removal & Rear Wheel Bearing Lubricate

LUBRICANTS RECOMMENDED -
Grease – Lithium Complex Grease.
Apply 10 – 12 gms in wheel end brg. & 10 – 15 gms in Brg. Carrier cavity (20–27 gms per wheel end)
Rear Axle Shaft and components exploded view
Back Plate Assy.
Thrust Washer
Lock Washer
Lock Nut
Outer Oil
Bearing Bearing Seal
Carrier
Axle Sub Shaft Assy. Dust Shield
Dismantling –
Jack up the vehicle & remove the wheel.

Remove the Brake drum.
Remove hand brake cable from rear brake.
264
Remove bundy tube connected on wheel cylinder.
Ensure and avoid brake fluid leakages.
Remove Back plate assy.
Ensure proper storage of brake liners and avoid

damages.
Remove the axle shaft from rear axle shaft tube.
Use MST 0505AAA0001ST.
Place the special tool flange over axle studs; tighten

with minimum 2 mounting bolts. Push the handle to
outside direction so that axle shaft assembly will
come out of the tube.
Open and remove the lock clip by using flat screw

driver.
Remove the lock nut by using MST 621.
Ensure that while removal, assembly should be fixed

on bench voice to avoid slippages. The locking nut is
fitted with locktite; it require high amount of force to
remove.
265
Remove lock washer.
Remove plane washer from axle.
Back plate, bearing carrier, bearing and axle can be separated.

Avoid damages and ensure that shaft seal is intact.
Cleaning & Inspection –
• Clean & Inspect the Bearing, carrier, axle shaft & oil seal.
Greasing –
• Apply 10-12 gms. Grease in wheel end bearing. 10-15 gms. In bearing carrier cavity.
Assembly –
NOTE: Assembly is in apposite to the dismantling procedure; follow the same in reverse.
• Assemble the bearing in carrier assembly.
CAUTION: Ensure and avoid contamination.
• Assemble the Axle Shaft along with back plate and shims.
• Insert plane washer.
• Insert plane washer and lock clip.
• Insert locking nut.
Use MST 621 to tight the lock nut.
NOTE:
Ensure to apply Locktite 262 is used on the axle shaft
threads before inserting lock nut.
266
CAUTION:
• Clean slotted lock nut with thinner before use.

• Align lock washer and apply Locktite 262 on shaft thread, leave below 3 threads without
locktite.
• Use LEFT HAND ROUGH thread lock nut on RH side axle shaft and RIGHT HAND ROUGH
thread lock nut on LH side axle shaft.
• ‘LH’ rough thread is etched on the lock nut which is only to be fitted on RH side. There is no
any mark on lock nut which is to be fitted on LH side axle shaft.
Left Hand Rough Thread – ‘LH’ marking Right Hand Rough Thread – No any mark
Match the washer lug to the lock nut groves. At least

one lug to be locked.
Use small drift/ flat screw driver and hammer to press

and lock the lugs.
Apply Locktite 5060 on wheel end shim interface.
• Assemble the drum brake assembly components.
267
• Connect the brake bundy tube to the wheel cylinder and locate parking brake cable.
• Fit the Brake drum and tighten the drum locking screw.
• Assemble wheel and remove the jacks.

• Top up brake fluid and do the brake bleeding. Ensure and use correct fluid only.
• Check and do the parking brake lever adjustment, if require.
• Check the differential oil level, top up if required. Ensure and use recommended fluid only.
• Brake system bleeding to be as per recommended.
 Wheel bearings to be lubricate at every 50000kms.

before lifting the vehicle & re-connect the LSPV spring & ensure that the setting
height is correct after job complete.
268
• Axle Shaft Oil Seal Removal
• Pinion Oil Seal Removal
• Disassembly of Rear Axle
269
• Axle Shaft Oil Seals Removal

• Genio Banjo axle shafts are having 2 oil seals each side. Outboard oil seal is fitted on the
bearing carrier assembly and inboard oil seal is inside the axle shaft tube.
• Refer section ‘Axle shaft Removal’ and remove the axle shaft which seal needs to be replaced.
Removal of Outboard Oil seal –
Remove the axle shaft assembly and remove

the bearing carrier unit.
The outboard seal is press fitted in the

bearing carrier unit assembly.
Remove the outboard seal by puller, MST

572.
Outboard Oil seal installation –
Place the new seal in dolly, align with the

bearing carrier seal locating area and press
gently.
NOTE:
• Use dolly while installing oil seal - MST
572.
• Lubricate oil seal lip before installation.
Use Locktite 641.
270
Removal of Inboard Oil seal –
Inner seal is press fitted inside the axle shaft

tube.
Remove the axle shaft assembly, and then

inner oil seal can be removed by using puller.
Use MST 0502CAA0012ST
Installation of axle shaft Inboard Oil seal –
Apply Locktite 641 on seal sitting area in the

flange. Lubricate oil seal lip before
installation.
Place the new seal on dolly shaft front end.
NOTE:
• Use dolly while installing oil seal - MST

0505AAA0002ST.
271
Align with the axle shaft tube/ seal locating

area and press gently.
Ensure proper installation of inner oil seal.
272
• Pinion Oil Seal Removal –

• Refer ‘Propeller Shaft’ section and remove rear propeller shaft assembly.
Removal of rear companion flange –
Use companion flange holding tool; MST 203
• Loosen the companion flange lock nut by

using box socket and spanner.
• After removing lock nut, fix special tool MST

208 on companion flange.
• Tight the centre bolt, flange will come out as

soon as tightening the centre bolt without
damaging seal and pinion.
• Remove companion flange and dust shield

from pinion end.
After removal of companion flange and dust shield, remove the pinion oil seal by screw driver or
Special tool MST 0502CAA0012ST can be used if pinion is removed. Refer illustration below -
Oil Seal fitment –
Place new oil seal on the pinion end of the

differential housing. Align the oil seal driver - MST
0502CAA0009ST and press the oil seal towards
the pinion shaft.
Use mallet to strike to the back of the tool till oil

seal assemble with its face.
273
1. DISASSEMBLY OF REAR AXLE –
Post removal activities -
• Park vehicle on certified 4 post lift and block front wheels.

• Drain the differential oil.
• Support frame long member at both sides and remove rear both side wheels and drums.
Refer below schematic for Rear Axle Shaft Exploded View –

Thrust Washer
Bearing Locknut
Back Plate Assy.
Locknut Washer Bearing Carrier
Bearing Outer Oil Seal
Wheel end
play adj. shim Axle Shaft Assy.
Dust Shield
Banjo Beam Sub Assy. Brake Drum Assy.
Remove the LH side axle shaft assembly.
Refer procedure mentioned above for Axle shaft

removal.
274
Remove the RH side axle shaft assembly.
Refer procedure mentioned above for Axle shaft

removal.
Remove rear propeller shaft assembly.
Disconnect the propeller shaft rear end connected

to rear axle as well as front end connected to
Transmission.
NOTE:
Make the mating marks on the flange yoke of the

propeller shaft and the companion flange of the
differential case.
• Place suitable supports below the long members.
CAUTION: Do not place jack under rear axle centre housing but only on axle tube especially on a
loaded vehicle.
WARNING: A serious injury can occur if vehicle is not properly jacked.
• Unscrew & remove the nuts & bolts connecting shock absorber to the bracket on rear axle.
• Remove the rear leaf spring U bolts connected to the rear axle.
• Remove the Leaf spring end pivot and shackle plate & pin and take out both side leaf spring
assemblies.
• Remove rear axle assembly from vehicle.
275
After the axle assembly is removed, disassemble the differential as outlined below:
Removal of the companion flange –
Hold the companion flange by using tool.
MST 203 – flange holding yoke.
Loosen and remove companion flange lock nut.

And then use MST 208 to remove the companion
flange.
After removing lock nut, Fix the MST 208 on

companion flange by using four bolts. Ensure that
the centre bolt of tool is aligned with pinion end.
Start rotating centre bolt in clockwise direction so
that the companion flange will come out.
Remove companion flange and dust shield.
Remove the carrier housing bolts attached to the

axle housing.
NOTE:
While removing carrier, keep upper 2 – 3 bolts in
loose and strike the lower part of differential carrier
assembly with mallet to loosen, and then remove
the carrier assembly.
Do not hit on pinion.
276
Use MST 0502EAA0001ST – Banjo Axle Gear Carrier

dismantling fixture Stand.
Inspection and Check point before disassembly -
Check Final Drive Gear Backlash –
With the drive pinion locked in place, measure the

final drive gear backlash with a dial gauge indicator
on the drive gear.
NOTE: Measure at least four points on the

circumference of the drive gear.
Final drive gear backlash: 0.125 to 0.250 mm.
Drive Gear Runout –
Measure the drive gear Runout at the peripheral

edge on the back side of the gear.
Service Limit : 0.05 mm
277
2. Differential Carrier dismantling -

Refer schematic of Differential Carrier/ Centre Assembly Exploded View –
Diff Case
Bearing
Diff Case
Diff adj. shim
Diff adj. shim
Hypoid Ring Gear

Diff Case
Washer Bearing
Thrust Washer
Side Gear Pinion Mate
Lock pin
Side Gear
Thrust Washer
Side Gear
Washer Pinion
Mate Side Gear
Shaft
Removal of Bearing caps –
Remove the side bearing cap bolts and caps LH &

RH.
NOTE:
Mating letters stamped on caps and carrier. It is

recommended to match the letters.
Keep the right and left side bearings and side

bearing bolts separate, so that they should not
mixed at the time reassembly.
Remove the differential case assembly.
Use MST 0502AAA0001ST.
278
Removal of side bearing race. Use universal bearing removal tool.
• Remove bearing shims after removing bearing.

• Identify shims and bearing from which side they are removed.
• If Shims are found damaged, replace with new shims at the time of assembly.
Remove lock pin.
Use a suitable small size drift to remove the pin.
Use hammer and hit the lock pin through the hole
provided on casing.
NOTE:
While removal ensure to punch the lock pin from
ring gear mounting bolt side.
Hold the centre assembly in bench voice loosen

and remove the ring gear mounting bolts.
NOTE: Ring gear mounting bolts have LH threads.

While removing torque in clockwise direction and
during assembly torque in anti-clocking direction.
Remove other side taper roller bearing and shims

279
Remove pinion mate shaft.
Remove the pinion gear and washers.
Removal of drive Pinion Assembly –
Remove drive pinion from inside the carrier

assembly.
NOTE: Make sure that the companion flange and

dust shield is removed. Push the pinion inside
housing to remove. Remove pinion by tapping with
mallet. Do not use hammer, pinion shaft can get
damage.
280
• Ensure that pinion oil seal is removed.
• Using a plastic mallet, remove the pinion

shaft.
After removal of the pinion from gear carrier assembly –

• Use the smaller adaptor to remove the outer cup.
MST 0502CAA0008ST ADAPTER_REMOVE PINION OUT CUP
281
• Use the bigger adaptor to remove the inner

cup.
MST 0502CAA0010ST - ADAPTER REMOVE

PINION INNER
Refer Schematic of Pinion Assembly Exploded View –
Banjo Beam Sub Assy.
Hypoid Pinion
Pinion head Brg. Shim
Pinion Inner Brg. Hypoid Ring Gear
Collapsible Spacer
Oil Slinger Diff Case
Companion
Gear Carrier Flange Pinion Outer Brg.
Assy.
Pinion oil
Seal Diff Case bearing
& adj. Shim
CAUTION:
Pinion gear tooth are having sharp edges. Take care and avoid personal injury while handling it.
282
3. Removal of Pinion Bearing –
Remove the pinion bearing.
Use universal bearing puller and remove the

bearing.
MST 0502CAA0014ST
BEARING REMOVAL TOOL
Usage-This tool can be used to remove the Pinion shaft and Differential side bearings.
Make sure that bearing and head bearing shim are

not damaged and can be reused.
283
1. REAR AXLE ASSEMBLY –

• Axle Shaft Assembly -
Axle Shaft Seal Installation –
• Ensure cleanliness of axle housing tube.

• Lubricate the seal locating area before seal
installation.
• Ensure proper installation of inner oil seal.
Refer procedure given earlier.
• Lubricate the lip of the seal to avoid damage

while axle shaft insertion.
• Ensure cleanliness of bearing carrier.
• Install bearing outer oil seal.
Refer procedure given earlier.
• Axle Shaft Bearing Lubrication & Installation -

• Lubricate the bearing and the carrier. Apply
10 – 12 gm grease in wheel end bearing and
10 – 15 gm grease in carrier cavity.
• Total 20 – 27 gm grease per wheel is

recommended.
284
• Ensure cleanliness of axle sub shaft assembly

before bearing installation.
Bearing-carrier Assembly -
• Keep the axle shaft in vertical direction and
insert the carrier keeping bearing upward
direction.
NOTE:
• Apply Locktite 641 on the shaft where
bearing is going to be located.
• Ensure the correct position of greased roller
bearing.
• Ensure that the oil seal face is downward and
the seal lip is lubricated before installing the
carrier assembly.
• Make sure that the taper roller bearing
internal diameter is grease free.
Ensure proper fitment of bearing. Check the

lubricant for proper application.
• Insert thrust washer after bearing fitment.
• Insert the locknut washer.
285
• Align the lock washer with thrust washer, as

shown by arrow marks in illustration.
NOTE:
• While inserting the thrust washer and locknut

washer into the axle sub shaft, ensure to
align plane faces to the axle threads gap.
CAUTION:
• Clean slotted lock nut with thinner before use.
• Align lock washer and apply Locktite 262 on shaft thread, leave below 3 threads without
locktite.
• Use LEFT HAND ROUGH thread lock nut on RH side axle shaft and RIGHT HAND ROUGH
thread lock nut on LH side axle shaft.
• ‘LR’ rough thread is etched on the lock nut which is only to be fitted on RH side. There is no
any mark on lock nut which is to be fitted on LH side axle shaft.
Left Hand Rough Thread – ‘LR’ marking Right Hand Rough Thread – ‘No mark’
286
• Insert correct lock nut.
• Use MST 621 to tighten the lock nut.
• After tightening the lock nut for proper

torque value, check the locking washer lug
matching to the lock nut grove.
Press and lock minimum two lugs to the lock

nut. Use crew driver to press and lock the lug.
287
• Check and confirm proper fitment of all the

axle components.
• Insert back plate assembly keeping back side

upward direction.
• Measure the thickness of wheel end play

adjusting shim.
• Refer chart given below for correct shims

thickness values.
288
• Insert correct* thickness to the back plate

mounting bolts.
NOTE:
* Check and confirm wheel end play by
mounting axle shaft to the axle tube housing,
if found out of limit, repeat the checking
procedure.
Do not put inboard oil seal till axle play gets

confirm. Once it’s confirmed then do the
complete assembly.
• Apply Locktite 5060 on wheel end shim

interface.
• Assemble the drum brake assembly components.

• Connect the brake bundy tube to the wheel cylinder and locate parking brake cable.
• Fit the Brake drum and tighten the drum locking screw.
Post fitment activities -

• Top up brake fluid and do the brake bleeding. Ensure and use correct fluid only.
• Check and do the parking brake lever adjustment, if require.
• Check the differential oil level, top up if required. Ensure and use recommended fluid only.
• Brake system bleeding to be as per recommended.
289
• WHEEL END PLAY - CHECK & ADJUST –

• Assemble the axle shaft and back plate to the
axle housing beam. Tight the mounting bolts
for recommended torque values.
• Use dial gauge, fix the base to the axle shaft.

Locate the dial gauge pointer on the back
plate or liner edge. Pull the axle shaft by
hand and check the dial gauge needle
movement.
Ensure the play is within recommended limit.
NOTE: It is recommended to cover the brake

liners by clean cloth or paper to avoid surface
damage.
• If not, then once again check the shim

thickness; add or delete the shims as per
requirement.
• Check and confirm axle play for correct value.
• Tighten the back plate mounting bolts for

recommended torque values.
• Follow the play checking procedure given

above.
290
• Refer below chart for wheel end play shims –
291
• Differential Carrier Assembly
A. RING AND PINION GEAR ASSEMBLY THEORY

Ring gear and pinion are supplied in matched set only. Matching numbers on both pinion and ring gear
are etched for verification. Refer illustrations.
SCHEMATIC – RING GEAR & PINION ASSEMBLY
If a new set is being used, verify the numbers of each pinion and ring before proceeding with
assembly. The mounting distance from the centre line of the ring gear to the back face of the pinion is
109.525 mm. on the head of the each pinion, there is etched a plus (+) number, a minus (-) number, or
a Zero (0) number, which indicates the best running position for each particular gear set. This
dimension is controlled by selecting shims, between the inner pinion bearing cone and pinion gear.
To change the pinion adjustment, use different shims which come in different thicknesses. Use the
table given in this section as a guide for selecting the correct number of shims to add or subtract from
the old shim pack.
NOTE: This procedure can only used when Ring & Pinion gear is being replaced. In case the bearings
are also replaced then gauge method is recommended.
292
B. PINION POSITION SHIM SELECTION

• Install pinion height master block
0502DAA0006ST over the inner bearing cup
seal.
• Install dial gauge on Pinion height setting

gauge tool 0502DAA0005ST
• Set the dial gauge to zero, on surface plate at

highest point.
• Install height setting gauge on differential side

bearing housing.
• Install dial gauge such that the plunger is in

contact with pinion master.
• Rock the height setting tool depth gauge.
• Record the reading when the indicator is at the highest point.
If the value assumed as ‘a’. the shim thickness can be calculated as –

Shim thickness reqd. = a – etched value on pinion (when etched +ve)
= a + etched value on pinion (when etched –ve)
293
Hypoid Set Backlash – Procedure
Refer below schematic while differential backlash setting -
1. Measure shoulder to shoulder dimension on gear carrier housing with Dummy Bearing.
2. Select shim & bearing, selected shim should induce preload of 0.15 mm in Diff bearing.
3. Press Diff bearing along with shim on Diff case

sub assembly.
Use MST 510 – side bearing installation drift.
4. Shim position is between bearing and diff case housing.

5. Place diff case assembly on gear carrier housing.
294
6. Place RH & LH bearing cap and tighten the bolt

to 60 to 85 Nm torque.
7. Measure Backlash.
Check and confirm the backlash, add or remove the

side bearing shims as per requirement. Repeat the
procedure till get the correct values.
• Refer below illustrations for Gear Tooth Contact Pattern –
295
• Assembly Specification –
1. Pinion preload rotational torque 0.800 - 1.200 Nm. Without seal.
2. Pinion preload rotational torque 2.500 - 4.500 Nm. With seal.
3. Differential bearing preload 0.150 mm.
4. Hypoid gear backlash 0.150 to 0.250 mm.
5. Backlash variation to be within 0.075 mm.
6. Differential gear end play 0.100 to 0.175 mm.
7. Differential gear free rotational torque 0.5 Nm maximum.
8. Total centre section sub assembly rotational torque 2.800 to 4.800 Nm.With seal.
• Diff Case Shim –
t (Thickness) Description Part No. C/L

2.946 Diff Case Adj. Shim 0502EAA05370N 1
• Worksheet for calculating ring gear backlash & differential bearing preload shims –
296
• Pinion Positioning & Preload –

1. Measure distance 141.1 & find variation in dimension.
2. Select pinion head bearing & shim pack to

position the pinion at correct mounting
distance as per value etched on pinion
stem when hypoid set tested on tester for
best running position.
3. Press pinion head & tail bearing cups on

banjo gear carrier housing on hydraulic
press.
4. Mount pinion positioning shim on pinion &

press pinion head bearing & butt the inner
bearing shoulder on hypoid pinion.
Use MST 0502CAA0004ST dolly for

installation.
5. Press pinion tail bearing & ensure force do

not exert on spacer.
297
Use MST 0703AD0900H001 dolly for installation of

the pinion tail end bearing.
6. Place oil slinger on bearing pinion tail

cone.
7. Place & press oil seal on banjo gear carrier

housing.
8. Do sub assembly of companion flange with

dust shield.
9. Tight pinion nut to achieve pinion preload

rotational torque of 2.5 to 4.5 Nm with oil
seal.
NOTE: Replace collapsible spacer every time

pinion nut is removed.
298
• Pinion Positioning Shims –
299
• Gear Carrier installation –

Ensure that the gear carrier is clean and free from
dust and dirt.
Apply adequate coat of Locktite RTV Sealant 5060.
Assemble gear carrier into banjo axle housing.
While assembling the gear carrier, ensure that two

mounting bolts are special threaded bolts and
should not replaced with other mounting bolts.
Refer illustration, those 2 nos. mounting bolts are

shown in green colour.
Ensure to keep these 2 bolts separate while

dismantling and reuse it if found ok at same
location.
Torque tight all the mounting bolts.
300
Description Value
TYPE : Semi floating single reduction without diff. lock
No of teeth on crown N1 41
No of teeth on pinion N2 10
Axle reduction ratio N1/N2 4.1
Pinion Pre load 23 to 45 Kg.cm.
Preloading of differential bearings 0.075 mm on each side; Total 0.150 mm
Crown-pinion backlash 0.125 to 0.250 mm
Maximum variation of backlash in a crown 0.075 mm
Run out of the ring gear / crown wheel 0.150 mm
Hub end play Service Limit 0.35mm max
Hub rotational torque Not applicable
Check for correct tooth contact on both the Check on both the driving & reverse flank. This
forward and reverse direction contact is for checking without load.
Clearance between and side( sun) gears and 0.250 mm
diff case
Rotational torque of differential case with 5 Kg cm
sun & pinion gears
Inner race interference Wheel End Bearing – 0.012 to 0.040mm
Outer race clearance - +0.021 to -0.021
Oil grade/ Viscosity/ Quantity 2.1 (+ 10%) liters SAE 80W90 GL5 (Factory Filled)
2.1 (+10%) liters EXL 80W-90 (Service Filled)
Axle Housing Banjo Type
Axle shaft Cold Extruded
Differential 2 Pinion Open Differential
Reduction gear type Hypoid
Reduction ratio 4.1
Axle shaft axial play 0.050 to 0.15 mm (this is Build value).
Limited slip differential preload NA
Press-fitting force of retainer NA
Clearance of snap ring and retainer NA
Final drive gear backlash 0.125 to 0.250 mm
Differential gear backlash 0.100 to 0.200 mm
Drive pinion turning torque w/o oil seal = 8 to 12 & with oil seal = 25 to 45 Kg cm
LUBRICANTS RECOMMENDED -
Grease – Lithium Complex Grease
Apply 10 – 12 gms in wheel end bearing
Apply grease 10 – 15 gms in Bearing Carrier cavity; Total 20 – 27 gms per wheel end.
SPECIFIED ADHESIVE -
Apply Locktite 262 on Threads (Wheel End Lock Nut)
Apply Locktite 641 on Wheel end Bearing Inner and outer races.
Apply Locktite 5060 at Gear carrier and Banjo Beam interface.
Apply Locktite 5060 at Flange and Wheel end shim interface.
301
Description Torque in Nm
Oil Drain plug 47.5 ± 6.5 Nm
Oil Filler plug 47.5 ± 6.5 Nm
Ring Gear Mounting Bolts 60 ± 10 Nm
Bearing Cap Mounting Bolts 100 ± 10 Nm
Pinion Nut 225 ± 75 Nm
Breather 16 ± 4 Nm
Back Plate Mounting Bolts 40 ± 7 Nm
Diff Case Mounting Bolts 50 ± 10 Nm
*also refer the torque values mentioned during the rear axle assembly and sub-assemblies where ever
applicable.
• Sealant Recommendation –
Sr. No. Location Sealant / Thread Locks Applicability

1 Axle Lock Nut Locktite 262 
2 Axle oil Drain plug Locktite 262 
3 Wheel End Shim Interface Locktite 5060 
4 Oil Seal OD Locktite 641 

Anabond 413
5 Breather 
( Retaining Grade )
Intersection of Centre Section &
6 Locktite RTV Sealant 5060 
Beam Stiffener Ring.
7 Wheel end bearing ID and OD Locktite 641 
302
• Special Tools –
Tool Usage View MST No./ Description
MST 0505AAA0001ST
REAR AXLE SHAFT PULLER
MST 621
AXLE SHAFT LOCK NUT TOOL
MST 572
BEARING CARRIER OUTBOARD SEAL DOLLEY
303
MST 0502CAA0012ST
AXLE SHAFT INBOARD SEAL REMOVAL TOOL
MST 0505AA0002ST
OUTBOARD OIL SEAL PRESSING DOLLEY.
MST 203
FLANGE HOLDING TOOL
304
MST 208
FLANGE PULLER
MST 0502DAA0005ST
PINION HEIGHT SETTING GAUGE
MST 0502DAA0006ST
PINION HEIGHT SETTING MASTER
305
MST 510
DIFF. SIDE BEARING INSTALLATION DRIFT
MST 0703AD0900H001
PINION TAIL END BEARING INSTALLER/ DOLLY
MST 0502CAA0004ST
DOLLY PRESSING PINION INN CONE
306
MST 0502EAA0001ST
DIFFERENTIAL CARRIER STAND
MST 0502AAA0001ST
GEAR CARRIER REMOVAL TOOL
MST 0502CAA0009ST
PINION SEAL PRESSING DOLLEY
MST 0502CAA0010ST
ADAPTER REMOVE PINION INNER CUP
307
MST 0502CAA0008ST
ADAPTER REMOVE PINION OUT CUP
MST 0502CAA0014ST
BEARING REMOVAL TOOL –
(PINION & DIFF CASE SIDE BEARING) REFER TOOL USGAE ILLUSTRATION.
UNIVERSAL BEARING REMOVAL TOOL
(THIS TOOL MAY ALSO BE USED FOR REAR AXLE

PINION / DIFF CASE SIDE BEARING REMOVAL)
NOTE: UNIVERSAL BEARING REMOVAL TOOL

IS READILY AVAILABLE IN MARKET, IT IS NOT
DEVELOPED AS A SPECIAL TOOL BY M&M.
308
Steering System
Contents…
• Description…………………………………………………………………. 310
• Care of the Axle………..……..…………………………………………… 316
• In Car Repairs……………………………………………………………… 321
• Working principle of the Steering Pump……………………………… 342
• Specifications……………………………………………………………… 343
• Special Tools……………………..………………………………………… 345
309
• Description
The power steering system is a rack and pinion type. The engine driven hydraulic –pump supplies oil to
a control valve situated in housing that supports the pinion shaft. Movement, imparted to the control
valve from the shaft in the steering column is via a torsion bar. This sensing bar moves the control
valve, which in turn directs the oil to one side or the other side of the ram piston inside the steering
rack.
The control valve is a rotary type spool valve controlled by the torsion bar interposed between the
steering shaft and pinion of the steering box. The spool valve is a shaft with six flutes and a sleeve,
which has six internal axial grooves, encases this. Radial ports in the sleeve and shaft pass the oil from
the supply to the lines connected to the ram chamber.
A series of the splines between the shaft and the sleeve limit the twist of the torsion bar to about 7
degrees in each direction; below this angle the torque applied by the driver to the steering box is
transmitted by the torsion bar. This fail-safe feature provides a mechanical drive from the steering
shaft to the pinion in the event of any power system failure.
The amount of the twist of the torsion bar and the movement of the spool valve is proportional to the
effort applied by the driver. Initial power steering assistance is obtained at about 0.5 degrees
deflection of the bar and this power rises progressively as the bar moves to about 4 degrees; the point
o maximum assistance.
When the wheel is in straight-ahead position, all the ports are open so oil is allowed to flow through
the valve and return to the reservoir.
As soon as the wheel is turned, the torsion bar is deflected; this allows the spool valve to rotate
relative to the sleeve, cutting off the oil flow both to the reservoir and one side of the ram. At the
same time the other side of the ram is subjected to oil pressure, which builds up sufficiently to move
the road wheel and return the torsion bar to no – torque position. During this stage the oil displaced
from the uncompressed side of the ram is returned to the reservoir.
On occasion when the resistance to road wheel movement is excessive, the oil pressures build up to
its maximum. At this pressure a relief valve fitted inside the pump opens and allows the oil to return
to pump inlet.
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The rack and pinion design is a simple design. However it is still susceptible to various problems in
particular to leaks. If the bellows are ripped or are unable to keep the contaminant’s away then it can
cause damage to oil seal and subsequent leaks.
One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold
and as the vehicle is driven/ warmed the power assist gradually comes back. It normally indicates that
grooves worn into the bore of the pinion aluminum housing by hard control valve seals.
Wear in the centre housing causes the fluid to leak around the rack piston causing either steering
wander or lack of straight-ahead stability. Another cause of steering wander and erratic control often
accompanied by clumping, thumping noise is the deterioration of rack mounting bushings.
Fluid levels can be hard to locate. Sometimes you will see a low level in the pump reservoir but no
evidence of escaping liquid. Squeeze the bellows and you will probably find that they are full of liquid.
To confirm if that side of the rack is the culprit, then remove the both the bellows, clean the rack
housing and then operate the system to observe the seepage directly.
It should be mentioned that a rusty input shaft U joint or deteriorated flexible textile/rubber coupling
could imitate rack problems.
CAUTION:
After attending to the repairs it critical that the system be completely flushed completely. Disconnect
the return line from the pump and put in a container, then disable the injection (remove the wire from
the shut off solenoid) and crank the engine. Add fresh fluid until you get a clear flow from the line.
Take care that the reservoir does not run dry during the flushing. Failure to do so will result in
premature failure of the repaired unit.)
The possible causes for the power steering complaints are tabulated below:
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Problem Possible Causes Corrections

Objectionable Hiss Noisy relief valve in hydraulic pump. There is some noise in all the
Steering gear noise valve noise is power steering system. One
transmitted trough the steering column of the most common is a
or open-air passages in the area where hissing sound most evident at
the column or controls pass through the stand still parking. Hiss is a
floor into the engine compartment. high frequency noise that is
present in every valve and
results from high velocity fluid
passing valve orifice edges.
There is no relationship
between this noise and the
steering gear performance.
DO not replace the
intermediate shaft or the
steering gear unless the noise
is too objectionable. Check
the dashboard seals between
the drivers area and under
hood to eliminate open
space/ gaps
Rattle or chuckle noise in Gear loose on frame. Check the gear mounting
Steering Gear bolts. Torque the bolts to
specifications.
Check the IBJ and OBH for
Steering linkage looseness. wear.
Pressure hose touching other parts of Adjust the hose position. Do

the vehicle. not bend the tubing by hand.
Replace.
Loose IBJ or OBJ Adjust to specification
Improper over centre- clearance. A
slight rattle may occur on turns because
of increased clearance off the high
point. This is normal and clearance must
not be reduced below specified limits to
eliminate this slight rattle.
Excessive wheel Kick Back Air in the steering. Add oil to the pump reservoir
or Loose Steering and bleed.
Tighten attaching bolts to the
Steering Gear Mounting loose. specified torque.
Replace loose parts.

Front wheel Bearings Incorrectly
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adjusted or worn.
Adjust the wheel bearings or
Steering Gear Improperly adjusted. replace as required.
Adjust to specifications
Dismantle and assemble the
Damaged or worn steering Gear. steering gear as specified.
Worn or damaged rubber bushing for Replace the rubber bushings.
mounting steering gear
Vehicle leads to one side Front end misaligned. Adjust to specifications.
or the Other (keep in mind Replace the gear Valve.
the road condition and Unbalanced steering gear valve. If this is
wind conditions.) Test the the cause steering effort will vary light in
vehicle , Going in Both direction of lead and heavy in opposite
directions , On a Flat road direction.
Steering shaft rubbing with the ID of the Align the column.
shaft tube
Steering linkage not level.
Adjust as required.
Momentary Increase in Low oil level in Reservoir. Add steering fluid as required.
steering Effort When Pump Belt slipping. Tighten or replace belt.
Turning the Wheel Quickly Refer to pump test.
To the Right or Left
High Internal leakage’s ( Steering Gear
or Pump)
Poor return of Steering Tyres under inflated. Inflate to specified pressure.
Loosen the pinch bolt and
assemble.
Lower coupling flange against the
steering gear adjuster Adjust the steering column.
Steering wheel rubbing against Replace the bearings.

directional signal housing.
Tight or seized steering shaft Relubricate/ replace the
bushing/bearings. joints.
Align the steering column.
Steering joint or linkage binding. Relubricate/ replace the ball
Steering column misaligned. joints.
Lack of lubrication in the suspension Check & adjust to
ball. specifications.
Adjust the preload.
Improper front end alignment.
Steering gear adjusted too tight. Replace the hose.
Kink in return hose.
Steering wheel Surges or Low oil level in Pump. Add fluid as required.
Jerks when Turning with Adjust tension as per
engine running, especially Loose pump belt. specification.
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during Parking. Clean the control valve or

Sticky flow control valve. replace the pump.
Refer to the power steering
System Test.
Insufficient pump pressure/
Hard steering effort in Low tyre pressures Adjust the tyre pressure.
both the directions Lubricate & relubricate at
Lack of lubrication is suspension or ball proper intervals.
joint. Align the steering column.
Tighten or replace belt.
Steering gear to column misalignment. Fill to proper level and inspect
Pump belt slipping. for leaks.
High internal leakage. Refer to pump Pressure test.

Replace or clean the valve.
Loosen the pinch bolt and

Sticky flow control valve. assemble correctly.
Adjust the preload in Straight-
Lower coupling flange rubbing against ahead position.
steering gear. Check & adjust to
Steering gear preload high. specifications.
Improper front end alignment

Foaming Milky Looking Air in the fluid and loss of fluid due to Check for leak & correct.
Power Steering Fluid. Low internal pump leakage causing overflow Bleed the system. Extremely
Level and Possible low cold temperature will cause
pressure aeration problems if the oil
level is low. If oil level is
correct and the pump still
foams then check for the air
leakage caused by loose joint
Low oil Pressure due to Check for kinks in the hose. Remove the kinks or replace
Restriction in the Hose the hoses.
Foreign objects stuck in the hose. Remove the foreign objet or
replace the hose.
Chirp Noise in Steering Pump belt slipping Tighten or replace Belt
Gear
Belt squeal ( Particularly Pump belt slipping Tighten or replace Belt
noticeable at Full wheel
Travel & Standstill Parking)
Growl noise in Steering Scored pressure plate, thrust plate or Replace Pump.
Pump rotor
Extreme Wear of cam ring Replace Pump.
Growl noise in Steering Low oil level Add the power steering fluid.
Pump Air in the oil. Poor pressure hose Bleed the system.
connection.
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Rattle or knock noise in Pump Vanes sticking in rotor slot Replace pump, flush system.
steering Pump Pressure hose touching other parts of Adjust hose position.
the Vehicle.
Swish Noise in steering Faulty flow control valve Replace pump.
Pump
Whine Noise In Steering Pump shaft bearing scored Replace pump.
Pump
Low oil Pressure Due to Flow control valve stuck or inoperative Replace pump.
Steering pump Pressure plate not flat against the cam
ring. Replace pump.
Extreme wear of the cam ring.
Air in oil. Replace pump, flush system.
Locate source of leak &
correct. Bleed the system.
Low oil level Add power steering fluid as
required.
Tighten or replace belt as
Pump belt slipping required
Replace as necessary.
Damaged hoses or steering gear
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• Care of the system
The lubricant level should be checked every 10000 Kms with the vehicle unladen and in a level ground.
The lubricant level should be between the maximum and minimum mark. The fluid level should be
checked with the engine in off condition. If the oil level is excess it will tend to come out from the filler
cap in use lubricant meeting oils specification of ATF (Automatic Transmission Fluid. The brand names
have been specified in the Operators Manual and also in the end of the Section.
This section also includes of –
• Power Steering Fluid – Level/Leak - Check
• Power Steering Pump Drive Belt Check
• Power Steering Pump Drive Belt Removal
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• Power Steering Fluid – Level/Leak - Check
Power Steering Fluid – Shell DONAX TG Special/Caltex TEXAMATIC1888

Capacity: 0.8 Lit.
1 Power Steering Fluid –

Level Check
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 at every 10000kms.
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 Power Steering Pump Drive Belt Check
PSP Drive Belt Type: 3PK, 815mm, GATES make.

POWER STEERING BELT - CHECK
POWER STG. PUMP DRIVE BELT Refer illustrations.
 Check the belt visually for -
1) Abrasion
2) Cracking
3) Improper Install
4) Uneven Rib Wear
5) Misalignment
6) Chunk-out
7) Gravel penetration
8) Pilling
 Check belt tension and reset tension to
specifications – Refer to procedure 704-
MAT-0029.
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 – 5. Misalignment –

Refer illustration shown. Refer illustration shown.
Belt shows damage to the side with the Sidewalls of the belt may appear glazed or the
possibility of breaks in the tensile cord or edge cord may become frayed and ribs removed.
rough edged ribs. A thumping noise may also A noise may result. In severe cases, the belt can
be heard when running. jump off the pulley.
318

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.
 Recommended belt tension for Power Steering Pump drive Belt is – New: 255 to
260 Hz & Used/ Stabilized: 215 to 225Hz.
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• Power Steering Pump Drive Belt Removal

Power Steering Belt Type: 3PK, 815mm, GATES make.
A 3 B
[B] - Power Stg. Pump mounting on Engine

[C] - Power Stg. Pump & drive belt layout
POWER STEERING PUMP DRIVE BELT – REPLACE

1. Remove NVH cover, Fan and Shroud.
2. Loosen pump fixing bolts 1 & 2 and loosen the lock nut 3 in sketch [A].
3. Remove power steering pump drive belt.
4. Refer belt tensioning procedure while refitting steering pump drive belt.
5. Check belt tension, correct if required.
Procedure for belt tensioning:
6. Loosen pump fixing bolts 1 & 2 And Loosen the Lock Nut 3
7. Screw tension bolt 4 as shown in fig to tighten the belt by appropriate amount.
8. Check tension value, should be between 200 – 230 Hz, if found less, screw in clockwise
direction, if found more than 235Hz unscrew in anticlockwise direction.
9. Final set value, New Belt: 255 - 260 Hz; & Used/ Stabilized Belt: 215 – 225 Hz.
10. Tighten the fixing Bolts 1, 2 & 3 to 25 N-m.
 If the belt is loose then it will give belt noise. If tightened excessively then it can
cause the power steering pump failure.
320
• In Car repairs
The following repairs can be carried out without removing the assemblies.
a) Removal of Outer Ball Joint & Tie Rod
b) Greasing of the OBJ (In case the rubber gaiter is torn.)
c) Removal & Refitting of Intermediate Shaft
d) Removal & Refitting of the Steering Wheel
e) Removal of Steering Gear Rack Assembly
f) Checking of Steering Play.
g) Steering Wheel - Centralize
h) Bleeding the system.
i) Steering Pump Dismantle & Working Principle
321
a) Removal of Outer Ball Joint & Tie Rod -
• Drive and position vehicle in the two post lift.

• Loosen the wheel nuts. Lift up the vehicle and remove the front wheels.
• Position the pads of two post lift underneath the vehicle, so that they are seated at the
intended jacking location and then raise the vehicle. (Refer “Wheels & Tyre” section for jacking
locations of the vehicle)
• Remove the front wheel nuts and then wheels from the vehicle.
WARNING
Improper jacking could lead to vehicle slippage and cause damage to the vehicle and person
• Tie-rod end lock nut is secured by a split
pin. Using a steep nose plier, press the
tail end of the split pin. Remove the split
pin from its position.
• Using a 17 mm socket and wrench set,

loosen (counter clockwise) the tie-rod
end lock nut and remove.
• Install the special tool (MST-562) by

pushing its edge between tie-rod end and
knuckle assembly. Rotate the special tool
bolt in clockwise direction such that it
pushes the tie-rod end out of the knuckle
assembly.
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• Slacken the track rod end lock nut.
• Remove the castel nut split pin and remove the castel nut.
• Remove the track rod end using the special tool.
• Remove the track rod end. While removing the track rod end, make a note of the number of
tuns required to remove the end.
• Insert the tie-rod end into the knuckle

assembly and then gently tap it with a
mallet till it is inserted fully.

tighten (clock-wise) the tie-rod end lock
nut to the torque of . Insert and push the
split pin through the hole in the lock nut.
Using a steep nose plier, pull and split tail
end of the pin.
• While fitting back the end or fitting a new end turn it back the same number of threads
CAUTION
Improper installation and usage of the special tool could damage rubber boot of the tie-rod end.
323
b) Greasing of the OBJ (In case the rubber gaiter is torn.)
• Refer above procedure for Removal of Outer ball joint.
• After removal of the track rod end -
• Remove the circlip
• Fill the joint with about 10 grams of grease
• Fit a new gaiter and put the lock
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c) Removal & Refitting of Intermediate Shaft
• Using a thin bladed short screw driver, remove covering caps of the lower panel lock screws
• Using a Phillips screw driver, loosen (counter clock-wise) the lock screws and remove. Remove
the lower panel from its position.

loosen (counter clock-wise) the
intermediate shaft coupling bolt from
the steering column and remove.

intermediate shaft boot cover mounting
nuts.

intermediate shaft joint lock bolts
present in the coupling. Remove the
upper shaft from the coupling.
325

intermediate shaft yoke coupling bolt.
Separate the intermediate shaft yoke
from the steering gear assembly
• Installation –
• Insert the intermediate shaft yoke over

the steering gear input shaft. Using 12
mm socket and wrench set, tighten (
clock-wise) the intermediate shaft yoke
coupling bolt to the torque of 19~25 Nm.
• Insert upper intermediate shaft inside

the vehicle. Using a 12 mm socket and
wrench set, tighten ( clock-wise) the
intermediate shaft boot cover mounting
nuts with floor panel to the torque of
• Insert lower end of the upper intermediate shaft in the coupling. Using a 12 mm socket and
wrench set, tighten (clock-wise) the intermediate shaft joint lock bolts present in the coupling to
the torque of
326
• Insert the intermediate shaft coupling

into the steering column shaft. Using a
12 mm socket and wrench set, tighten
(clock-wise) the intermediate shaft
coupling bolt with steering column to
the torque of 19~25 Nm.
• Install the lower panel in its position. Using a Phillips screw driver, tighten (MUC0093, clock-wise)
the lock screws. Insert the covering caps of the lower panel lock screws.
NOTE -
• After installation, turn the steering wheel to check its free and smooth movement. When turned
lock to lock from home position, number of turns on either side should be same. When the road
wheels in straight ahead position, steering wheel should be in home position. Repeat the removal
and installation of the steering wheel to bring it in home position, when the road wheels are in
straight ahead position
327
d) Removal & Refitting of the Steering Wheel
• Keep the road wheels in straight ahead position and lock the steering wheels (remove the ignition
key from key barrel).

loosen the (counter-clock wise) steering
wheel lock nut and remove.
• Install the steering wheel puller special tool (MST-547) on the steering wheel base plate.
• Locate both the bolts of the special tool in

the holes of the steering wheel base plate.
Using a 17 mm socket and spanner set,
tighten (MUC0055, clock wise) the bolts with
steering wheel base plate.
• Using a 22 mm socket and wrench set, tighten (MUC0055, clock wise) the center long bolt of the
special tool. Tightening continuously, will bring the steering wheel from steering column shaft.
• Installation –
• Install the steering wheel on the steering column shaft.
328
• Tighten the lock nut by hand. Using a 17 mm

socket and wrench set, tighten ( clock-wise)
the nut to the torque of 40~54 Nm.
• Install the driver side steering wheel cover

pad.
329
e) Removal & Refitting of Steering Gear Rack
FLUSHING THE POWER STEERING (PS) FLUID

• Drain and flush the PS fluid from the system. (Refer procedure “Power steering fluid flushing” in
this section for instructions)
CAUTION
Avoid spillage of PS fluid on other components. Wipe off immediately, if any spillage is noticed.
Adequately cover the power steering reservoir and lines from the entry of any foreign material/dust.
REMOVAL OF POWER STEERING PRESSURE LINE

• Remove the Power Steering pressure line hose from the vehicle.
NOTE
Plug the inlet and outlet hole of the PAS rack to avoid entry of any foreign particle. Plug both the ends
of the PAS pressure line hose to avoid entry of any foreign particles.
REMOVAL OF TIE-ROD END

• Remove both the tie-rod ends. (Refer procedure “Tie-rod end” in this section for instructions)
REMOVAL OF STEERING GEAR ASSEMBLY

intermediate shaft yoke coupling bolt.
Separate the intermediate shaft yoke
from the steering gear assembly.
• Using a 20 mm socket and wrench set, loosen ( counter clock-wise) the steering gear assembly
mounting bolt lock nuts from the chassis cross-member. Remove the rack assembly from its
position.
INSTALLATION OF STEERING GEAR ASSEMBLY

• Install the PAS gear assembly on the chassis cross member. Using a 20 mm socket and wrench
set, tighten (clock-wise) the lock nuts.
330
• Insert the intermediate shaft yoke over

the steering gear input shaft. Using 17
mm socket and wrench set, tighten( clock-
wise) the intermediate shaft yoke
coupling bolt to the torque of 19~25 Nm.
INSTALLATION OF TIE-ROD END

• Install both the tie-rod ends. (Refer procedure “Tie-rod end” in this section for instructions)
INSTALLATION OF POWER STEERING PRESSURE LINE
• Install one end of PS pressure line in the steering gear and the other end of the PS pressure line
in the pump.
CAUTION
Install the inlet tube and outlet tube of the fluid lines in the intended ports of the steering gear.
Interchanging lines will damage the PS gear and pump.
FILLING OF POWER STEERING FLUID
• Fill the power steering fluid (PS) in its reservoir. Check the level from the dip tube to ensure that
it is up to the “MAX” mark.
• Check for Steering wheel centralization, correct if required.

• Do the Toe-in check, correct if required.
- Toe-in recommended values for Genio is 0 to 1 mm ( 0 to 13’)
NOTE
Never reuse the Power Steering fluid, if the same is found to be contaminated.
331
f) Checking for Steering Play
After driving the vehicle in a straight road, check

the wheel spokes for angular play.
If more than 25 to 30 degrees then check -Tie-rod

25/30 end ball joint or steering gear inner ball joint or
degrees Lower arm ball joint or universal joint.
Replace the defective part/parts.
CAUTION
While checking ensure that the engine is in off condition and wheels are in Straight Ahead Position
(SAP position)
332
g) Steering Wheel - Centralize
CAUTION: This procedure for centralizing the Steering wheel is valid only if the misalignment of the
spokes is less than 30 degrees. In other words this procedure is only for fine-tuning the steering
wheel position not for gross error. If it is more 30 degrees then remove the steering wheel and
initially realign to less than 30 degrees.
• To check for the centralization of the steering wheel. Drive the vehicle on a level road surface; note
the angular position (misalignment of the steering wheel spokes.
• Lift up the vehicle
• Mark the position of the track rods and the track

rod ends
• Slacken the track rod end lock nuts and also

remove the gaiter outer retaining clips.
• Rotate both track rods in the same direction

Clock approximately 30 degrees for every 1-degree of
wise Anti
steering misalignment error.
error clock
• If the steering wheel has an anticlockwise

angular error then both track rods must be
rotated clockwise- when viewed from the left –
hand side of the vehicle
333
Clock • If the steering wheel has an clockwise angular

Anti error then both track rods must be rotated
wise anticlockwise- when viewed from the left – hand
error clock
side of the vehicle
• Check the front wheel alignment (Toe In) after the steering wheel has been centralized.
334
h) Bleeding the system
• Before starting the Bleeding operation, ensure that the Vehicle is on level ground, and the
reservoir is filled to the maximum specified level.
• As with any hydraulic system ensure that the recommended fluids only is used. Ensure that no
dirt enters the system while topping up. Before opening the reservoir cap, wipe the area with
a cotton cloth and open the cap.
CAUTION:
• Ensure that the front wheels are jacked up and wheels are lightly touching the ground.
• If this is not done then the steering linkage and components will be under undue stress.
• Even with the wheels partly jacked up; do not hold the steering in fully locked position for
more than 10 second. Failure to do so may damage the pump beyond repairs.
• Start the engine.
• Rotate the steering wheel from lock to lock; 3 to 4 times.
• Check if the oil in the reservoir has dropped down drastically- if so check for any leaks.
• Check if any foaming/ frothing are taking place.
• Repeat the rotation from lock to lock till the foaming subsides
• If the foaming is not subsiding after ¾ of the above cycle, check for the tightness of the hoses in
particular the reservoir to the steering pump and later the steering gear to reservoir. The loose
connection in these pipes will allow air to sucked into the system.
• After completing the bleeding operation, ensure that with the engine running the oil level is
between the maximum and minimum mark.
• Close the cap
335
i) Steering Pump Dismantle & Assemble
Using the Special Tool, hold the steering gear in

the vice.
Using the special tool remove the steering gears

pipes connecting the control valve to the gear.
Remove the outer Ball Joint.
Loosen and dislodge the outer clips holding the

bellows with the help of screw driver and pliers
336
Remove the bellows along with the clips.
If the bellow is having any crack, or swelling then

discard them. It is also advisable to use new clips
along with the bellows.
Note that the RHS and LHS bellows are not equal.
Before removing the Inner Ball Joint (IBJ). Cover

the threads with tape so that during handling and
reassembly they do not get damaged.
Remove the claw washer after opening it using

screwdriver.
Remove the inner Ball joint

Remove the IBJ on the other side.
CAUTION: During assembly check that the steering rack hole is not clogged with grease. If the hole is
clogged, the pressure inside the boot will change after it is assembled and the steering is turned.
337
Remove the bottom end cover, used for

controlling the preload using the special tool.
Remove the endplay-controlling plug. Note the

condition of plastic wear area. Remove the spring
Remove the end cap on the tube side.
Remove the end bush (tube end)
Before removal of the control housing the rack should be pressed to the either end.(At the extremes
of the rack the clearance with the pinion teeth is more hence assembly and removal is easy)
338
Remove the control housing
Remove the rack.
The Teflon piston seal should be removed and refitted by fingers only. Smear power steering oil on
seal before assembly.
To remove and refit the inner seal use the special tool.
CAUTION: While refitting the rack ensure that rack teeth do not damage the inner seal in the tube
and the housing
To remove the pinion bearing use the special tool.

For assembly also use the same tool but the other
end.
339
For removal and refitting the pinion outer bearing

use the special tool.
Tap out the pinion from the control housing using

the special tool.
Remove the bearing & the sleeve.
Push the pinion along with the control housing.
While assembly fit the control sleeve using the

special tool.
340
Press the oil seal using the special tool.
After the rotating torque has been adjusted by using the end plug. It has to be locked.
Press the oil seal at the tube end using the special tool.
Fit the end plug (tube end) using the special tool.
Fit the bottom plug using the 18-mm socket. Fit the inner ball joint
Fit the bellows.

CAUTION:
• Ensure that the outer clips are fitted on top of the groove. (The rubber boot also has a
beading, which sits on the groove.)
• The tube side boot is smaller than the control housing side.
341
• Working principle of the Steering Pump –

The steering pump is non-serviceable. Hence it cannot be repaired.
The pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief
valve) and it is gear driven by engine. The power steering pump consists of housing, drive shaft,
cartridge assembly & bearing(s) apart from the valve.
As the pump rotates a vacuum is created at the inlet, which causes atmospheric pressure to force the
fluid in to pump from the reservoir. As the rotor rotates, the inlet port closes and the fluid is trapped
between the vans. Further movement forces the fluid to be pressurized as the profile of the cam ring
constantly reduces the available volume. At the minimum point of the profile the chamber opens into
the outlet port.
The rotor is having 10 vanes, thus each rotation is equal to 5 pumping action. The discharge rate of the
power steering pump increases in proportion to the pump speed increases.. The flow control valve is
provided to maintain the optimum flow of the supplied oil for power steering operation, at all engine
speeds. The relief pressure will open when the system pressure exceeds the set value. This normally
happens when the steering wheel is turned and held in the lock position.
342
• Specifications
STEERING SYSTEM :
Type (Manual / Power assisted – Hydraulic / Power Assisted, Rack & Pinion
Power assisted – Electric / Other)
Steering wheel
Position(center/offset) Offset
Outside dia mm 395mm Opt:-391mm
Number of spokes 4
Steering Column Make/ Type Rane Madras Ltd; / Tilt & collapsible Type
Intermediate shaft
Rane Madras Ltd., Sterling Industries, Shareen
Make Auto Pvt. Ltd.
Type / Model Collapsible

Maximum No. of rotation of steering wheel from 3.3
lock to lock
Offset of the steering column with respect to the 50.0 mm to left of Seat centre line
seat
Steering Gear
Type of steering gear ( Recirculating ball / Warm Rack & Pinion Type
& Roller / Rack & Pinion / Others)
Make RANE TRW STEERING SYS LTD
Steering gear ratio 18:1
Wheel lock angle(deg) Inner Outer
Left 37 39
Right 34 36
Power Assistance YES
Type of assistance HYDRAULIC
Make RANE TRW STEERING SYS LTD
Oil Specification SPIRAX S3 ATF MD3
Oil capacity (l) 750 ml
Pressure setting, kg/cm2 / bar / kPa 75 bar
Min turning circle diameter (mm) 12300
Min. turning circle clearance diameter (mm) 12600
Minimum road clearance (mm)at differential 200
Approach angle (deg) 24
Departure angle (deg) 21
Ramp-over angle (deg) 20.5
343
• Tightening Torques
Description Torque Value Nm (lbf-ft)

Steering Gear Centre Bolt 120 ±10 Nm (88 ± 7 lb-ft)
C Clamp side mounting 85 + 13Nm(62 lb-ft)
Casting side bolt 85 + 13Nm(62 lb-ft)
OBJ- tie rod end 80 + 10Nm(59 lb-ft)
Upper column top mounting 22 + 3Nm(16 lb-ft)
Upper column bottom mounting 22 + 3Nm(16 lb-ft)
Column grommet 22 + 3Nm(16 lb-ft)
Lower I shaft mounting on gear 22 + 3Nm(16 lb-ft)
Connector mounting on upper I shaft 22 + 3Nm(16 lb-ft)
Steering pressure hose 25 + 3Nm(18 lb-ft)
Steering return hose 25 + 3Nm(18 lb-ft)
Hose clamp on pump 22 + 3Nm(16 lb-ft)
Hose clamp on gear 13 + 2Nm(9 lb-ft)
Steering wheel nut 47 + 7Nm(34 lb-ft)
Steering column and ignition lock sub-assembly 14 + 1Nm(10 lb-ft)
Fitment of steering arm to knuckle LH/RH 80 + 10Nm(59 lb-ft)
• Recommended Lubricants
 The recommended brand names are: SPIRAX S3 ATF MD3
 Capacity is 0.8 lts.
344
• List of the MSTs –

MST – 547
Steering wheel puller
MST – 548
Steering stand
MST – 549
Tie rod end remover
MST – 550
Socket steering pump Nut
MST – 551
Unit wrench –12 mm
345

MST – 552
Spanner power Steering Lock nut
MST – 553
Drift pinion assembly
MST – 554
Rack stopper wrench
MST – 555
Installer power Steering Oil End Cap
MST – 556
Driver needle bearing
MST – 557
Driver bearing rack Housing
346

MST – 558
Installer oil seal-Steering
MST – 559
Installer pinion Housing Upper Pinion Oil seal
MST – 560
Installer oil seal Power steering.
347
Front Suspenssion
Contents…
• Description…………………………………………………………………. 349
• Care of the Axle………..……..…………………………………………… 352
• In Car Repairs……………………………………………………………… 353
• Specifications & Wear Data……………………………………………… 369
• Special Tools……………………..………………………………………… 372
348
• Description
The front suspension is independent. The front suspension in the 2WD vehicle is wishbone type with
helical spring and telescopically acting hydraulic dampener.
The front also employs anti roll bar with ball joints on the connecting links as shown in the sketch to
transfer the loads to the outer wheel during turns.
349
A squeak noise from the shock absorber can be produced if movement between the rubber bushing
and metal occurs. Tightening the attaching parts can usually stop this noise. If the squeak noise
persists then inspect for worn or damaged bushings and attaching components.
Repair as necessary if anything found amiss. Squeak also happen due to relative movement from
suspension arm’s bush inner sleeve (serration end) and chassis bracket. This situation happens, if
torque is not as per specs. Torque tightening the LCA & UCA bolts normally resolves the issue. The
shock absorber bushings do not require any kind of lubrication. Do not lubricate the bushings to
reduce bushing noise. Grease or mineral oil base lubricants will deteriorate the bushing.
The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must
be replaced. To test a shock absorber hold it upright in fully extended position for 10 minutes. Then
force the piston in and out of the cylinder four or five times. The action throughout each stroke should
be smooth and even.

One Edge Wear Excessive camber  Check and adjust:
 Camber to be checked and
adjusted.
 Check for the wheel turning
angle.
Feathered Edge Incorrect Toe In  Check & correct Toe In

Wear  Check the chassis bend
 If tyre rotation not carried out
as per schedule. Do the tyre
rotation.
 If the wheel alignment values
are OK and only one tyre is
having the complaint then look
at the upper control arm
bushes.
Excessive Vehicle 1. Body Mounts loose.  Tighten the body mounts.
rolling 2. Suspension mounting loose.  Tighten the suspension
3. Broken or deteriorated mounts.
stabilizer  If broken stabilizer
4. Worn stabilizer bush bar- replace
5. Malfunctioning  Replace the bushes &
shock absorber tighten to the
6. Stabiliser link bolt loose specified torque,
 Replace the shock absorber.
 Tighten the link bolts
Vehicle inclined Broken or Replace the coil
deteriorated coil spring
spring
350
Noise 1. Parts worn or 󲐀 Tighten the parts or replace

loose 󲐀 Replace the coil
2. Broken coil spring spring
3. Malfunctioning 󲐀 Replace the shock
shock absorber absorber
Do not lubricate the suspension bushes/joints. For fitting & removing bush use soap solution only.
351

 Wheel alignment to be done only at every 40,000 Km or if the tyre is showing abnormal tyre
wear or if the front suspension camber bolt has loosened
 Inspect the bolts for loosening ( visual) if loosened, tighten and bring to the original marking
Working principle, Dismantling & Assembly of the Front Suspension 2WD
The front Wheel suspension in the 2 WD vehicles is wishbone type with helical spring and
telescopically acting hydraulic dampener. Both the lower and upper arm employ two point mounting.
An anti roll bar is used to transfer the loads to the outer wheel during turns. The telescopic shock
absorbers are used to dampen the wheel oscillations and ensure proper wheel contact irrespective of
the road condition.
Points to be ensured while fitting any new bushes in the suspension
The bolts should be fully tightened only when the wheels are in ground. When the bolts are tightened
with any particular wheel jacked up then it causes preloading of the rubber bush in the normal
operating zone and thus reducing its life.
•
352
• In Car repairs
 Wheel alignment, Specifications and detail procedure.
 Front and Rear ride height – Check
 Upper Control Arm and Bush – R&R
 Lower Control Arm and Bush – R&R
 Stabilizer bar and Bush – R&R
 Coil Spring and Shock Absorber – R&R
 Suspension bush – Check
 Front hub assembly R&R
353
• Specification for wheel alignment –
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°75' to 3°75'
King pin angle 10.5° to 12.5°
Steering angle- Inner 35˚ to 38˚
Steering angle- Outer 34˚ to 36˚
Ride height (215 tyre)
Ground to frt camber bolt head centre RH & LH 269 ± 10 mm
Ground to rear lower link bolt head centre RH & LH 298 ± 10 mm
354
• Decision tree for wheel alignement :
Do the wheel
Has the vehicle covered Yes alignment as per the
40,000 Km, process
No
Yes
Any abnormal tyre
wear?
No
Does the vehicle pull to

one side even with
Yes
correct tyre pressures?
No
Yes
Check the front
Front ride height loss suspension bushes
more than 10 mm? and shock absorbers
bushes
No
Yes Torque tighten the

Front suspension bolts and align the
bolts loosened? original marks.
No
Wheel alignment not required
355
• 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 caster value
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
356
• Wheel alignment process -
Pre Work Process

Tyre pressure : Should be 2.4 bar in all the tyres in Unladen condition.
Observe : The intial positon of the camber/ castor bolts.
Sequence :
Torque : All the camber /castor bolts have to be torque tightened to 200 NM. This is a
critical activity
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 SOP.
357
Ride height - Is the verticle distance between front camber bolt nut side end center to the ground
plane.
The ride height should be 269 ± 10 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 shock absorber bushes. 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.
Hint for doing the wheel alignement:
 Vehicle should be unladen and parked on level surface

 Ensure that the wheel hub play is correct.
 Check that the chassis and the under body are not coated with mud. If in doubt get the vehicle
cleaned before doing the checking.
 Check the ride height variation as per the specification.
 Replace the parts of suspension if found badly damaged
 Before starting the measurement, ensure that the parking brakes are applied and the rear wheels
are blocked
 Before doing the wheel alignment – ensure that the linkages i.e. the ball joint are not worn or
loose. Check the free play in the steering.
 All the tyres and the wheel disc should be of the same type.
 The wheel turning angle check at the last will ensure that the vehicle pulling after
doing the wheel alignement is avoided.
358
Do’s –
1. Front shock absorber top stud length after assembly should be 26mm, measured from the top
of the nut.
2. Only flanged hardware should be used. Use of spring washer and plain washer to be
prevented (except for pan hard rod).
3. Both front & Rear Suspension should be tightened in unladen condition and not in rebound.
4. All bushings should be free from oil. If oil is found on any bushings then it needs to be
replaced.
5. While fitment of bottom bolt front shock absorber, head side should be at rear end to avoid
fouling of the bolt with brake housing caliper in full turn condition.
6. All silent block with voided bushes should be mounted as per the specified orientation.
Don’ts –
1. Torque values should not be less than specified in any case.

2. Locktite should not be applied on thread for torque loss concern. (This will damage the
threads)
359
• UPPER CONTROL ARM & BUSH – R & R

• UCA mtg. bolt on frame. 02 nos. 18 mm. 90 ± 10 Nm.

• UCA ball joint nut 01 nos. 16 mm. 140 ± 20 Nm.
For removing the upper and lower arm bushes use the Special tool MST 564 & 565
Removal Steps –
1. Remove Wheel assembly.
2. Remove Stg. joint on knuckle
3. Remove UCA ball joint nut &
disconnect it from knuckle.
4. Remove UCA mtg. bolts on frame.
5. UCA bushes to be removed with help
of press machine.
1. Refit & Check UCA bushes &
UBJ boot for proper fitment.
2. Refit UCA mtg. bolts on frame,
do not tight fully.
3. Refit UCA ball joint on knuckle.
4. Refit Stg. ball joint on knuckle.
5. Refit wheel assembly.
360
Refer below illustrations for correct fitment of voided bush on Upper Arm.
VOIDED BUSH - CORRECT POSITION ON UPPER ARM
Wrong fitment
of voided bush
• During refitting use the dolly.

• In the UCA while pressing the bush in the arm it has to ensure that the solid rubber
portion of bush should match parallel to the arm.
• Use of any lubricant will result in degradation of the rubber bush and lower life. Pressing
without soap solution will damage the bush.
361
• LOWER CONTROL ARM & BUSH – R & R

• LCA mtg. bolt on frame. 02 nos. 22 mm. 200 ± 20 Nm.
• LCA ball joints to LCA 04 nos. 13 mm. 45 ±5 Nm.
• LCA ball joint nut 01 nos. 16 mm. 140 ± 20 Nm.

1. Remove Wheel assembly. Refer illustrations.
2. Remove Stg. joint on knuckle 1. Check LCA bushes & UBJ boot for
3. Remove LCA ball joint nut & proper fitment.
disconnect it from knuckle. 2. The washers need to be crimped
4. Remove LCA mtg. bolts on frame. using the special tool
5. LCA bushes to be removed with help 3. Refit LCA mtg. bolts on frame, do
of press machine. not tight fully.
4. Refit LCA ball joint on knuckle.
5. Refit Stg. ball joint on knuckle.
7. Do Wheel alignment.
362
Refer illustrations below for correct fitment of voided bush on LCA.
VOIDED BUSH - CORRECT The washer has to be crimped to

POSITION ON LOWER ARM ensure bush performance

• LCA is fitted with voided bush on its rear end.
• In the LCA while pressing the bush in the arm it has to ensure that the solid rubber portion
of bush should match parallel to the arm.
363
• STABILIZER BAR & BUSH – R &R

• Stab bar mtg. bolt on frame. 04 nos. 16 mm. 40 ± 10 Nm.

• Link mtg. bolts on knuckle & Stab bar 02 nos. 18 mm. 40 ± 10 Nm.
Removal Steps –
1. Remove Wheel assembly.

2. Remove Stabilizer bar links
connected on Stab bar LH & RH side.
3. Remove Stabilizer bar mtg. bolts on
frame.
4. Stabilizer bar now can be removed
from vehicle.
NOTE:
Check the stabilizer bar bushed for
wear and tear, cut marks, bulging
etc.. Replace if required.
1. Check Stab bar bush condition &

replace if required.
2. Refit Stab bar on frame.
3. Refit Link on Stab bar LH & RH side.
(Vehicle test drive is recommended)
364
• COIL SPRING & SHOCK ABSORBER – R & R

Shock absorber upper mtg. bolt on chassis. 03 nos. 13 mm. 40 ± 5 Nm.

Shock absorber mtg. bolt on LCA 01 no. 16 mm. 120 ± 10 Nm.
Removal Steps –
1. Remove wheel assembly.
2. Remove UCA from knuckle assy.
3. Remove Shock ab. assy. upper mtg. nuts.
4. Remove Shock ab. assy. Bottom mtg. bolt.
5. Use MST to separate Coil from Shock
absorber.
1. Assemble spring & shock absorber, set the
height of Shock absorber upper mtg. nut and
spring mtg. plate. (Refer below sketch)
2. Refit Shock ab. bottom & upper mtg. bolts
and nuts.
3. Refit UCA on knuckle assy.
Shock Absorber upper Bushes
365
Refer following illustration and adjust Shock absorber projection height –

366
• SUSPENSION BUSHES - CHECK
a. Check lower control arm bush condition (both LH & RH) for wear & tear, cracks &
separation. Replace if necessary.
b. Check upper control arm bush condition (both LH & RH) for wear & tear, cracks &
separation. Replace if necessary.
c. Check the ball joint boots for damage, cracks. Replace if necessary.
d. Check Shock Absorber Bushes, dust boot & Stabiliser Bar Links and Bushings for wear &
tear, cracks and shift. Replace if necessary.
1
• 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.
367
• FRONT WHEEL HUB ASSEMBLY - R & R

• Wheel Nuts 05 nos. 21 mm 94 Nm.
• Hub Lock Nut 01 no. 28 mm 400 Nm.
A B
[A] Front Wheel Hub Assembly &

[B] Front Wheel Hub Disassembly
Removal Steps –
1. Jack up the vehicle & remove the wheel.
2. Remove the calliper assembly without disconnecting the brake hose.
3. Remove Disc assy after removing grub screw.
4. Remove the hub cover using a screwdriver.
5. Remove the locknut, take out the washer.
6. Pull out the hub along with the bearings.
• The Hub is with unitized bearing and if required, complete Hub assembly is to
be replaced.
• The bearing is pre-adjusted, greased and Sealed for life.
• It is maintenance free and no adjustment required for unitized bearing.
• While refitting ensure the torque is applied.
• Ensure that the brake hoses are not stretched/ damaged. Put the calliper without
straining the brake hose.
• Please ensure that the hub assembly being replaced is with the circlip.
368
• Specifications and Wear Data –
Description Specification
Type Independent, double wish bone with telescopic
shock absorbers
Front Shock absorbers- 2WD Shock Absorber Standout – 26 mm
Coil Spring .
Coil spring Load Identification 1 yellow Dot

2 yellow Dots
Camber
-30’ to +10’
369
Difference between LH & RH ±0.5° (±30’)

Camber
Castor
Difference between LH & RH ±0.75 ° ( ± 45’)
castor
Toe in 0 to 1 mm ( 0 to 13’)
Total Toe in 0 to 2 mm ( 0 to 26’)
Shock absorber stand out 26 mm

King pin Inclination 10.5° to 12.5°
Wheel Turning Angle- Inner 35° to 38°
Wheel Turning Angle- outer 34° to 36°
Ride height Variation Between 10 mm
LH & RH. (Up to LCA front pivot bolt)
370
• Recommended Lubricants –
No lubricants / grease to be used in the suspension bushes. Only soap solution to be used
during assembly
Location Torque Nm
UCA mtg. bolt on frame. 90 ± 10 Nm
UCA ball joint nut 140 ± 20 Nm.
LCA mtg. bolt on frame. 200 ± 20 Nm.
LCA ball joints to LCA 45 ±5 Nm.
LCA ball joint nut 140 ± 20 Nm
Stab bar mtg. bolt on frame. 40 ± 10 Nm
Link mtg. bolts on knuckle & Stab bar 40 ± 10 Nm
Shock absorber upper mtg. bolt on chassis. 40 ± 5 Nm
Shock absorber mtg. bolt on LCA 120 ± 10 Nm.
Wheel Nut 94 Nm
Hub lock nut 400 Nm
371
• List of the MST’s –
Sr.No. Suspension Tools Description
1 0402BAA0002ST PAN HARD ROD TOOL KIT – XYLO
2 0402BAA0003ST UPPER LINK SUSPENSION TOOL KIT – XYLO
3 0402BAA0001ST LOWER LINK SUSPESION TOOL KIT – XYLO
4 0401BAA0003ST LOWER ARM TOOL KIT – XYLO
5 0401BAA0004ST UPPER ARM TOOL KIT – XYLO
6 0401BAA0005ST SUSPENSION TOOL FIXTURE - XYLO
7 0401BAA0006ST ASSEMBLY SUSPENSION SPECIAL TOOL KIT - XYLO
372
Rear Suspenssion
Contents…
• Description…………………………………………………………………. 374
• In Car Repairs……………………………………………………………… 377
• Specification……………………………………………………………….. 381
373
• Description
The rear suspension is a progressively rated multi leaf spring with double acting shock absorber. The
front end of the springs is mounted at the pivot end through rubber bushings. The bushings isolate the
road noise and road harshness as the springs move. The rear end of the spring is connected to the
springs through shackle
Again the spring and shackles use the rubber bushes to isolate the noise and road harshness. The
shackles allow the variation of the spring length when the vehicle moves over the different terrain
causing the wheel to move up and down.
The travel of the spring is controlled by bumper, which is mounted on the axle. The springs are
connected to the axle with U-bolts and spring plate. All suspension components that use rubber
bushings should be tightened with the vehicle at normal height. If the springs were not at normal ride
height condition the ride quality would be affected and also the life of rubber will also be affected.
Rubber bushings must never be lubricated.
The ride control is achieved by the use of double acting shock absorbers and leaf springs. The shock
absorbers dampen the jolt and the rebound as the vehicle travels over the various road conditions.
The top end of the shock absorber is connected to the chassis while the bottom end is connected to
axle.
374
A squeak noise from the shock absorber can be produced if movement between the rubber bushing
and metal occurs. Tightening the attaching parts can usually stop this noise. If the squeak noise
persists then inspect for worn or damaged bushings and attaching components. Repair as necessary if
anything found amiss.
The shock absorber bushings do not require any kind of lubrication. Do not lubricate the bushings to
reduce bushing noise. Grease or mineral oil base lubricants will deteriorate the bushing.
The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must
be replaced. To test a shock absorber hold it upright in fully extended position for 10 minutes. Then
force the piston in and out of the cylinder four or five times. Also check for any hydraulic oil leakage.
The action throughout each stroke should be smooth and even.

Suspension Noise 1. Check if mud is between  Clean with pressurized water.
the leaf springs.
2. Check tip insert if  Replace the tip between the
broken/ worn out. leaves.
3. Check bushes.  Replace the bushes.
4. Check shock absorber  Tighten the shock absorber
bush- worn out/ loose. mounting bolt or replace the
bushes.
5. Check leaf breakage.  Replace the spring assembly.
Vehicle ride Jumpy/ Jerky 1. Improper tyre pressure.  Keep tyre pressure as
2. Shock absorber bushes recommended.
worn out.  Replace the shock absorber.
3. Spring leaf bushes worn  Replace the bushes.
out.
4. Shock absorbers leaking/  Check the shock absorber and
weak. replace if required.
 Check the bump clearance as per
5. Leaf spring sagging / the specified procedure. Replace
broken. springs.
375
1. SHOCK ABSORBER REMOVAL
2. LEAF SPRING - BUSH REPLACEMENT
- PIVOT END BUSH REPLACEMENT
- SHACKLE END BUSH REPLACEMENT
3. LEAF SPRING ASSEMBLY - REPLACEMENT
376
• SHOCK ABSORBERS - REMOVAL
• Remove the upper attaching nut and washer.

• Remove the lower attaching nuts, washer and bolts from the axle. Remove the shock
absorber.
• While fitting ensure that they are tightened to a torque of 45 to 55 Nm (33 to 40 Lb ft)
377
LEAF SPRING - BUSH REPLACEMENT
• Pivot End Bush Replacement –
BUSH
Tightening Torque
50 ~ 70 Nm.
• Support the vehicle in chassis

1. Loosen the shackle mounting bolts.
2. Remove the pivot mounting bolts by rotating and pulling.
3. Pull out inner bush by pulling it out.
4. Lower the axle and bring the spring out of pivot.
5. Remove the bush by pulling it out.
While assembling ensures that:

• The rubber bushes are liberally coater with soap water.
• The hole in the centre of the pivot and the hanger bracket are clean and not
blocked by mud.(The hole is provided so that while assembling the air should
not get trapped between the two bushes- preventing proper assembly.)
• The eyes in spring and pivot/shackle are properly aligned before the bushes are
inserted.
• After the bushes are inserted, remove the support from the chassis & axle (if
used) and then tighten the pivot and shackle bolts to the desired torque.
378
• Shackle End Bush Replacement –
BUSH SHACKLE BRACKET
Tightening Torque
50 ~ 70 Nm.
• Support the vehicle in chassis

1. Loosen the shackle mounting bolts.
2. Remove the shackle/pivot mounting bolts.
3. Pull out one bush at a time. Each eye is having two collared bushes. They can be pulled out.
While assembling ensures that:

• The rubber bushes are liberally coater with soap water.
• The hole in the centre of the pivot and the hanger bracket are clean and not
blocked by mud.(The hole is provided so that while assembling the air should
not get trapped between the two bushes- preventing proper assembly.)
• The eyes in spring and pivot/shackle are properly aligned before the bushes are
inserted.
• After the bushes are inserted, remove the support from the chassis & axle (if
used) and then tighten the pivot and shackle bolts to the desired torque.
379
• LEAF SPRING ASSEMBLY - REPLACEMENT
• The leaf springs need to be replaced only if the springs are broken or are sagging.
• To check for the spring sagging it is recommended that bump clearance in unladen conditions
is measured.
The bump clearance has to be measure after ensuring that -

• The vehicle is in level ground.
• It is unladen.
• The tyre pressure is as per the recommendations and also no variation between
left and right tyres.
• The bump stop is not in deteriorated or damaged condition.
• The bump clearance is 85±10 mm and the variation between Left and right is
allowed to be 7 mm
Re-cambering of the spring is not recommended. (Please note that the spring is of progressive type –
any re-cambering will result in the ride becoming linear as well as stiff.
380
• Specifications
Type and description (Leaf / Coil / Air / Semi-pneumatic / Torsion bar)

Independent, Coil springs, Double Wishbone type
Front
with Anti-roll bar
Rear Rigid with Leaf Spring
Type of spring Leaf spring
Main spring
Stack height, at center 46.0
Width at the center point / stack point 70.0
Flat length 500.0
Free camber 139.0 ± 5 mm – reference only
Difference between LHS & RHS bump 7 mm
clearance
RR ride height Unladen/ Laden 346.0/ 281.0 mm
No. of leaves 3
No. of leaves 1
No. of spacers 3 in Centre & 4 in End
Suspension- Shock absorber :
Type and Number
Front Telescopic twin tube - 2
Rear Telescopic twin tube - 2
Suspension- Stabilizer :
Front Yes
Rear No
381
• Torque Chart
Description Torque (N-m)

Bolt – Leaf spring pivot 60 ± 10 Nm
Bolt - Shackle 60 ± 10 Nm
U Bolt 130 ± 10 Nm
Shock Absorber Top 50 ± 10 Nm
Shock Absorber Bottom 50 ± 10 Nm
Assembly Plate End Pivot 25 ± 10 Nm
382
Brake System
Contents…
• Description…………………………………………………………………. 384
• Care of the Axle………..……..…………………………………………… 392
• In Car Repairs……………………………………………………………… 402
• Working Principles of various systems……………………………….. 417
• Specification………………………………………………………………. 419
383
• Description
The purpose of the brake system is to allow the driver to reduce the vehicle speed or stop the vehicle
in a stable & safe manner. The function of the brake system is to convert kinetic energy of the vehicle
into heat energy through the application of friction.
Common brake systems use mechanical, electronic and hydraulic components to assist the driver to
apply friction on wheels.
A vehicle is also equipped with a parking brake mechanism to be used in parking conditions of vehicle
or in case of hydraulic brake failure, usually through the application of a hand operated lever.
Generally the braking power is three to five times more than the engine power. Brake systems use
friction to slow down, stop and hold the wheels of a vehicle. Brake systems apply friction by the use of
brake shoes or brake pads. Although friction is being applied to the brakes it is actually the friction
between the tires and road surface that stops the vehicle.
A disc brake uses brake pads to carry the friction material. The brake pad friction material is bonded to
a steel pad (backplate). Most brake pad manufacturers use a combination of metallic fibers in a resin
material to create the friction material.
A drum brake uses a brake shoe to carry the friction material. The friction material may be riveted or
bonded on to a steel shoe (web).Kevlar or a steel and mineral fiber mix is a common friction lining for
the brake shoe. Brake friction materials must be able to withstand temperatures up to 700 degrees
Celsius for short periods.
The brake system in GENIO is vacuum assisted ‘H’ split type. The front brakes are single pot callipers
with ventilated rotor (with angular vanes, hence the LHS and RHS are different). The rear brakes are
drum type with self-adjusting mechanism. The parking brakes are actuated in the rear through cable.
Both the front disc pads and the rear brake liners are non asbestos.
The braking system includes a Load sensing Proportioning Valve. It controls the brake fluid pressure
going to the rear depending on the load on the vehicle. Normally when the vehicle is loaded and
brakes applied; due to the weight transfer the load on the rear wheels become very less. In vehicles
without the LSPV; the full pressure of brake fluid going to the rear wheels tends to lock them. In
vehicles fitted with LSPV, the LSPV reduces the brake fluid going to the rear circuit depending on the
load hence avoids the rear wheel locking. Since the rear wheel locking is avoided it results in reducing
the braking distance (distance covered before the vehicle comes to a standstill)
The brake circuit is having an inbuilt bypass valve in the LSPV. In an unlikely situation of the front
brake circuit failure; the LSPV valve is bypassed and the full pressure of brake fluid goes to the rear.
This ensures that braking is achieved. The complete details about the LSPV valve & its functioning and
setting are mentioned later.
384
Preliminary checks involve inspecting fluid level, parking brake action, and wheel and tyre conditions,
checking for obvious or external leaks or component damage and pedal response. A road test will
confirm or deny the existence of the problem.
While road testing if the complaint involved low brake pedal, make several low speed stops and note if
pedal comes back to normal height. Check the pedal response with gear in neutral and engine
running. The pedal should remain firm under steady pressure. During road test make normal and firm
brake stops in speeds of 40 to 60 Km/h. Note faulty brake operation such as pull, grab, drag, noise, low
pedal, hard pedal, fade, pedal pulsation, etc.
Diagnosis –
Pedal falls away / Pedal sinking

A brake pedal that falls away under steady foot pressure is generally the result of system leak. The
leak point could be at a brake line, fitting hose, wheel cylinder or Master Cylinder Internal leakage’s
caused by worn or damaged piston, seals may also be the problem cause.
If leakage is severe fluid will be evident at or around the leaking component.
Low pedal
If a low pedal is experienced, pump the pedal several times. If the pedal comes back up, worn lining
and worn rotors or drums are the most likely cause. However, if the pedal remains low and / or the
warning light illuminates then the problem is in the master cylinder, wheel cylinder, or callipers.
A decrease in master cylinder fluid may only be the result of normal lining wear. Fluid level will
decrease in proportion to the lining wear. It is a result of the outward movement of caliper and wheel
cylinder pistons to compensate for normal wear. Top up reservoir fluid and check brake operation to
verify the complaint.
Spongy pedal
A spongy pedal is most often caused by air in the system. However thin drums or substandard brake
lining and hoses will also cause a condition similar to spongy pedal. The proper course of action is
bleed the system or replace thin drums and suspect quality brake lining and hoses. In case the system
has not been maintained as per recommendations and the brake hoses have not been replaced then
due to swelling of the hoses during braking – it also causes spongy braking. In such a condition it is
advisable to replace the hoses and replace all the seals and change the brake fluid.
Hard pedal or high pedal effort
A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed or
badly worn. Defective vacuum assistance will also cause hard operation. The vacuum booster or check
valve (NRV) could also be faulty. Test the booster function. As detailed below —
1. Start engine & check booster hose connections as well as the EGR valve connections. Correct
any vacuum leak before proceeding further.
385
2. Stop the engine and put in neutral.

3. Pump the brake pedal until all the vacuum in the reservoir is exhausted (normally after 6 to 8
pedal applications the brake pedal will become hard)
4. Press and hold brake pedal under light foot pressure
a. If the pedal hold firm then proceed to step 5.
b. If the pedal does not hold firm then and falls away then the master cylinder is
defective.
5. Start the engine and note pedal action.
a. If the pedal falls away slightly under light pedal action and then hold firm then
proceed to step 6
b. If no pedal action is discernable then vacuum pump or vacuum check valve is
defective.
6. Rebuild the vacuum reserve as follows. Release brake pedal. Increase engine speed to 1500
rpm and then bring it to idle and shut off engine.
7. Wait for about 90 seconds and try brake action again. Booster should provide two or more
vacuum assisted pedal applications. If vacuum assist is not performed then perform check for
the check valve and booster.
Find the enclosed flow chart for reference –
386
TROUBLE SHOOTING OF VACUUM BOOSTER ASSEMBLY

BASIC TEST
ENGINE OFF. Depress & release brake pedal several times to remove vacuum from Booster
Assembly. After this the pedal application will feel hard to press.
Depress the brake pedal & hold with light pressure of @ 10kgs. & start the ENGINE
If the booster is functioning satisfactory, the pedal will fall slightly & then hold. Here less pressure
will be needed to hold the pedal dawn.
IF THE BOOSTER IS NOT OPERATING If the BOOSTER is

Disconnect the vacuum hose from the NRV. Then with OPERATING pl. turns over & do
ENGINE RUNNING, Check vacuum supply with a the VACUUM LEAK
vacuum gauge. There should be at least 600 mm of Hg TEST.
vacuum for Diesel vehicle.
If VACUUM SUPPLY IS BELOW 600 mm of Hg for If VACUUM SUPPLY IS

diesel vehicle replace or repair vacuum hose & 600 mm of Hg for or more for diesel
vacuum source. vehicle, then the booster is faulty & should
be replaced.
When adequate vacuum supply is

obtained, repeat basic test.
387
VACUUM LEAK TEST
Run engine to medium speed. Release accelerator

& turn Engine OFF. This builds up vacuum.
Wait for 90 sec. & apply brakes. Two or more

applications should be vacuum assisted.
IF APPLICATIONS ARE NOT VACUUM IF APPLICATIONS ARE

ASSISTED disconnect vacuum hose from VACUUM ASSISTED there is no
vacuum source or NRV whichever is vacuum leak.
easier. If disconnected from NRV, attach DO THE HYDRAULIC LEAK
short length of hose to valve. TEST
Blow into hose attached to NRV. If air passes

through, valve is defective.
IF NRV or CHECK VALVE IS IF NRV OR CHECK VALVE

DEFECTIVE install new NRV IS OK, vacuum booster is
& repeat VACUUM LEAK TEST. leaking & should be replaced.
Depress & release brake pedal several

times. Then hold pedal depressed with
medium pressure.
IF PEDAL FALLS AWAY hydraulic system is IF PEDAL DOES NOT FALLS

leaking. Check for external leakage at wheel AWAY hydraulic system is not
cylinders, callipers, brake pipes, hoses & leaking.
joints.
If there is no external leak, there may be an
internal leak (master cylinder seals).
Repair or replace parts needed to correct leak.
388
CHECK VALVE OR NRV -- NON RETURN VALVE, MOUNTED ON VACUUM BOOSTER FRONT FACE.
Brake drag
Brake drag occurs when the lining is in constant contact with the rotor or drum. Drag can occur at one
wheel, all wheels, front only or rear only. It is caused by incomplete shoe release. Drag can be minor
or severe enough to overheat the lining, rotor and drum.
Brake drag has a direct effect on fuel economy. Undetected minor drag can be misdiagnosed as an
engine complaint. In case of severe drag it can also cause clutch slip.
Minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in the
rotor or the brake drum from the overheating/ cooling process. In most cases the rotors, drums,
wheels, and tyres are quite warm to touch after the vehicle is stopped.
Severe drag can char the brake lining all the way through. It can also cause distort and score rotors
and drums to the point of replacement. The wheels, tyre and brake components will be extremely hot.
In severe cases the lining may generate smoke as it chars from overheating.
Some common causes of brake drag are:
• Loose or damaged wheel bearing

• Seized or sticky caliper or wheel cylinder piston.
• Loose caliper-mounting bracket.
• Loose mounting bolts of the rotor.
• Bent sliding pins in the calliper.
• Distorted brake drum or shoes.
• Rear brake shoes binding on worn/ damaged support plates
• Misassembled components
• Incomplete release of parking brake
• No free play
• Clogged master cylinder return port
• Broken master cylinder return spring
• Early lock of rear wheel due to change in setting distance of LSPV .
If the brake drag occurs at all the wheels, the problem may be related to a blocked master cylinder
compensation port or faulty vacuum booster (binds does not release).
An improperly mounted brake light switch can also be a cause of drag. An improper mounting may
prevent the brake pedal to return completely. This will cause the master cylinder feed port to be
blocked. The brakes would be partially applied causing the drag.
389
Brake Fade
Brake fade is a product of overheating caused by brake drag. However overheating and subsequent
brake fade can also be caused by riding the brake pedal, making repeated high deceleration stops in a
short time span,
Constant braking on steep roads also cause brake fade. If the brake lining is contaminated with oil or
glazed then also the brake fading will take place.
Pedal Pulsation
Pedal pulsation is caused by components that are loose or beyond tolerance limits.
Disc brake rotors with excessive lateral run out or disc thickness variation, or out of round drums are
the primary cause of pulsation. Other causes are loose wheel bearings or calipers and worn, damaged
tyre
Brake Pull
A front pull condition would be the result of:
• Contaminated lining in one caliper.

• Seized caliper piston
• Binding caliper.
• Loose caliper.
• Loose or corroded slide pin.
• Improper brake shoes
• Inadequate contact of pad.
• Damaged rotor
• Incorrect tyre inflation (High variations between two wheel)
• Shoe return spring weak or broken
A worn, damaged wheel bearing or suspension components are further cause. A damaged front tyre
(bruised, ply separation) can also cause pull.
A common and frequently misdiagnosed pull condition is where the direction of pull changes after a
few stops. The cause is a combination of brake drag followed by brake fade at the dragging brake unit.
As the dragging brake overheats, efficiency is so reduced as the fade occurs. If the opposite braking
unit is still functioning then its braking effect is magnified. These causes pull to switch direction in
favour of the brake unit that is functioning normally.
While diagnosing a pull in change in pull condition, remember that pull will return to the original
direction if the dragging brake unit is allowed to cool down (and is not seriously damaged)
390
Rear Brake Grab
Contaminated lining, bent, or binding shoes and support plate usually causes rear grab (or pull). This is
particularly true when one wheel is involved. However when both rear wheels are affected the master
cylinder or the proportionate valve could be at fault.
Brakes do not Hold after Driving through Deep Water Puddle
This condition is generally caused by water soaked lining. If the lining is only wet it can be dried by
driving with the brakes lightly applied for 2 to 4 kms. However if the lining is both wet and dirty then it
will be necessary to dismantle, clean and reassemble.
Brake Fluid Contamination
There are two causes of brake fluid contamination. The first involves allowing dirt, debris, or other
liquid material to enter cylinder reservoir when the cover is off. The second involves adding to, or
filling the cylinder with a non- – recommended fluid. Brake fluid contaminated with only dirt, or debris
usually retains a normal appearance. In some cases the foreign material will remain suspended in the
fluid and be visible. The fluid and foreign material can be removed from the reservoir with a suction
gun but only if the brakes have not been applied. If the brakes are applied after contamination, system
flushing will be required. The master cylinder may have to be disassembled, cleaned and the piston
seals replaced. Foreign material lodged in the reservoir compensator/ports can cause brake drag by
restricting the fluid return after application.
Brake fluid contaminated by a non recommended fluid will usually be discoloured, milky, oily looking
or foamy. In some cases it may even appear as if the fluid contains sludge. However remember that
the brake fluid will darken in time and occasionally are cloudy in appearance. These are normal
conditions and should not be mistaken for contamination.
If some type of oil has been added to the system then the fluid can separate into distinct layers. This
can be verified by draining off a sample with a clean suction gun. Then pour the sample into a glass
container and observe fluid action. If the fluid separates into distinct layers, it is definitely
contaminated.
The only real correction for contamination by non-recommended fluids is to flush the entire
hydraulic system and replace all the seals and the brake hose.
Brake Noise
Squeak/Squeal
Brake squeak or squeal may be due to lining that are wet or contaminated with brake fluid, grease or
oil. Glazed linings and rotor/drums with hard spots can also cause squealing. Dirt and foreign material
embedded in the system will also cause squeak/squeal. Worn retaining pins can also cause disc pad to
squeak/ rattle.
391
A very loud squeak or squeal is frequently a sign of severely worn brake lining (or the drum or the
rotor). If the lining has worn to the rivets then metal to metal contact takes place. If the condition is
allowed to persist then rotors/drums can become so scored that replacement is necessary.
Thump/clunk
Thumping or clunking noise during braking are not caused by the brake components. In many cases
such noises are caused by loose or damaged steering, suspension or engine components. However
calipers that bind on the slide surface can generate thump or clunk noise. In addition, worn out
improperly adjusted, or improperly assembled rear brake shoes can also produce a thumping noise.
Chatter
Loose or worn components or glazed/burnt lining usually causes brake chatter. Rotors with hard spots
can also contribute to chatter. Additional causes of chatter are out of tolerance rotors, brake ling not
secured properly to shoes, loose wheel bearings and contaminated brake lining.
Brake lining contamination
Brake lining contamination is usually a product of leaking calipers or wheel cylinders, driving through
deep puddles, or lining that has become covered with grease and gravel during repair.
Wheel & Tyre Problems
Some conditions attributed to brake components may actually be caused by a wheel or tyre problem.
 A damage wheel can cause shudder, vibration and pull. A worn or damaged tyre can also
cause pull.
 Severely worn tyres with very little tread depth can produce a condition similar to grab as the
tyre loses and recover traction.
 Flat spotted tyres can cause vibration and wheel tramp and generate wheel shudder during
brake operation.
 A tyre with internal damage such as bruise or ply separation can cause pull and vibration
Defective Parking Brake
This can be caused by excessive hand brake lever play. Sticky parking cable, grease or oil on shoe,
excess shoe clearance (normally caused by malfunction of automatic adjusting mechanism)
392
The brake fluid should conform to DOT 3 specifications.
The brake fluid should be replaced twice a year or every 40,000 Kms. whichever is earlier. This is
because brake fluid is hygroscopic in nature hence it absorbs moisture. The normal braking operation
also results in brake fluid getting heated. The process of heating and cooling also results in moisture.
The brake fluid boiling point keeps coming down due to the presence of moisture hence if not
changed it can cause higher corrosion of the wheel cylinders/ master cylinders/ brake tubes as well as
spongy or poor braking.
Do not mix brake fluid of different brands. Do not use any brake fluid, which is kept in an open
container. Always use brake fluid from a sealed container.
The brake fluid should not be contaminated with any mineral oil. Do not use reuse brake fluid that has
just been bled. The list of the recommended lubricants is enclosed at the end of the chapter.
This section consists of following Maintenance activities –
• FRONT BRAKE DISC/ BRAKE PAD CHECK
• REAR BRAKE – CHECK
• BRAKE BOOSTER – CHECK
• LSPV – SETTING
• PARKING BRAKE – CHECK
• BRAKE FLUID LEVEL & LEAK – CHECK
393
• FRONT BRAKE DISC/ BRAKE PAD CHECK
Front Brake Disc & Calliper Assembly Front Brake Disc & Calliper Disassembly

1. Remove wheel assembly. 1. Check & refit Disc assy.
2. Remove top side one sliding pin bolt. 2. Check Pad assembly and refit with
Lift & rotate the caliper. caliper assy.
3. Remove inboard & outboard Pad 3. Refit wheel assy.
4. Remove Disc assy.
Inspection of Brake Pads, Brake Disc –

Refer below illustrations.
7 mm
Check Pad Thickness
22 mm
12 mm
Check Disc Thickness
394
Front Brake – Check

1. Check the disc for abnormal wear/grooves (Minimum usable thickness of the disc is
22mm, check at 12mm inside from 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 (7 mm).
4. Pad wear indicator is also provided to know pad wear limit.
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 brake Pads at every 20000kms.
395
• REAR BRAKE – CHECK
1 2
Check Liner Thickness
Brake Drum/ Liners – Check
1. Rear Brake – Open the drum & clean the brakes by blowing compressed air. Check the
wheel cylinder for oil leakage. (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 of the liner is 3.5
mm (The brake liners must be replaced before the rib starts touching the drum).
3. Measure the wear of the brake lining at the place worn the most.
4. Replace the brake shoe and lining assembly if the lining thickness is less than the limit, if it
is not worn uniformly.
5. 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 shoe, linings 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 shoe and the lining assembly
on the left and right sides, check sliding movement of the piston.
 Rear Brake drum & liners to be inspected at every 20000kms.
396
• BRAKE BOOSTER – CHECK
Brake Booster Operation Check -

• Step 1
- Switch off the engine and pump the brake pedal till it becomes hard.
- Press and hold the pedal, start the engine.
- If the pedal moves down slightly, immediately after the engine starts, the Booster unit is
operating.
• Step 2
- Start the engine.
- Turn the engine off after 1 or 2 minutes.
- Depress the pedal with usual force.
- If the first pedal stroke is long and becomes shorter with subsequent strokes, the Booster
unit is operating.
Brake Booster Functional Test
Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and
their connections should be correctly secured in. Check the hoses for breakage, holes and
collapsed areas. Inspect the check valve on the brake booster for damage.
• Connect the vacuum gauge to the booster check valve with short length hose.
• Start and run the engine at idle speed for one minute.
• Observe the vacuum supply. If the vacuum supply is not adequate, repair the vacuum
supply.
• Shut the clamp hose between the vacuum source and the check valve.
• Switch off the engine and observe the vacuum gauge.
• If vacuum drops more than one inch Hg (33millibars) within 15 seconds, booster
diaphragm or check valve is faulty.
397
• Booster Non-return valve Test

Brake
• Disconnect the vacuum hose from the check valve.

• Remove the check valve and the valve seal from the booster.
• Use a hand operated vacuum pump for test.
• Apply 15-20 inches vacuum at large end of check valve
• Vacuum should hold steady. If the gauge on pump indicates vacuum loss, then the check
valve is faulty and should be replaced.
398
• LSPV – SETTING
LSPV is mounted on 2 bolts on bracket fitted on chassis. It has got three brake fluid connections. One
is LSPV inlet from TMC, 2nd is LSPV outlet towards Rear wheel, 3rd is LSPV bypass connected to front
four ways TEE. The LSPV spring other end is mounted on the bracket on differential.
LSPV Setting - The LSPV setting is must in first service.

(This is necessary as the suspension gets settled and setting may change)
NOTE:
 The LSPV setting length is 112.25mm.
 The gauge used for LSPV setting is MST 0602BAA0001ST.
 Before start of LSPV setting, ensure the vehicle is Unladen.
Procedure for fitting and setting the LSPV Valve –

• Mount the LSPV valve on the bracket in the chassis. Fit all the hydraulic connections before
fitting / setting the LSPV valve ensure that the
• Vehicle unladen condition (Kerb weight) means No driver and no additional load.
• Fuel tank is assumed to be ¾ full.
• Before doing the fitment/setting run the vehicle through rough road /normal road for 5 to
10 kms. This is essential for the spring/ bushes to settle.
1. Remove the clip. Remove the Washer. Refer illustration shown.

2. Slide the control spring out from the bolt. Put the projecting pin of the tool in the eye of the
spring & allow the tool to hang freely..
3. Loosen the nut the M8 Hex Nut (Use 12 Ring Spanner) during removal hold the other end with
14 Spanner & move the bolt in such a way that the bolt is aligned & enters in the slot on the
tool. Refer illustration shown.
4. Retighten the nut in such a way that the bolt is in the correct position as indicated by the tool.
5. Remove the tool.
6. Pull down the spring and locate the eye in the bolt. Ensure that the spring is sitting properly
in its position. Fit the washer & the ‘e’ clip.
1 3
399
• PARKING BRAKE – CHECK

Schematic - Parking Brake
Parking brake cable-

Front
Turn
buckle
assembly
Lock
Nuts
Rr. LH & RH side

Parking brake cable
PARKING BRAKE – CHECK (Refer illustration shown)

1. Check Parking Brake Lever operation & setting*.
• Park the vehicle on a slope and apply Parking Brake to check the effectiveness.
• Release the Parking Brake & check the free rolling.
• Loosen or tighten the adjuster nut to achieve the correct setting*.
2. Check the parking cables (especially rear) for correct routing / fouling.
*Setting Procedure – Do the Parking Break cable setting as follows:
• Before starting the Parking Break Setting, ensure all the parts are assembled properly.
• Parking Brake setting can be done through Turn Buckle Assembly located on bracket
welded on vehicle under body. (Refer Photograph no.1)
1. Lift the Rear Wheels by using four post / Jack.
 Before doing the setting, check the freeness of wheels by rotating the wheels.
2. The setting near Hand Brake lever to be kept around open thread length 20 mm. Tighten
the Nut and Lock nut by applying max 5 N-m torque.
 Note: Ensure that cable is not getting twisted during tightening.
3. Rotate the Turn buckle (Refer Photograph) till the stud end reaches into the hole of the C-
Bracket.
4. Lift the Rear wheels and apply 2 notches of Park lever and see the rotation of both wheels.
If wheels are Jam, tighten the Lock nut (Torque 5 N-m).
5. If both wheels are still rotating, rotate the turnbuckle again to increase the setting. Check
the wheel jam and tighten the Lock nut.
6. Apply the Hand Brake lever and check for notches. Normally in 4 to 6 notch reading,
Parking Brake Setting can be completed.
7. Release the lever and check for freeness of Rear Wheels to ensure no drag on Wheels.
400
• BRAKE FLUID LEVEL & LEAK – CHECK

Clutch /Brake Fluid – DOT4 standard /SAE J1703/IS 8654Type-2 Specification
Capacity – 0.9 Lit
MAX
MIN
Common Fluid Reservoir for Brake & Clutch System
BRAKE/CLUTCH FLUID – LEVEL & LEAK - CHECK

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.
 Clutch slave Cylinder inlet banjo.
 GENIO is 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, System bleeding required for Brake as well as
Clutch system.
 Recommended fluid: DOT4 type brake fluid meeting SAE J1703 FMVSS No.116 or IS
8654 Type-2specification.
 Recommended to check brake & clutch fluid level & leak first at 5000kms, then at
20,000kms and after that every 10000kms.
401
• In Car Repairs -
 FRONT BRAKE CALLIPER REMOVAL
 BRAKE SHOES/ LINERS REMOVAL
 REAR BRAKE WHEEL CYLINDER – R&R
 WHEEL CYLINDER OVERHAUL
 BRAKE PEDAL CHECK
 BRAKE MASTER CYLINDER (TMC) – R&R
 BRAKE BOOSTER – R&R
 BRAKE BLEEDING
 WORKING PRINCIPLE OFBRAKE BOOSTER
 WORKING PRINCIPLE OF LSPV
402
FRONT BRAKE CALLIPER – R&R

 Apply hand brakes. Place wheel chocks on rear wheel
 Jack up the front of the vehicle and remove the front wheels by loosening / removing the wheel
nuts.
 Disconnect the hose from the calliper by removing the banjo bolt
1. Loosen and remove the bottom retaining

bolt of the guide pin.
2. Remove the calliper sub assembly after removing the top retaining bolt.
(There is no need to remove the Carrier Assembly with pads from the rotor or stub axle.) Clean the
calliper sub assembly externally with alcohol or fresh brake fluid.
3. Remove the calliper pistons from the bore by blowing dry compressed air through the inlet port
of the calliper. Care must be taken to remove both the pistons at a time. Also to avoid the
damage to the pistons, place a wooden block in front of the pistons. (approx. 30 mm thick )
4. Remove the boot.
5. Remove the seal- Pistons from the groove by using a blunt edged connector or feeler gauge.
Take care during seal removal the bore is not damaged.
6. Remove the bleed screw from the calliper body.
Cleaning & Inspection –
All the removed parts should be cleaned properly using fresh brake fluid or alcohol and kept in a
clean tray.
 NEVER USE ANY MINERAL OIL BASE FLUIDS LIKE KEROSENE, DIESEL and PETROL
etc. FOR CLEANING OF REMOVED PARTS.
 DO NOT CLEAN THE BORE OF THE CALLIPER WITH WATER OR STEAM.
The Piston seals are to be lubricated with fresh brake fluid and assembled in to the seal grooves in
the calliper bores. Make sure the seating of this is properly done. Then lubricate the outer surface
of the pistons with fresh brake fluid.
403
Remove the boot - piston with the help of a screwdriver. Care must be taken not to damage the seat
of the boot in calliper body.
The piston boots are to be lubricated internally with the special grease supplied in Calliper Repair
Kits before it is assembled on the pistons.
Locate the boots on to the calliper pistons. Insert the calliper pistons into the bore & push it gently
into the bore.
Once the piston is home, ensure the fitment of the boot on to the boot groove on the piston.
The piston should be inserted into the bore in a straight position only. If it gets tilted while pushing,
there is a chance that the piston will get jam half way & also can damage the seal.
Once the piston is inserted inside the bore, put a wooden block on the piston & with the help of a ‘C’
Clamp push it inside the bore. Face to face fitment of the boot to be insured. Repeat the procedure
for the other piston.
The wooden block should have the corners rounded to ensure the proper fitment of boot into the
grooves. Otherwise the wooden block can foul against the radius on calliper body.
Replacement of Sliding pin Kit –
1. Loosen and remove the bottom retaining bolt of the guide pin.
2. Remove the top retaining bolt of the locking pin.
3. Remove the guide pin.
4. Remove the locking pin with bush from the carrier.
5. Remove the boot – Pin from the carrier.
Smear the pins and the pin bores with the special grease supplied in Sliding Pin Kit. Apply light grease
on locking pin. Fit the pin boots on to the pins and assemble it on to the carrier bore. Ensure proper
location of the boot lip on to the carrier. Move the pins in and out 3 to 5 times in order to allow for
the trapped air inside the bore to escape.
 Repeat the above procedure for the other side calliper assembly.
404
REAR BRAKE SHOE – R&R

Jack up the vehicle.
Remove the wheels.
Slacken the adjuster to keep the shoes in a completely retracted position.
Remove the brake drum. (Refer to the

instructions for removal of drum).
Push the hand brake lever away from the shoe

rim and remove the cable from the operating
lever hook.
Using a ‘spring pliers’ remove the shoe return spring at the wheel cylinder end.
Remove the shoe hold down pins from both the shoes using B.I. Shoe hold down spring tool No.
64927118.
Remove both the shoes from back plate along with the abutment end spring.
Slip an elastic band over the wheel cylinder to retain pistons within the cylinder.
Assembly precautions –
1. Place one shoe on back plate & assemble pin shoe hold down cup. Fit one end of the shoe return
spring - lower in the slot provided on brake shoe. Assemble the other end of the shoe return
spring – lower in the second shoe. Tilt & place the shoe on the back plate & fit the shoe hold
down pin & cup. While fitting the lower return spring take care that end with the fewer turns is
facing the trailing shoe (towards the rear of the vehicle.)
2. Place the auto adjuster assembly between the shoe web slot & hand brake lever slot.
405
3. Assemble shoe return spring –Upper return spring on adjuster lever. Place a screw driver inside
the small hook of the spring & by pulling fit the spring in the shoe slot. Ensure no damage to the
Auto Adjuster Lever.
4. Ensure that the auto adjuster lever edge is properly located on tooth of auto adjuster wheel.
5. Connect the Parking brake cable in reverse order of dismantling.

Before refitting the brake drum check that the drum thickness has not gone below 1 mm.
A thin brake drum will flex during braking reducing the braking efficiency and also it will cause
improper functioning of the parking brakes.( Useful brake drum Ø is 284 mm)
 Apply brakes few times to adjust the brake shoes.
RELINING* THE SHOES - (*IF APPLICABLE)

 Inspect the linings.
 Lining should not be allowed to wear down to the rivet heads.
 If the linings are worn down to rivets, they must be replaced.
 De rivets them carefully.
 Before de riveting, detach the hand brake lever cable from the trailing shoe this may be done as
follows:
 Remove the retaining plate from the pin groove by sliding with a screwdriver.
 Remove spring plate; Lightly tap the pin to remove the Hand brake lever from the shoe.
 If excessive wear on this pin is noticed, it should be replaced.
WHILE DE RIVETING, ENSURE THAT THE HOLES IN THE SHOE RIM ARE NOT ENLARGED.
Clean the shoe rim to ensure a smooth even surface for the lining.
ALWAYS USE GENUINE APPROVED GRADE OF SERVICE REPLACEMENT LININS DURING RELINING,
INCLUDING THE RIVETS SUPPLIED ALONG WITH THE RELINING KIT.
Clamp the lining evenly to the shoe rim and start riveting at the centre and progress outwards to the
ends of the shoe. A flat ended anvil of the correct diameter should be used against the rivet head
and the tubular shank of rivet should be properly clinched.
CARE SHOULD BE TAKEN, SINCE OVER RIVETTING MAY CRACK THE LINING. ENSURE THAT NO
CLEARANCE EXISTS BETWEEN THE LINING AND SHOE RIM.
Fit the hand brake lever to the trailing shoe in the reverse order of removal.
Ensure that the spring plate convex side is towards the retaining plate.
MAKE SURE THAT HAND BRAKE LEVER IS FREE TO OPERATE. DO NOT CONTAMINATE THE LINING
SURFACE WITH OIL OR GREASE.
Refit the shoes in accordance with following instructions:
406
FITTING SHOES -
Clean the back plate.
 Check the back plate pads for grooving or other damages.
 The pads must be smooth and not corroded.
 If necessary, smoothen the pads with file or emery cloth, but do not remove any more material
than is absolutely necessary and note that each set of these pads should be reduced equally.
Clean off the metal fillings.
NEW SHOE RETRACTING SPRING SHOULD ALWAYS BE FITTED DURING MAJOR OVERHAUL.
 Remove the elastic band over the wheel cylinder.
Check the wheel cylinders for leaks by lifting the dust cover. Check the piston for freedom of
movement. If a leak is suspected from the wheel cylinder or if the piston movement is unsatisfactory
the unit must be overhauled. Refer to “WHEEL CYLINDER SERVICING”. Inspect the wheel cylinder
dust covers for cuts, hardening or other signs of deterioration. If in doubt, the dust cover should be
replaced.
Lightly smear high melting point graphite grease to the back plate shoe pads and abutment.
Position the leading shoe (the shoe with the longer lining) on the back plate and fit shoe hold down
pin. Spring cup washer as shown in figure. Ensure that the convex face of each washer is towards the
spring.
THE LEADING SHOE (THE SHOE WITH THE LONGER LINING) SHOULD BE FITTED TOWARDS THE FROTN
OF THE VEHICLE. HOOK THE SMALLER SPRING AT THE ABUTMENT END (BOTTOM) OF THE SHOE AND
THE LONGER SPRING TOWARDS THE WHEEL CYLINDER END.
 Position the trailing shoe (the shoe with the shorter lining and hand brake lever) on to the back
plate and hook the smaller spring at the abutment end. Move the hand brake lever and fit the
shoe hold down pin spring and washers.
If the rubber sleeve on the strut is removed or if you are fitting a new rubber sleeve, ensure that the
rubber sleeve is fitted in such a way that the flat portion of the sleeve is towards the straight edge of
the strut. Position the strut between the leading and trailing shoe webs.
Two slots are milled on either end of strut. One of them is wider that the other. The narrow slot
should be on the leading side. Using spring pliers, hook the longer spring on to the trailing shoe.
WHILE USING THE SPRING PLIERS EXTREME CARE MUST BE TAKEN AS OTHERWISE THE LINING MAY
BE DAMAGED.
 Connect the hand brake cable to the hand brake lever in the reverse order of removal.
DO NOT HANDLE THE LINING NORE THAN IS NECESSARY AND BE SURE THAT THEY ARE COMPLETELY
FREE FROM GREASE.
Centralize the brake shoes relative to the backplate, before fitting the drum by lightly tapping in the
required direction.
 Refit the drum and wheel.
 Adjust the brakes as explained under “Brake Adjustment”.
 Check the hand brake cable adjustment in accordance to the vehicle manufacturer’s instructions
and road test.
407
REAR BRAKE WHEEL CYLINDER – R&R

When removing or servicing wheel cylinders, it is
necessary to draw fluid from the system and
remove the brake shoes.
Attach a bleed tube to the bleed screw having

first removed its rubber dust cap. Unscrew the
bleed screw ½ to ¾ turn and pump out the fluid
into a suitable container by operating the brake
pedal. Remove the bleed tube. Remove the
brake shoes as explained under “Removal of
shoes”.
Disconnect the bundy pipe from wheel cylinder. Remove the bleed screw. Remove the wheel
cylinder mounting set screws and takeout the wheel cylinder from the backplate.
DISMANTLING OF WHEEL CYLINDER -
Clean the wheel cylinder externally. Remove the
dust covers fitted on wheel cylinder assembly.
Push out the piston seals, air excluders and
spring. Discard all rubber parts. Clean the parts
thoroughly in fresh brake fluid or alcohol and
place them on a clean sheet of paper.
NEVER CLEAN THE WHEEL CYLINDER OR

INTERNAL PARTS WITH KEROSENE, PETROL OR
DIESEL.
EXAMINATION OF WHEEL CYLINDER -
Examine the cylinder bore and pistons. If they are not scored, corroded or ridged and are smooth to
the touch, new seals can be fitted. If there is any doubt about the condition of bore, a new wheel
cylinder assembly must be installed.
If the system has been contaminated with mineral fluid of any type, the system should be flushed
out with fresh brake fluid or alcohol and all rubber parts including hoses should be replaced. For
example, a contaminated seal be identified by comparing it with the new seal (but do not let them
touch). If the old one is appreciably larger, seal are serviced, replacement of seals and dust covers
from an appropriate TVS-Girling wheel cylinder kit is strongly recommended.
ASSEMBLING OF WHEEL CYLINDER -
ABSOLUTE CLEANLINESS HAS TO BE MAINTAINED AND CLEAN BRAKE FLUID MUST BE USED. NEVER
USE BRAKE FLUID BLED FROM THE SYSTEM.
 Lubricate the wheel cylinder bore liberally with the fresh brake fluid. Dup new seals, air
excluders, spring and pistons in fresh brake fluid.
 Insert one of the cup seals in the bore, the flat face of the seals towards the open end of the
wheel cylinder.
 Push the seal partly down the bore by inserting the piston behind the seal.
 Reverse the dust cover. Fit the smaller dia. of the dust cover on the neck of the piston.
 Insert the spring assembly in the bore.
 Insert other cap seal (flat face of the seal towards open end of the bore) followed by the second
piston and fit dust cover.
 Fit a rubber band around the pistons to retain them within bore.
408
REFITTING OF WHEEL CYLINDERS -
Install the wheel cylinder assembly to the backplate and secure with bolts and washers. Tighten the
wheel cylinder mounting bolts to a torque of 6.0 Nm. Fit adapters with a new gasket on to feed port
and tighten to a torque of 27 Nm. Fit the bleed screw (17) and tighten to a torque of 6.0 Nm.
Remove the rubber band from the wheel cylinder. Refit brake shoes as described under “FITTING
SHOES” Connect the bundy pipe to the adaptor port.
 Refit the drum and wheel.
 Bleed the system.
 Adjust the brakes as explained under “BRAKE ADJUSTMENT” and road test.
BRAKE PEDAL – CHECK
The push rod serves as the brake pedal stopper

when the pedal is fully released.
Brake pedal height adjustment should be
performed as follows –
NOTE-
Measure the brake pedal height after making
sure the pedal is fully returned by the pedal
return spring.
Pedal height (L2) must be measured after
starting the engine and increasing the revolution
several times by stepping on the accelerator
pedal.
 Pedal free play (L1): 7-11 mm.
 Height (L2) : 164-174 mm.
Note:
 Pedal free play must be measured after turning off the engine and stepping on the brake pedal
firmly five times or more.
 If the measured value deviates from the above range, adjust the brake pedal as follows:
- Disconnect the stop lamp switch.
- Loosen the lock nut on the push rod.
- Adjust the brake pedal to the specified height by rotating the push rod in the appropriate
direction.
Clearance -
Between the Switch Housing and the Brake

Pedal (A).
A = 0.5 to 1.00 mm.
409
BRAKE MASTER CYLINDER – R&R

REMOVING THE MASTER CYLINDER -
Connect a bleed tube to one of the rear wheel cylinders bleed screws and drain the fluid into the
container by pumping the pedal from secondary circuit. Repeat the same by connecting the bleed
tube to one of the caliper bleed screws and collect the fluid from the primary circuit. Disconnect all
outlet pipes from the master cylinder. Loosen master cylinder mounting nuts and remove the same.
Now the master cylinder can be separated from servo.
OVERHAULING OF MASTER CYLINDER -

Master Cylinder should be overhauled once in 12 months or 30,000KMs which occurs earlier. During
the first overhaul all rubber parts should be discarded and replaced with genuine Brakes India Seals
provided in the kit. During second overhaul, all internal guts including plungers and springs should be
replaced. Subsequently, if the condition of the bore is satisfactory, further overhauling should be
undertaken, or else, the whole cylinder should be discarded and fitted with a new assembly.
DISMANTLING OF THE MASTER CYLINDER -

Hold the fluid reservoir and rocking it on either side lift the seal fluid tank in the master cylinder.
Remove the seal fluid tank from the master cylinder body using a connector screw driver with blunt
edge. Slightly push the primary plunger and remove stop pin with gasket.
Without removing the stop pin, if any attempt is made to dismantle the master cylinder, the
secondary plunger cannot be removed. By slightly depressing the primary plunger, remove the cir
clip and retainer washer. Tap the cylinder on a wooden block and remove the primary and secondary
plungers along with the seals, springs etc. By slightly compressing the spring retainer unscrew the
connecting screw from primary plunger. Remove recuperating seal and seal shim from front end of
primary plunger. Remove back seal from the primary plunger using a connector screw driver.
Remove secondary spring seal retainer recuperating seal shim from the front end of the secondary
plunger. Remove gland seal from the secondary plunger using connector screw driver. Discard all the
rubber parts. Clean all the parts in fresh brake fluid or isopropyl alcohol and place them on a clean
sheet of paper. Never clean the master cylinder or internal parts with mineral oil like kerosene,
petrol, diesel etc. Be sure that the four holes in the cylinder body (two recuperating holes and two
feed holes visible through the primary and secondary inlet ports) are clear. This should be
determined by blowing dry compressed air only. Do not poke the holes with sharp instrument.
EXAMINATION OF MASTER CYLINDER AND PARTS -
Examination of master cylinder. If it is not scored, ridged or corroded and is smooth to the touch the
master cylinder can be rebuilt using appropriate parts from the Brakes India repair kit. If there is
slightest doubt about the condition of the bore like having deep groove or pit marks there is no
other way than to fit a new master cylinder. Examine both the plungers for rust, burrs or ridges.
Ensure that both primary and secondary plungers are in satisfactory conditions. Remove the adapter
with gasket along with the valve seal and valve spring from the secondary outlet port. Remove the
valve seal separately.
NOTE: If contamination has been observed in the removed seals (normally they would have swollen
and can be compared with new seals from kit which will tell clearly that the size is enlarged) the
entire system. i.e. caliper rubber parts and rear wheel cylinder rubber parts including both front and
rear hoses must be discarded and the entire system should be flushed.
410
ASSEMBLING THE MASTER CYLINDER -
Dip, plungers and all seals in fresh brake fluid. Fit back seal on to primary plunger groove such that
lips are towards the flange on the plunger which has holes. Fit seal shim and recuperating seal on to
the primary plunger, making sure that the lip of the seal is towards the primary spring. Assemble
spring retainer into primary spring through the larger dia. of the coil in such a way that the small
petals are towards the seal and the big petals are towards the spring. Fix the primary spring small
end of the coil on the primary plunger. Insert the retaining screw through the spring retainer hole. By
slightly compressing the retainer against the primary spring, screw in the retaining screw until the
shoulder of the screw touches the plunger and release the spring retainer. Assemble gland seal in
secondary plunger groove such that the seal lip faces towards the primary spring. Fit seal shim and
recuperating seal on the stem side of the secondary plunger in such a way that the lip of the seal
faces towards the secondary spring. Fit seal retainer.
Fit secondary spring small end of the coil on the stem of the secondary plunger. Lubricate the bore of
the master cylinder liberally with fresh brake fluid. Insert the secondary plunger assembly into the
bore leading the spring end, taking care to guide the seals into the bore without allowing them to get
trapped. Now insert primary plunger assembly in the same manner into bore. Depress the primary
plunger and fit retaining washer and circlip. Make sure that the retainer sits squarely into the master
cylinder groove. Depress the primary plunger with the help of a hylem rod down the bore fully and
fit stop pin with new gasket and tighten it to 6 Nm. Release the hylem rod and watch for quick return
of both the plungers. Actuate a couple of times. Fit valve seal spring small dia into the valve seal and
fit the valve seal into the adapter. Now fit the adaptor with new gasket to the outlet port and tighten
them to the torque of 18.0/15.0 Nm Fit seal fluid tank to both inlet ports by liberally lubricating the
same with fresh brake fluid. Position the reservoir into seal fluid tank and slightly rocking them on to
either side, press it home.
NOTE:
It is essential that the reservoir filler cap must be removed. The baffle plate taken out from its place
and the breather hold in the cap is cleared and the baffle plate refitted before fitting the filler cap on
the tank. It is advisable to replace the gasket in the filler cap during very overhaul.
Now the master cylinder is ready for fitment on to the servo. The master cylinder is to be fitted back
onto the servo in the reverse order of removal. Reconnect the outlet pipes.
BRAKE BOOSTER – R&R
The parts available to service the unit are – filters, a non-return valve kit and a service kit. Servicing
of the internal parts is not recommended and if a major fault is apparent, a new complete
guaranteed unit should be fitted. The air filter should be changed every 40,000 KMs or two years
when the hydraulic cylinders or hoses are replaced. If dusty conditions prevail, the rod is retained
internally and cannot be extracted. If the rod or the domed screw on the rod end is damaged the
super-vac unit must be replaced completely.
NO ATTEMPT SHOULD BE MADE TO ADJUST THE DOMED SCREW. THIS IS CORRECTLY SET AT THE
FACTORY AND SHOULD NEVER BE DISTURBED.
411
REPLACING THE FILTER –
Pull back the dust cover and filter retainer. Hook out the filters and cut to remove from the input
rod. Cut the new filters, press into the neck of the valve body as shown and refit the filter retainer
and dust cover. If the dust cover is damaged fit a new from Brakes India Service Kit.
REPLACING THE NON RETURN VALVE –
Before removing the non return valve note the angle of the same in relation to the front shell so that
the new valve can be fitted in the same position.
 The non return valve fitted is push-in type valve.

 To remove this valve inserts a flat bladed screw driver between rubber grommet and valve
cotter. Leave the valve from the grommet.
 Then remove the grommet from the front shell and make sure that even by mistake you do not
drop the same into the vacuum chamber.
 Fit the new grommet.
 Lubricate the ribs of the new non-return valve with Castor oil and push fully into grommet.
412
• BRAKE FLUID REPLACE & BRAKE BLEEDING –

Clutch /Brake Fluid – DOT4 standard /SAE J1703/IS 8654
Capacity: 0.9 Lit.
Common Fluid Reservoir for Brake & Clutch System
Hose connected
from Reservoir
to CMC
Description –
The brake fluid should be replaced once a year or every 40,000 Kms – whichever is earlier. Inspect first
at 5000kms then at every 10000kms from 20000kms onwards. The fluid and reservoir are common for
Brake and Clutch system in GENIO. Fluid reservoir is mounted on the brake master cylinder. Refer
above illustration. There are three compartments in reservoir; fluid is being supplied to front brake
circuit, Clutch master cylinder and rear brake circuit.
Fluid replacement procedure –
Open the bleed screws on Callipers, Rear brake drums, LSPV and Slave cylinder and allow the fluid to
drain out completely. To ensure complete draining, brake and clutch pedal can be depressed.
After the fluid is drained, hand tightens bleed screws on Front Callipers, Rear brake drums, LSPV and
Slave cylinder. Refill recommended fluid in the reservoir till the MAX mark. Ensure that fluid is getting
in and air in the system getting passed through bleed screws; tighten bleed screws as soon as continue
flow of fluid starts. Both systems bleeding need to be done.
Refer below mentioned brake bleeding sequence and illustration -
1. Rear left 2. Rear right

3. LSPV 4. Front left
5. Front right
The procedure at each of the bleed point is to pump the pedal for 2 to 3 times, open the bleed screw
by 1/4th turn, close the bleed screw. Again pump the pedal for 2 to 3 times then open the bleed screw
keeping the pedal pressed down. Close the bleed screw and release the pedal. Repeat the operation
413
until no bubbles are coming. The Bypass valve is inbuilt in the LSPV & it should be bleed at the time of
bleeding.
NOTE: It is also advisable to keep the engine running at idling so that the pedal travel is complete.
5 2
4 1
Refill the fluid in clutch system; ensure that the fluid is getting refilled in system as well as air in the
system is getting pass through the bleed screw on slave cylinder. Tightens bleed screws as soon as
continue flow of fluid starts. Bleed the Clutch System and ensure no air trapped in the system.
• While bleeding we suggest that the bleed screw nipple is fitted with a transparent
plastic pipe. This pipe should be submerged in a glass bottle filled with brake fluid.
• If any air bubbles are present then it can be easily seen in the container as well as
the plastic pipe.
• The reservoir should be continuously filled with brake oil to avoid air entering thru
the empty reservoir.
• Always use brake fluid from a new sealed container to do this activity (an open
container may have got contaminated with moisture.)
• Recommended replacement interval is at every 40,000 kms. or 1 year, whichever is
earlier.
414
 Following are the important alerts on the braking system –
WARNING
Brake fluid contains poly glycol ethers and poly glycols. Avoid contact with the eyes. Wash
hands thoroughly after handling. If the brake fluid comes in contact with the eyes, flush the
eyes for 15 minutes with cold running water. Get medical attention if irritation persists. If
taken internally, drink water and induce vomiting. Get medical attention immediately.
Failure to follow these instructions will result in personal injury or prove fatal.
CAUTION
• If brake fluid is spilt on the paint work, the affected area must be immediately washed with
cold water.
• The brake fluid reservoir must remain full with new & clean brake fluid at all times during
bleeding.
• Make sure that the pressure bleeding equipment is filled with new brake fluid to the correct
specification.
• To prevent corrosion of the bleed nipple make sure that the bleed nipple cap is installed
after bleeding the brake lines. Failure to follow this instruction may result in seizing of the
bleed nipple.
415
• WORKING PRINCIPLE OF BRAKE BOOSTER -

SUPER VAC SERVO / BOOSTER (MECHANICAL)
The brake booster converts mechanical force applied by driver/customer into hydraulic force through
master cylinder. The booster is installed on the firewall/dash panel with brake pedal. It consists of
servo (tandem diaphragm), master cylinder, brake fluid reservoir & low brake fluid warning sensor
(FLWI).
The servo consists of 254 mm diameter Single Diaphragm in tandem with push rod connected to brake
pedal. The output rod connects the booster to the tandem master cylinder (TMC).
Servo is connected through vacuum hose to exhaust cam shaft driven vacuum pump.
TMC is designed to operate dual line (front & rear) hydraulic braking system. Brake Fluid is filled in
brake fluid reservoir consisting of two independent chambers working in tandem for brake system and
third independent chamber fro clutch system.
Even if leakage/damage occurs in one chamber or circuit the other remains operative. FLWI is a
contactless sensor connected to instrument cluster to warn the driver if the brake fluid level is closer
to minimum level marked on reservoir.
When the push rod is pressed by brake pedal, air enters through filter in vacuum servo. Power assist is
generated by utilizing the pressure differential between atmospheric pressure and vacuum. The force
gets multiplied based on boost ratio & applied to the output rod going inside master cylinder. The
output road strokes the master cylinder pistons & it generates hydraulic pressure in hydraulic brake
lines going to front & rear braking system independently. The super vac is a vacuum assisted
mechanical servo unit with 7.5: 1 boost ratio.
The Booster is a non- serviceable Unit & it should never be tampered with.
Ensure booster output rod is correctly aligned to the primary piston bore during the coupling of TMC
to the booster. The Scorpio vehicle is equipped with a Tandem type vacuum booster to assist driver’s
effort. This is achieved by using vacuum from the vacuum pump provided on alternator in case of
diesel engines & from inlet manifold in case of petrol engines.
A single diaphragm is provided between the two shells of the booster & difference of pressure on two
sides of diaphragms (one side vacuum & other side atmospheric pressure) gives mechanical
advantage. This amplifies the driver’s pedal effort while braking. The booster assembly & TMC
assembly are coupled with the help of two nuts & washer. The meting dimensions of booster & TMC
are factory set. Hence –
Do not alter the height of the output rod of the Vacuum Booster unit at any stage and ensure
Booster output rod is correctly aligned to the primary piston bore during the coupling of TMC to the
booster.
416
 WORKING PRINCIPLE OF LSPV
Description –
When there is a large difference in vehicle weight between laden &

empty conditions; during dynamic braking, the weight on the rear
axle tends to shift towards the frontal direction of vehicle ( known
as Load / Weight Transfer ) resulting into less vertical load on rear
axle which results into rear wheel locking. LSPV regulates the
pressure in the rear brakes in proportion to the load in vehicle.
Hence it is called as Load Sensing Proportioning Valve.
Installation & Working Principle –

This valve is mounted on vehicle chassis with the help of two bolts
near the rear axle. It is provided with a control spring which is
attached to the rear axle by a special bolt passing through a bush.
The control spring is in pre elongated condition. This spring senses the deflection of rear axle under
different loads & thereby automatically adjusts the operating characteristics (Knee point Pressure) of
the valve. Inlet port of the valve is connected to the delivery port of secondary circuit of TMC & outlet
port of the valve is connected to rear brakes through piping. The front inlet (bypass) port of valve is
connected to the front (secondary) circuit of the TMC to sense the front circuit failure.
Working of LSPV/ Valve – Refer illustration.
Area ‘A’
Area ‘P’
Spring Force ‘F1’
Initially the main spring force keeps the piston pressed in upward direction keeping outlet port
connected to rear circuit open at seal, till knee point i.e. inlet pressure is transmitted to the rear circuit
through outlet port without any pressure regulation.
417
Further pressing of brake pedal increases the inlet pressure to LSPV & in turn increases the downward
force acting on the piston. (The downward force is created by hydraulic pressure available in front
circuit acting on area ‘A’.)
The downward movement of the piston closes the entry of oil from rear inlet port to outlet port at
sealing point ‘P’.
At this point there are three forces acting on the piston –
1. Upward force ‘F1’ of main spring.

2. Hydraulic force acting on area ‘P’.
3. Hydraulic force acting downwards on area ‘A’.
Since the resultant force is positive, the piston lifts upwards & the Oil entered from Inlet port is fed to
outlet Port & the pressure to outlet increases. Further increase in inlet pressure (due to pressing of
brake pedal) again results into downward movement of piston, thereby closing the outlet at point ‘P’
& results into drop in outlet pressure. The process continues & follows a fixed pattern.
LSPV Performance in Front Fail Condition (Bypass Function) –

In case of leakages – Internal or External, in the front circuit there is a failure of front circuit & front
calipers become ineffective. Under this emergency condition the bypass valve operates automatically.
This is achieved by following mechanism. In front fail condition the force acting on piston will only be –
1. Control Spring Load ‘F1’ acting upwards

2. Hydraulic force acting on area ‘P’
3. Upward force at ‘O’ ring in front circuit
This keeps the sealing point ‘P’ always open. (Due to the front circuit failure the hydraulic force acting
on area ‘A’ is zero.) So input pressure becomes equal to output pressure. This is called bypass function
& transmits the whole pressure developed in rear circuit of TMC to rear brakes without any pressure
reduction.
Maintenance Precautions –
LSPV is a non-serviceable unit & should be replaced if any problem arises.

During vehicle servicing control spring setting should be checked & corrected if required with the help
of an ‘Installation gauge ‘provided for the purpose. The stretched length of the control spring should
be set at 92.5 mm with the help of Installation gauge.
The correct setting of Control Spring ensures adequate oil pressure to rear circuit & thereby ensures
no skidding of rear wheels. The LSPV setting needs to be carried out if:
1. The axle has been removed.

2. LSPV Valve replaced.
3. Any change in rear suspension carried.
418
Type (Mechanical/hydraulic/air/air Hydraulic Circuit, Assisted by Vacuum Booster with

assisted/vacuum assisted/others) LSPV acting on Rear Wheels and with Auto-adjuster
Control system & braking wheel Tandem master cylinder with vacuum assisted on all
wheels. Front - Disc & Rear - drum
Braking wheel - Rear & Front.
Brake lining or pad :
Nominal Dimensions, (mm) (Length x Width x Thickness x Qty)
Front wheel 126 x 50 x 11.35, 4Nos
Rear wheel 570 x 50.8 x 5.6, 2Nos
Effective area per axle (cm²)
Front axle 220
Rear axle 580
Make
Front wheel / axle M/s.RBL - RBL - R808 NF(Asbsetos free ) , India
Rear wheel / axle M/s.RBL - RD0011 (Asbestos free), India
Whether asbestos or asbestos-free Asbestos Free
Brake drum or disc :
Front axle ( Disc / Drum ) Disc
Effective diameter mm 281
Rear axle ( Disc / drum ) Drum
Effective Diameter, mm 282
Master cylinder or brake valve :
Make M/s.Brakes India Ltd, India
Inner diameter of the master cylinder (mm) 22.22
Operating stroke mm 45
Wheel cylinder / Wheel Chamber - Diameter (mm)
Front 60
Rear 25.4
Type (single acting/double acting)
Front Single Acting
Rear Double Acting
Make of wheel cylinder / slave cylinder M/s.Brakes India Ltd, India
Booster :
Make M/s.Brakes India Ltd, India
Type Single Diaphragm, Vacuum type
Boost ratio 7.5 : 1
Size of the booster (mm) (diameter) 254
419
Load sensing valve :

Make M/s.Brakes India Ltd ; India
Characteristics Ratio 3.33:1
Identification TVS Girling
Brake fluid :
Make Castrol for DOT3 / Shell for DOT4
Trade name Castrol universal heavy duty / Shell
Specification/ grade as per Indian standard Castrol DOT3 / Shell DOT4 as per IS.8654
Parking brake :
Make M/s.Suprajit Engg Ltd, Gujarat
Type (mechanical/spring brake) Mechanical
Acting on Transmission/wheel Rear Wheels
Control System & Braking wheel Hand lever, Braking on the rear wheels
Lining/pad Lining
420
Wheels and Tyres
Contents…
• Description…………………………………………………………………. 422
• Care of the System…..……..…………………………………………… 425
• In Car Repairs……………………………………………………………… 430
• Specification……………………………………………………………….. 432
421
• Description
The tyres fitted in GENIO are radial tubeless tyres and with a suitable wheel disc.
In the TYRE SIZE P 215/70 R15 - The 215 is the width of the tyre in mm at the designated air pressure
and load. The 70 is the aspect ratio of the tyre.
The tyres play a very important and vital role in the vehicle handling and ride characteristic. Hence it is
advised that any change not as per the specification have to be done with caution.
The air pressure maintained has a direct influence on the fuel average obtained, braking and also on
ride characteristic. Hence it is imperative that the tyre pressure be maintained as per specification.
The tyre specified with the specific air pressure gives these tyres a safe speed of 180 Km/hr.
422

 Maintain the correct tyre
pressure.
 Do the tyre rotation.
Rapid wear at Shoulder Under Inflation

Lack of rotation
Excessive cornering.

pressure.
Rapid wear at centre

Over inflation
pressure.
Cracked Treads Under Inflation

Check and adjust:
 Hub end play
 Camber to be checked and
adjusted.
One Edge Wear Excessive camber

Excessive cornering
423
 Check & correct Toe In

 Check the chassis bend
 If tyre rotation not carried out as
per schedule. Do the tyre
rotation.
Feathered Edge Wear Incorrect Toe In

No tyre rotation.
 Balance the tyres.
 Check the brake drum roundness.
 Check jammed wheel cylinder/
calipers.
 Check the wheel bearings.
 Avoid driving with sudden brake
locking.
Bald Spots Unbalanced tyre
Out of round brake drums in

rear.
Faulty wheel bearings.
Sudden braking.
Lack of rotation or Worn or  Tyre rotation.
Out of Alignment Suspension  Check & replace the suspension
components.
Wavy / Scalloped wear

Side Wall crack- radial/
diagonal Kerb damage
Stone hit
Side wall crack
circumferential / tyre Run Flat
bulging ( It is more obvious from
inside )
424
The tyre is one of the most abused components hence maintaining the tyre is of utmost importance.
The recommended tyre pressures are given below:
COLD TYRE INFLATION PRESSURE

TYRE SIZE P 215/70 R15 (UNLADEN)
FRONT REAR
psi 35 35
Kg/cm. sq. 2.4 2.4
TYRE SIZE P 215/70 R15 (LADEN)
FRONT REAR
psi 35 60
Kg/cm. sq. 2.4 4.2
TYRE PRESSURE – CHECK AND ADJUST (Tyre Type: Radial, Tubeless P 215/70 R15)
Refer above chart –
1. Check and adjust tyre pressure as per the recommended values.

2. Ensure to check and adjust the tyre pressure in the spare tyre.
3. Ensure to replace dust cap on valve seats after checking tyre pressure.
The tyre pressure should be checked once in a fortnight. (Once in a week during summers). The tyre
pressures should always be checked & corrected in cold condition. The valve should be always covered
with the valve cover. An opened valve can have the valve needle stuck in a partial position causing the
tyre to bleed during operation..
The tyre pressure specified can cater to continuous high-speed performance. Hence it is not advisable
to increase the tyre pressure before going on a high speed run.
The practice of keeping the tyre pressure lower in summer is actually detrimental to the tyre. To
understand that let us examine what happens – if lower pressure is kept. Then the sidewall flexing is
going to be more hence the heat generation will also be higher which will result in a faster increase in
tyre pressure. So the wear rate is going to be higher.
Similarly the practice of bleeding the tyre pressure to reduce the pressure after a long run can cause
the sidewall to crack and in a worst scenario sidewall bulging.
Before going on a long drive it is a good practice to remove the stones/pebbles trapped in the treads.
The probability of a puncture due to stone trapped and digging through the crown once it gets heated
up is reduced.
425
It should also be kept in mind that a radial tyre with higher pressure is more prone to burst under
impact from stone at high speed or kerb impact. Lower air pressure results in higher sidewall flexing
and drastically increases the chance of sidewall damage / cut in bad roads.
Wheel balancing should be done at least every 20,000 Kms. It is compulsory to do a balancing of the
wheel after any puncture.
The tyre rotation should be carried out every 10,000 Kms.
An improper wheel alignment will have an adverse affect on the life of the tyre. Hence it is suggested
that the wheel alignment be checked initially at 10,000 kms then every 20,000 Kms. (In case the
vehicle has traversed through extremely bad terrain at high speed then it should be done earlier. If the
wheel disc is having any deformation particularly in the bead seating area then do not wait until the
mileage has covered- get it balanced.) In case of abnormal tyre wear refer to the Trouble shooting
section and take the corrective action suggested.
The grooves in the tyre are used to pump out the water between the road and the tyre. In case the
water is not pumped out the tyre will ride on water. Since the coefficient of friction of water is very
low that will result a sliding action. Obviously the amount of water which the tyre can pump out
between the ground and the tyre will depend on the depth of the groove which is acting as a channel.
The tyre manufacturers recommend that a minimum tread depth of 1.6 mm should be present.
Once the tread depth is less than 1.6 mm it is recommended to replace the tyres. I t is not advisable to
retread the tyre.
Any kind of lubricant on the tyre is detrimental as it promotes degradation of rubber and also
increases the chance of hardening. Normally this happens when a mechanics rubs the spare oil or
grease on to the sidewall of the tyre.
426
• Tyre Rotation – Refer below schematic to follow tyre rotation flow.
• Check & ensure tyre pressure at 2.4 bar in all wheels in unladen condition; and 4.2 bar at Rear
both side in case of laden.
• Rotate (swap the positions) the wheels as shown in the diagram above.
• Driver side rear goes to Driver side front position.

• Driver side front wheel goes to Co-Driver side rear position.
• Co-Driver side rear wheel goes to spare wheel position.
• Spare wheel goes to Co-Driver side front position.
• Co-Driver side front wheel goes to Driver side rear position.
In case the vehicle reports for wheel wobbling then the sequence of balancing & rotation should be as
follows:
Important:
• Before going ahead with the procedure; do road tests and at that time:-
• Please remember that the road shocks can come to the steering wheel while going over rough
or uneven patch.
• The important point is that after the road shock is over then it should not continue to vibrate.
Preliminary Stage:
• Mark each tyre assembly position with respect to the hub/ axle shaft.
• Balance all the tyre and place it back it each wheel in the same position.
• Now follow the sequence of Stage A, Stage B, Stage C. Road test after each stage:
427
• Sequence of operations:
Road Test A Road test B Road test Road test
C Road test
Caution: If the stages of A, B, & C are done together then improvement may not be noticed. In worst
case scenario the problem may get aggravated.
Before dismounting the wheel Mark the position of the wheel & tyre assembly with respect to the hub
Procedure
(uses anyfor wheel
wheel balancing
mounting bolt as a reference and applies a paint mark to hub with respect to disc +
tyre.
Check the wheel

balancing.
If the imbalance amount is If the imbalance is >

less than 40 gm. 40 gm
Rotate the wheel assembly & check the

imbalance
Imbalance location should not change If any of the criteria is not met then
more than 80 mm in circumference. the machine calibration is not OK.
The max imbalance can be 40 gms Do not proceed further till this is
resolved.
While mounting the wheel assembly, rotate the wheel assembly by 180
degrees. Now the matching marks will be opposite
428
Flow chart to attend Vibration Concern
Vibration observation at certain speed
Loosen & r e-torque al l S uspension

Joints, B ody M ounts, E ngine M ounts,
Seat M ountings & T ransmission
mounts as specified in manual.
Not Resolved Resolved
Stop
Check Shock Absorber for dampening value

(by hand f eel), S uspension B all J oints &
Steering Intermediate Shaft for play
Replace the part (s), All parts are OK,

if required Not Resolved
Resolved Loosen & r e-torque

Propeller S haft
mountings
Stop
A - Loosen all the body mounting

bolts. Then torque them to 45 ± 5 Not Resolved Resolved
Nm
NOTE: After each exercise, take Road Rotate the tyre Stop
one by one from
Test to decide whether problem is Front to Rear
Resolved or Not Resolved
Resolved Not Resolved
Stop Swap the t yre(s)

one by one with
good vehicle tyre(s)
Resolved, Change Not Resolved, Call

the Particular tyre Technical Support Cell
429
• Puncture Repair -
The tyres should be removed and then only be attended for puncture or damage.
• For removal of the tyre from the vehicle the jacking points are:
For 2WD Front- to be supported on the chassis, behind the lower arm just below the first outrigger.
For the rear wheels: below the axle.
Vehicle Jacking Point – Rear Side
Vehicle Jacking Point – Front Side
CAUTION
Never go under the vehicle when it is jacked up. This jack is meant for only raising the wheel. For any
under body work/inspection support the vehicle on vehicle stands.
If the vehicle is run with severely under inflated tyres – the vehicle stability may be affected. A run flat
wheel can also damage the wheel disc- besides literally shredding the tyre.
Removal & Refitment of the tyre –
It is recommended that the tyre removal and re-fitment on the wheel disc be done in a tyre specialist
shop where the tyre fitting machines are available. The advantage of the machine over the
conventional method is that the damage to the beading area is totally avoided.
In absence of the machine; ensure that:

• No sharp tools are inserted while removing the tyre.
• No sharp tools/ screwdriver is used while fitting the tyre.
• While refitting the tyre the use of powder between the tube & the tyre is recommended.
• It is recommended that the tyre be inflated to a pressure of 40 PSI. This will ensure that the
bead is locked in properly and also in centralizing. Then later reduce the pressure to the
recommended pressure.
430
• Removal & Refitment of the spare wheel from the vehicle –
Locate the wheel winch cable guide near the spare

wheel.
Use jack Tommy, align it with wheel winch cable

guide.
Rotate the Tommy anticlockwise to lower the

wheel on to the ground and take off the locating
tang from the disc.
The fitment of the old tyre to the spare wheel carrier is the reverse of the above procedure.
While fitting the tyre on to the axle ensure that :
- The bolt holes in disc are not oblong.
- The threads of the bolt are not having dirt –

neither is there dirt/ mud in the nut.
(Generally while removing a wheel the nuts
are left in the ground collecting dirt/mud. It is
a better practice to keep the removed nuts on
vehicle.
While tightening the wheel nut tighten in diagonally opposite order to each other.
Caution: Failure to do so can cause vibration of the steering wheel at high speed.
431
Description Torque in Nm (lbf-ft)

Wheel Nut 97.5± 5 Nm (72 ±4 lbf-ft)
Body Mounts 45 ± 5 Nm (33 ± 4 lbf-ft)
• Specification & Wear Data –
Description Value
Run out of the tyre- radial 1.5 mm
Run out of the tyre- lateral 1.5 mm
Unbalanced allowed- tyre Max. 1.8 Kgf
Minimum tread depth 1.6 mm
432
Chassis
Contents…
• Description…………………………………………………………………. 434
• Frame Repair…………………………………………………………… 436
• In Car Repair……………………………………………………………….. 438
433
• Description –
The chassis has C in C pressed and welded section. The section in the centre is largest. The front & rear
have smaller section. This feature ensures optimum chassis design for the loads in the given section.
The cross members connect the side members to each other.
Frame alignment
Normally frame misalignment is happens only due to:
♦ Collision
♦ Excessive overloading.
An improper frame alignment will affect axles alignment thus influencing the tyre wear. It will also
affect the door closure & window operation. In severely misaligned frame it will affect the vehicle
handling.
Frame Inspection & Measurement -
Inspection:
Before proceeding with measurements, inspect all component for visible damage and other damage.
All damaged areas must be repaired or replaced.
Measurements
Measure the frame for misaligned with body attached to the frame. The inspection sketch attached
gives the alignment reference dimensions.
However before proceeding with any measurements, the following precautions have to be taken.
• Place vehicle on level ground.

• The vehicle is in unloaded condition. With full fuel tank
• If any extra fittings have been fitted, please remove them. (E.g. winch)
• Measure the tyre inflation pressure. Keep it as per recommendation
434
• Diagonal frame measurements –
 Select reference points along one frame long member. It is suggested that the body mounting
points be used.
 Transfer these points to the surface floor with a plumb bob.( Attaching paper sheets below on the
ground will improve the measurements accuracy)
 Locate the reference point on the other long member.

 Measure the frame outer distance in front and the frame outer distance in rear.
 Move the vehicle away.
 Measure the distance between all the reference points diagonally. The measurement should not
vary more than 10 mm
 Divide the distance between the front outer points and the rear frame outer points. This gives the
center of the frame.
 Join the center of the frame width at front and the center of the frame width at rear. Place a chalk
line between these two points. This gives the center line of the chassis.
 Determine how close to center line is to diagonals intersection point.
 The reference mark on the floor will provide an illustrated indication of the degree of
misalignment.
 A reference point transferred from one side’s long member may be 5 mm ahead or behind the
reference point from the opposite long member.
 Frame bow to the side should not exceed 5 mm.
435
• Refer below layout for GENIO Chassis frame – chassis referance diamensions are given in separate chart.
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 t he vehicles ar e m anufactured. The r eproduction, t ranslation, transmission, i n par t of or whole of the pr esent doc ument, ar e pr ohibited without t he pr ior written c onsent of M ahindra & M ahindra Lt d. The use o f this doc ument by any per son ot her t han t he t rained per sonnel, at t he
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
• FRONT SUSPENSION MOUNTING BRACKET DIMENSION – BODY SECTIONAL VIEW
manufacturer i n t he pr oduction o f t he various c omponent uni ts and ac cessories f rom w hich t he vehicles ar e m anufactured. T he r eproduction, t ranslation, t ransmission, i n par t o f or w hole of the pr esent
437
• In Car Repair –
This section consists of -
• Cabin mounts/ triggers Removal.
• Cargo box mountings Removal.
• Spare Wheel Winch Removal.
438
• Cabin mounts/ triggers Removal

Nut/ Bolt description Torque Value – Nm.
Body/ Cabin mounting bolts 65 + 05 Nm.
TOP MOUNT
4 Cabin Mounts (Rr. Side)
5 Cargo Mounts/ Side
BOTTOM MOUNT
Front 2 Cabin Mounts
Cabin Mount Removal –

NOTE: The front RH & LH side Cabin mounts is different than cabin rear mounts. It is smaller in size
Compare to rear mounts.
 Lift the vehicle on 2 post lift.
 Loosen the bolt and washer of the body mount which is to be removed.
- Body mounts are fitted with bolt and plane washer.
- Ensure and replace the body mounting bolt while replacing body mount.
- Torque tighten the mounting bolts.
 Park the vehicle on 2 post lift.

 Since the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected
439
• Cargo box mountings Removal.

Cargo Box Mount bolts 45 + 05 Nm.
Cargo Box Packing
Cargo Box Mounting Bolt
CARGO BOX MOUNTS LOCATIONS -
Cargo Box Mount/ packing Removal –

NOTE: The cargo box has total 10 mounts; 5 mounts on each side, LH & RH side.
 Park the vehicle on level ground.
 Loosen the bolt and washer of the body mount which is to be removed.
 Remove the packing fitted between the cargo and chassis frame.
- Ensure and replace the body mounting bolt while replacing body mount.
- Torque tighten the mounting bolts.
440
• Spare Wheel Winch Removal

Spare wheel winch nuts 50 + - 10 Nm.
Wheel Winch
Removal Steps –
 Remove spare wheel.

- Use extension rod/ Tommy rod to operate and loosen wheel winch cable.
 Remove cable bracket.
- Loosen and remove the cable clamp mounting bolts.
 Remove winch assembly by removing its mounting nuts.
Assembly procedure is reverse to the removal, except any special note is given.
441
• Frame Repair -
It is not recommended to repair the chassis frame. In case of any bend, twist due to accident collision
if the bend is beyond the specified limits then it has to be replaced.
• Torque Values -
Location Torque (Nm)

UCA mtg. bolt on frame. 90 ± 10 Nm
UCA ball joint nut 140 ± 20 Nm.
LCA mtg. bolt on frame. 200 ± 20 Nm.
LCA ball joints to LCA 45 ±5 Nm.
LCA ball joint nut 140 ± 20 Nm
Stab bar mtg. bolt on frame. 40 ± 10 Nm
Link mtg. bolts on knuckle & Stab bar 40 ± 10 Nm
Shock absorber upper mtg. bolt on chassis 40 ± 5 Nm
Shock absorber Front mtg. bolt on LCA 120 ± 10 Nm.
Wheel Nut 94 Nm
Hub lock nut 400 Nm
Upper Link mtg. bolt 150 ± 10 Nm.
Lower link mtg. bolt. 150 ± 10 Nm.
Pan hard rod mtg. bolt 150 ± 10 Nm.
Shock absorber Rear mtg. bolt 45 ±5 Nm.
Body/ Cabin mounting Bolts 65 ±5 Nm.
Cargo Box Mounting Bolts 45 ±5 Nm.
442
Electricals
Refer GENIO Wiring Manual (MAN-000108) for additional details on the wiring system.
Refer below Technical Specifications for GENIO Wiring System –
PARAMETER Mahindra GENIO SC 2-WD BS-III & BS-IV (2 seater)

Battery :
Type & number MFS70 or 65D26R, 1
Voltage & Capacity Ah 12 V, 65 Ah Option 75 Ah
Wind Screen Wiper :
Type (Manual/power) Power - Electrical operated
No. of wipers 2 Blades
Wiper motor
Make M/s Lucas TVS Ltd
Type 2 speed, Link Type
Identification mark Lucas TVS 26071284A
Rated voltage 12
Number of sweep Frequencies 2
Highest sweep frequency (Cycles/min) 65
Lowest sweep frequency (Cycles/min) 45
Wiper arm
Length Driver-540mm,Codriver-600mm.
Make M/s Bombay Commerial syndicate
Wiper blade
Length Driver-600mm,Codriver-500mm.
Make M/s Bombay Commerial syndicate
Identification Driver-3013J,Codriver-3009J.
Washer tank
Type Electrically Operated
Make M/s Prabha Engg.
Identification No./Part No. PRABHA, ID No. Frt - 050000/13
Capacity,I Frt - 2.5 litre
Material HDPE
443
Washer tank motor

Make M/s Prabha Engg.
Model Washer Pump - 12V
Horn :
Make and Country of origin(if imported) M/s Hella India
Type(As per IS 1884 -1993) 2 B (Low & High Tone)
Operating voltage 12 V - DC
M/s Hella India - High -101 567 200 HT &
Identification No. / Part No.
Low - 985 564 300 LT
Lighting Installation requirements :
Head lamp levelling system (manual /
Head lamp aiming device - Manual
automatic)
Stop position (if manual) Zero position marked in HLLD switch
Initial inclination -1.30 %
Beam symbol screen printed on Head lamp levelling
Tell-Tale for leveling switch
switch
Head lamp : Main beam
Make and Country of origin(if imported) M/s Lumax
Type of Lens (Glass/Plastic) Plastic
Identification No./Part No. LUMAX 2130-01-00 R & L
Number and Colour of Lens 2, white
Dipped beam
Number and Colour of Lens 2, white
Front Fog Lamp : Optional
Identification No./Part No. 2119-00-00
Number and Colour of Lens 2,WHITE
Registration Plate lamp :
Make M/s Lumax
Number and Colour of Lens 2, White
Position lamp / Parking Lamp-Front Front Position Lamp
Make Incorporated with Head lamp
Identification No./Part No. See E5.1.3
444

Position lamp / Parking Lamp-Rear
Rear Position Lamp Part of Rear Combination Lamp Assy
Make M/s Lumax
LUMAX 2131-02-00 for RH &
Identification No./Part No.
LUMAX 2131-03-00 for LH
Number and Colour of Lens 2, Red
Stop lamp (S3) for M1 category
Make M/s Lumax
Identification No./Part No. LUMAX 2121-02-00
Number and Colour of Lens 1, Red
Reversing lamp : Part of Rear Combination Lamp Assy
Make M/s Lumax
Direction indicator Lamp :
Front Incorporated with Head lamp
Make M/s Lumax
Number and Colour of Lens 2, Amber
Rear
Make Part of Rear Combination Lamp Assy
Side
Make M/s Lumax
Identification No./Part No. LUMAX 1913-01-00 Opt. LUMAX 2189-02-00R/L
Type of flasher I.C.Based
Rear
Make and Country of origin(if imported) LUMAX
Identification No./Part No. Lumax 01 01 0221
Number and Colour of Lens 2, RED
Area 21 Sq.cm
Shape Rectangular
Automotive bulbs:
Head lamp bulb(main and dip)
1)M/s. Philips(Germany)
Make and Country of origin (if imported) 2)Opt.M/s Osram(China),
3)Opt.M/s Halonix
Designation as per AIS 034 12H4
Direction indicator lamp Bulb- Front
1)M/s. Phillips(France),
Make and Country of origin (if imported)
2)Opt. Osram(Germany)
Designation as per AIS 034 12P21W
445
Direction indicator lamp Bulb-Rear

Make and Country of origin(if imported)
2)Opt. Osram(Slovakia)
Direction indicator lamp Bulb-Side
1)M/s. Phillips( France),
Designation as per AIS 034 12W5W
Front Position Lamp Bulb
Rear Position Lamp (tail lamp)Bulb
Stop lamp bulb
Designation as per AIS 034 12P21/5W
Number plate lamp bulb
2)Opt. Osram (Germany)
Reversing lamp bulb
Stop Lamp Bulb(S3)
Make and Country of origin(if imported) M/s Philips(France)
Designation as per AIS 034 12Y2.3W
Front Fog Lamp Bulb
Make and Country of origin(if imported) M/s. Phillips (Germany)
Designation as per AIS 034 12H27W/2

Any other features (As declared by the
vehicle manufacturer) :
Immobilizer
Make and Country of origin(if imported) Interface
Identification No./ Part No. 1309AAA00291N
Frequency of communication 125KHz +/- 4KHz
446
Appendices
Contents…
• Abbreviations and Measuring Units……………………………………. 448
• Lubrication Chart……………………………………………………………….. 449

• Greasing Points………………………………………………………………….. 450
• Do’s and Don’ts………………………………………………………………….. 451

• Vehicle Preservation………………………………………………………….. 452
• List of MST………………………………………………………………………… 454
447
APPENDEX – A
• Symbols and Abbreviations -
PDI : Pre Delivery Inspection

VIN : Vehicle Identification Number
S.L. No. : Serial Number
CQAV : Central Quality Assurance - Vehicle
ACC : Accessories
2WD : 2 Wheel Drive
4WD : 4 Wheel Drive
2WDH : 2 Wheel Drive High
4WDH : 4 Wheel Drive High
4WDL : 4 Wheel Drive Low
N : Neutral
T/F Case : Transfer Case
FIP : Fuel Injection Pump
OEM : Original Equipment Manufacture
NOx : Nitrogen Oxides
O2 : Oxygen
SAE : Society of Automotive Engineers
CI : Compression Ignition
• Measuring Units –
KM : Kilo Meter
CC : Cubic Capacity
Mm : Millimeters
Kw : Kilo Watt
Hp : Horse Power
RPM : Revolutions per Minute
Kg : Kilogram
Nm : Newton Meter
Amps : Amperes
Km/h or kmph : Kilo Meters per Hour
M : Meter
L : Liters
C : Centigrade temperature scale
448
APPENDEX – B
• Lubrication Chart - Refer below chart for GENIO mDICRDe vehicle lubrication details.
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 t he vehicles ar e m anufactured. The r eproduction, t ranslation, transmission, i n par t of or whole of the pr esent doc ument, ar e pr ohibited without t he pr ior written c onsent of M ahindra & M ahindra Lt d. The use o f this doc ument by any per son ot her t han t he t rained per sonnel, at t he
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
APPENDEX – C
• Greasing Point –
Refer bellow illustrations for Propeller Shaft greasing point shown by arrow marks.
Prop Shaft at Transmission end Prop Shaft - Greasing Nipple
(A) Lubricate the Propeller Shaft at the greasing nipple shown
449
APPENDEX – D
DO’S
1. Use recommended lubricants only. Replace oil in engine, gear box & transfer case, front &
rear axles, steering box & Brake & Clutch master cylinder periodically as per schedule.
2. Use only genuine oil filter and fuel filter elements.
3. In order to obtain trouble free and enhanced engine life, clean air filter element regularly.
Replace filter element when service indicator shows red band even after cleaning the
filter element.
4. Ensure periodic servicing as per maintenance schedule.
5. Insist on use of genuine MAHINDRA spare parts for all replacements.
6. Allow the starter pinion to come to rest before again attempting to start the engine in
order to avoid pinion and flywheel ring gear damage.
7. Replace thermostat in the event of failure and ensure fitment of pressurized radiator cap
to get better engine life.
8. Maintain correct tyre pressures as specified in chart. Before moving the vehicle releases
the parking brake.
9. Maintain electrolyte level in the battery (using distilled water). Keep battery terminals
clean and cable joints tight. Apply Vaseline/petroleum jelly on terminals.
10. Disconnect alternator/battery/electrical connection while carrying out welding work on
the vehicle. Observe correct polarity when connecting battery terminals.
DONT’S
1. Do not run the vehicle with leaky air pipes, fuel pipes and water hoses.
2. Do not run the vehicle without a battery in its electrical circuit as the life of alternator will
be reduced.
3. Do not run the engine without radiator cap. Use genuine cap only, to keep system
pressurised.
4. Do not open radiator cap when engine is hot. Never add cold water when engine is hot as
this may lead to cylinder head/block crack.
5. Do not continue to run the engine when temperature gauge shows more than 1000 C.
6. Do not use clutch pedal as a foot rest. It will cause premature wear of clutch plate, release
bearing and clutch finger /diaphragm and also result in high fuel consumption.
7. Number of passengers carried should be within approved seating capacity.
8. Do not race or rev the engine especially when starting. This is destructive to engine.
449
APPENDEX – E
• VEHICLE PRESERVATION – VEHICLE MAINTENANCE WHEN OUT OF USE
Long term storage of new vehicles requires special care to keep vehicles factory fresh and
ready for reuse. The following guidelines should be performed to minimise vehicle
component/ part degradation due to extended vehicle storage conditions.
STORAGE LOCATION & PARKING
• Vehicles should be stored in a Dry, Well Ventilated and Drained area with a Roof
above.
• If an indoor storage area or other location with a roof overhead is not available, the
following conditions should be met:
- Location should be where damage to painting due to factory smoke, metallic powder,
acid rain, salty winds, bird droppings, tree sap etc. can be prevented.
- Floor of such a storage area should be paved and have good water drainage.
• Ensure to remove the Adhesive Film (if any) from Exterior Trim / Mouldings / Seats.
• Ensure that the Window Glasses are covered with cardboard or Cloth to prevent
fading and deformation of the Instrument Panel, Upholstery and Seats.
• Park vehicles with at least 3-feet gap in between them and enough space in the front
and rear to walk around.
• Park the vehicle in First / Reverse gear. DO NOT apply Parking Brake.
• Ensure that all windows / sun roofs are closed.
• Lift the Wiper Arm / Blade from the wind screen glass.
OTHER INFORMATION
If the vehicles in the storage area are exposed to salty environment, sea breeze, corrosion
with rust may appear in some of the ferrous parts. If rust is found, remove it and apply
suitable rust inhibitor.
The disc brake rotors are made of cast iron and may show gradual build up of surface rust
during long storage, accelerated if the environment is salty. On a monthly basis, drive the
vehicle to 50 Kmph and brake normally to stop the vehicle to remove rust. Repeat this
exercise at least 10 times.
Plastic materials used in the vehicle as well as insulation material of wires might attract small
rodents which nibble at these components. Inspect the vehicle for “Rat-bite” at the time of
PDI/ reuse. Small birds and rodents might find it interesting to build their nests inside air
cleaners, exhaust system. Inspect these areas thoroughly at the time of reuse.
449
 List of activities/checks to be done during vehicle long time storage condition -
 ELECTRICALS & BATTERY

• Ensure that all electrical accessories are turned OFF.
• Remove the memory fuse* (*if applicable).
• For Long Term Storage, it is recommended to remove the battery negative cable.
• Ensure to reset all memory related components before delivery to the customer.
• Test & charge battery, as per Battery service manual, before reinstalling.
 TYRE
• Inflate the road tyres to 20% - 30% higher than the recommended pressure. Ensure to
reduce the pressure at the time of reuse.
• Rotate each wheel by ¼ turn on a monthly basis. This is to prevent tyre flat spot from
developing.
 ENGINE
• Condensation may form within the engine, if vehicles are run for short intervals (5
minutes or less) during storage.
• On a weekly basis, run the engine in idle for at least 10-minutes to avoid condensation
possibility. Also, gradually raise the engine speed to max RPM for 10-times to
eliminate moisture from the exhaust.
• Move the vehicle to approx. 30 to 40 feet to lubricate the Transmission / Differential
assembly.
 Drive the vehicle a little forward and backward once a fortnight.

 Cooling system - Add anti-rust to the water. Add antifreeze during cold weather.
 Cover the instruments.
 Clutch - Press the clutch pedal to the floor board and hold it in this position. Operate the
clutch pedal a few times once in a week, check and top-up clutch fluid in master cylinder
reservoir once in a month.
 Brakes - Operate the brake pedal a few times once in a week, check and top-up brake
fluid in master cylinder reservoir once in a month.
 Body - coat rust proof to all bright metal. Cover up with upholstery.
449
APPENDEX – F
• List of MST – Refer below Mahindra Special Tool (MST) data. Tools applicable for
GENIO vehicle/ aggregates, component dismantling and assembly.
Sr. No. MST Number Tool Description Application
1 MST - 273 Lock pin for Chain Tensioner Engine
2 MST – 543 Extractor Flywheel Bearing Engine
3 MST – 544 Drift Flywheel Bearing Engine
4 0305BAC0008ST High Pressure Fuel Pump Removal Engine
5 0703AD0900H002 Dolly – counter shaft roller bearing Transmission
6 0703AD0900H001 Dolly – counter shaft roller bearing Transmission
7 0703AD0900H004 Dolly – outer race of roller bearing rear housing. Transmission
8 0703AD0900H003 Dolly – counter shaft ball bearing Transmission
9 0703AD0900H011 Dolly – bearing on output shaft Transmission
10 0703AD0900H005 Dolly – intermediate plate bearing Transmission
11 0703AD0900H015 Dolly – ball bearing in rear housing Transmission
12 0703AD0900F007 Fixture bearing on output shaft Transmission
13 0703AD0900F004 Assembly fixture Transmission
14 MST - 530 C-Clamp for OEY ball joint servicing OEY Axle
15 MST – 531 Ball joint receiver OEY Axle
16 MST – 532 Ball joint removal adaptor OEY Axle
17 MST – 533 Upper ball joint installer dolly OEY Axle
18 MST – 534 Upper ball joint installation adaptor OEY Axle
19 MST – 535 Lower ball joint installer dolly OEY Axle
20 MST – 536 Lower ball joint installation adaptor OEY Axle
21 MST - 537 Socket split ring OEY Axle
22 0505AAA0001ST Rear Axle Shaft Puller Rear Axle
23 MST – 621 Axle Shaft lock Nut Tool Rear Axle
24 MST – 572 Bearing Carrier Outboard Seal Dolly Rear Axle
25 0502CAA0012ST Axle Shaft Inboard seal Removal Tool Rear Axle
26 0505AA0002ST Outboard oil Seal Pressing Dolly Rear Axle
27 MST - 203 Flange Holding Tool Rear Axle
28 MST - 208 Flange Puller Rear Axle
29 0502DAA0005ST Pinion Height Setting Gauge Rear Axle
30 0502DAA0006ST Pinion Height Setting Master Rear Axle
31 MST - 510 Diff side bearing installation drift Rear Axle
32 0703AD0900H001 Pinion Tail End Bearing Installer Rear Axle
33 0502CAA0004ST Dolly Pressing Pinion Inner Cone Rear Axle
34 0502EAA0001ST Diff Carrier Stand Rear Axle
35 0502AAA0001ST Gear Carrier Removal Tool Rear Axle
36 0502caa0009ST Pinion Seal Pressing Dolly Rear Axle
37 0502CAA0010ST Adapter Pinion Inner Cup Removal Rear Axle
38 0502CAA0008ST Adapter Pinion Outer Cup Removal Rear Axle
39 0502CAA0014ST Bearing Removal Tool Rear Axle
449

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Man-00120 - Genio Repair Manual

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REPAIR MANUAL

(BS-III & BS-IV)

TECHNICAL PUBLICATION CELL

About the Repair Manual

• How to use this manual………………………………………………………………………. 03

How to use this manual

• Description section gives an overview of the functioning of the system.

Term Symbol Denotation

Gear shifting control system (Sketch

Wiper motor M/s Lucas TVS Ltd, 12V

Code for Month and Year of production

2.49L mDI CRDe (BS-III & BS-IV)

Engine Identification: Engine Serial Number

The engine serial number is stamped on engine

The engine serial number code is stamped as -

Engine Component Locations

1. Engine components location – front view

Engine Component Location – Front View

Engine Component Location – Front Side Refer illustration.

2. Engine component location – LH & RH Side Views

Component Location – LH & RH Side Views

Engine Component Location – LH & RH Side

3. Engine component location – Rear view.

1. Engine lifting hook - Rear

4. Engine component location – Top view.

Refer sample illustration.

Cylinder compression pressure Test

 Remove all the injectors.

Engine cylinder Head Gasket Failure Diagnosis

An engine cylinder head gasket leak can be:

A. Between adjacent cylinders

Cylinder head gasket failure between cylinders is indicated by

Cylinder to Cylinder Leakage Test

Cylinder to Water jacket Leakage Test -

• Remove the radiator cap.

Symptom Causes Remedial action

bolts. Replace gasket if required.

7. Worn out rings, liners,  Change oil, filter, service the

the rocker cover. gasket. If after that also the

Oil leaks 1. Worn oil seals  Replace seals.

• Care of the System -

Job Description Page No. Job Description Page No.

• INTERCOOLER* ASSEMBLY – R&R

• ELECTRIC FAN & SHROUD – R&R

Electric Fan Shroud

1. Remove Coolant reservoir tank [A].

 Do not tamper or service the fan assembly.

• ACCESSORY MAIN DRIVE BELT – R&R

ACCESSORY DRIVE BELT LAYOUT

Removal & Refitting – Refer illustration shown.

 Check the drive belts visually for any crack, fraying.

• AUTO TENSIONER – REPLACE

Dummy pulley DRIVE BELTS - LAYOUT

Auto Tensioner dowel

Removal Steps – Assembly Procedure –

1. Remove NVH cover. 1. Refit Auto tensioner assy.

• BREATHER PIPE – R&R

Refer illustrations shown -

Rocker Cover Fitment & Cut section view

• ROCKER COVER – R&R

Removal Steps – Assembly Procedure –

1. Remove NVH cover. 1. Check gasket for any damage.

• Rocker Cover mounting bolt Tightening Sequence –

Removal Steps – Assembly Procedure –