Jeeto Maintenance Manual

Maintenance Manual
MAN-00295
MAINTENANCE MANUAL
JEETO
Revision — 1
JUNE - 2015
Published by — Service Engineering
Technical Hub
Maintenance Manual MAN-00295
JEETO JUNE - 2015/Rev 1
Table of Content
1 About the Maintenance Manual ............................................................................................ 4
2 Explanation on Colour Codes Used In Illustrations .............................................................. 6
3 Good Workshop Practices ..................................................................................................... 7
4 Legend Of The Safety Symbols............................................................................................... 8
5 JEETO Maintenance Schedule .............................................................................................10
6 JEETO lubrication Chart .......................................................................................................11
7 JEETO Maintenance Parts List........................................................................................... .12
8 726-MAT-0012/ Engine Oil- Replace/0.15 HRS .............................................................13
9 726-MAT-0013/ Engine Oil Filter- Replace /0.05 HRS...................................................17
10 726-MAT-0017/ Timing Belt- Inspect/ 0.65 HRS ...........................................................20
11 726-MAT-0018/ Timing Belt- Replace/ 0.70 HRS ..........................................................22
12 726-MAT-0015/ Alternator Belt- Inspect/ 0.05 HRS ....................................................26
13 726-MAT-0016/ Alternator Belt- Replace/ 0.10 HRS ...................................................29
14 726-MAT-0021/ Coolant Level & Leak- Inspect/ 0.10 HRS...........................................32
15 726-MAT-0022/ Coolant- Replace/ 0.20 HRS ...............................................................34
16 726-MAT-0031/ Air Filter Element- Clean/ 0.10 HRS ...................................................37
17 726-MAT-0032 / Air Filter Element - Replace / 0.05 HRS ............................................41
18 726-MAT-0042/ Fuel Filter- Replace/ 0.10 HRS ............................................................45
19 726-MAT-0046/ Water Sediment Drain - Fuel Filter/ 0.05 HRS .................................50
20 726-MAT-0056/ Clutch Free Play - Adjust / 0.15 HRS .................................................52
21 726-MAT-0062/ Transaxle Oil- Replace / 0.15 HRS .....................................................57
22 726-MAT-0131/ Brake Fluid Level & Leak Inspect / 0.05 HRS ...................................61
23 726-MAT-0132/ Brake Fluid - Replace / 0.30 HRS .......................................................64
24 726-MAT-0133/ Front Brake Pads Or Caliper - Inspect/ 0.40 HRS ............................72
25 726-MAT-0135/ Brake Drum & Lining - Inspect/ 0.30 HRS ........................................77
26 726-MAT-0137/ Parking Brake- Check & Adjust/ 0.15 HRS .......................................81
27 726-MAT-0141/ Suspension Bushes - Inspect/ 0.10 HRS ...........................................83
28 726-MAT-0142/ Suspension Arms & Links - Inspect / 0.10 HRS ...............................85
29 726-MAT-0146/ Wheel Alignment / 0.40 HRS .............................................................88
30 726-MAT-0161/ Battery Electrolyte - Inspect/ 0.05 HRS ............................................91
31 726-MAT-0162/ Battery Specific Gravity - Inspect / 0.10 HRS ..................................93
32 726-MAT-0163/ All Light, Horn, Wiper, Washer - Check / 0.05 HRS.........................96
33 726-MAT-0122/ Tyre Pressure- Adjust & Inspect/ 0.05 HRS ................................... 101
34 726-MAT-0121/ Tyre Rotation/ 0.20 HRS................................................................... 102
35 726-MAT-0182/ Cargo Mounting Bolts - Inspect/ 0.20 HRS .................................... 104
36 726-MAT-0185/ Door Latches & Door Locks - Lubricate/ 0.05 HRS ...................... 106
37 Maintenance Check Sheet ................................................................................................ 107
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document, are
prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd., will Page 3
amount to unauthorized use and shall be liable for penalty/prosecution© 2015 Mahindra & Mahindra Ltd.
1 About the Maintenance Manual
P5AMM0001
• The maintenance manual outlines the correct standard operating procedures (SOPs) for
carrying out maintenance operations in a JEETO vehicle.
• Carrying out the periodic maintenance operations, as specified, is crucial for safe and trouble-
free operation of the vehicle.
• The recommended maintenance schedule /operations are published in the owner’s handbook.
• This manual covers the correct method of carrying out the maintenance operations, using the
correct process/procedures, tools, parts and lubricants. The manual consists of
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
Page 4 are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd.,
will amount to unauthorized use and shall be liable for penalty/prosecution© 2015 Mahindra & Mahindra Ltd.
1.1 Maintenance Schedule

The maintenance schedule outlines the operations to be carried out in specified interval such as
specified kilometres or Month. These operations include Adjust (A), Inspect & Correct (I), Replace (.
R) & Clean (C). The maintenance periods are specified in Kilometers (Kms).
1.2 Standard Operating Procedures(SOP)

Each maintenance operation is coded by an operation code726 - MAT - XXXX. Here726 stands for
the model family code, MAT indicating it is a maintenance operation and XXXX the operation
number.
Each maintenance operation is explained step-by-step, in the SOP section of the manual. The man-
hours required to complete the operation is mentioned along with the operation code. The correct
grade of lubricants /coolants to be used, torque values, special tools are also mentioned wherever
applicable.
1.3 Check Sheets

Check sheets for each service, list outs the operation which need to be carried out by the technician,
when the vehicles report for scheduled maintenance service. These check sheets need to be
attached to the Repair Order.
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Page 5
Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2015 Mahindra & Mahindra Ltd.
2 Explanation on Colour Codes Used In Illustrations
Main Component
t o be removed
Specia l Tool/
Spanne r
Fas t ener or s ub component

t o be remove d before
remova l of main component .
P5AMM0002
1. All visible components in an illustration are shown Light Grey in colour with black line art
edges.
2. Main component to be attended for removal or refit are shown in White colour.
3. The fasteners and component’s which needs to removed before removing the main
component is shown in Dark Green colour.
4. The special tools/spanners used to remove or refit are shown in Light Green colour.
3 Good Workshop Practices

3.1 Attire/Dress
1. Always wear clean uniform
2. Wear safety shoes
3. Wear gloves, when required
4. Wear belt cover
3.2 Vehicle Protection

Install seat covers, steering wheel cover, before starting the operations.
3.3 Safety
1. When working with 2 or more persons, be sure to check safety for one another.
2. When working with engine running, make sure to provide ventilation for exhaust fumes in the
workshop.
3. If working on high temperature, high pressure, rotating, moving or vibrating parts, you should
wear appropriate safety gear and take extra care not to injure yourself or others.
4. When jacking up the vehicle, be sure to support the specified location with a safety stand.
5. When lifting up the vehicle, use appropriate safety equipment.
3.4 Parts And Tools

Before starting the operation, prepare tool stand, MST (Special Tools), gauges, oils and parts for
replacement.
3.5 Removed Parts

1. Place removed parts in a separate box to avoid mixing them up with new parts or
contaminating new parts.
2. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new
ones as instructed in the manual.
3. Retain the removed parts for customer inspection, if requested.
4. The removed parts should be packed in clean bags and handed over to the customer.
4 Legend Of The Safety Symbols

To emphasize information and procedures regarding safety, use, maintenance, etc., the following
symbols are used throughout the manual.
Term/ Symbol Denotation

DANGER indicates an imminently hazardous
P5A010001 situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a potentially hazardous

P5AMM0141 situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous

P5AMM0142 situation which, if not avoided, may result in
minor or moderate injury.
Indicates important information relevant to the

P5AMM0143 vehicle, the vehicle's use or to sections of this
manual to which particular attention must be
paid for optimum use of the vehicle.
If you see this symbol, it indicates “no”, “do

P5AMM0144 not,” “do not do this,” or “never”.
4.1 Legend Of The Symbols
Symbol Denotation
Locate/ Show
P5AMM0156
Move/ Fit
P5AMM0157
Turn Clockwise
P5AMM0158
Turn anti-clockwise
P5AMM0159
Inspection
P5AMM0145
Wrong practice
P5AMM0146
Right Practice
P5AMM0147
LOCTITE
LOCTITE
0000 Sealant Application
P5AMM0148
Dis - assembly Sequence

P5AMM0149
Assembly Sequence
P5AMM0150
Torque Tightening
P5AMM0151
Tightening Sequence
P5AMM0152
S OAP
SOLUT ION
Lubrication Symbol (Soap oil)
P5AMM0153
OIL Lubrication Symbol (oil)

P5AMM0154
Lubrication Symbol (Semi solid)

P5AMM0155
5 JEETO Maintenance Schedule

JEETO DISTANCE COVERED (IN KMS) IN SERVICE WHICHEVER IS EARLIER
Free Services Paid Services
Description
3000 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
A = Adjust as Necessary I = Inspect and correct. Replace if worn out or faulty R = Replace L = Lubricate C = Clean D = Drain
Engine
Engine Oil 1 R R R R R R R R R R R
Engine Oil Filter R R R R R R R R R R R
Timing Belt I I R
Alternator Belt I I R
Coolant level 3 I | | | R | | | R | |
Air, Fuel and Exhaust
Air filter element 4 C C C R C C R C C R C
Fuel Filter Assembly R R R
Draining water from Fuel Filter D D D D D D D D
Clutch
Clutch free play A A A A A A A A A A A
Transaxle
Transaxle Oil 2 R R R
Brakes
Brake Fluid - Level & Leak B | | | R I | R | I R |
Front and Rear Brakes | | | | | | | | | |
Parking Brake A A A A A
Suspension
Suspension Bushes | | | | |
Suspension Arms and Links I I I I I
Steering
Wheel Alignment* I I
Electrical
Battery Electrolyte Level I I I I I I I I I I
Battery Electrolyte Specific Gravity I I I I I I I I I I
All Lamps, Horns, Wipers and Washers I I I I I I I I I I I
Final Inspection
Tire Pressure I I I I I I I I I I I
Tire Rotation I I I I I I I I I I
Cargo mounting bolts for tightness I I I I I I
Door Latches, Door Lock L L L L L L L L L L L
Road Test I I I I I I I I I I I
*On chargeable basis; 3- Change as per the km or 3 years whichever earlier
1- Change as per the km or 1 year whichever earlier 4- Under extreme operating conditions clean the air filter frequently
2 - Change as per the km or 2 years whichever earlier B - Change brake fluid every 30k km or every year whichever is earlier
A = Adjust as Necessary I = Inspect and correct. Replace if worn out or faulty R = Replace L = Lubricate C = Clean D = Drain
6 JEETO lubrication Chart
System Lubricant Capacity Specification Remarks

In case of non availability of "Maximile"
MAHINDRA brand, other brands meeting API CH4
Engine Oil "MAXIMILE Special Engine SAE 15W-40 specification can be used
2.0 liters
PREMIUM ECO" oil as second preference and oil change
GENUINE ENGINE OIL
period should be reduced to 5,000 km.
Engine Oil _ _ Use only the Recommend oil filter for better engine
Filter protection and lubricant life.
Brand Specific. Don’t use other coolants / water for
MAHINDRA top up. In case of emergency, coolant meeting JIS
Engine “MAXIMILE _ K2234 specification should be used (30%
Cooling ULTRA COOL”
GENUINE COOLANT
concentration diluted with distilled water) and coolant
change period to be reduced as 30,000 km.
In case of non availability of "Maximile"
MAHINDRA Special brand, other brands meeting API GL4,
“MAXIMILE Manual SAE 80W-90 specification can be used
Transaxle 1.25 liters
SYNCHRO UV2” Transmission as second preference and oil change
GENUINE TRANSMISSION OIL
Fluid period should be reduced to 20,000
km.
MAHINDRA
Brake “MAXIMILE DOT 0.6 liters Brake Fluid Meeting SAE J1703 FMVSS No.116 DOT
3” 3 or IS 8654 Type-1 Specification.
Genuine brake fluid / TVS Girling DOT 3
7 JEETO Maintenance Parts List
Sl No Part No Description Quantity
1 0311AAC00260N Engine oil drain plug washer 01
2 0303BAU00261N Oil filter 01
3 0306GAU00081N Belt 3PK (Alternator drive Belt) 01
4 0310AAU00231N Timing Belt 01
5 0313AAU02031N Element air filter 01
6 1001CAB00411N Fuel filter assy 01
7 SF0401063 Transaxle Drain plug washer 01
8 0703DK0800N Filler plug (Transaxle filler plug 01

washer)
9 EOECOPRE20 MAXIMILE PREMIUM ECO 02 liters
10 TMOUV2SYN20 MAXIMILE SYNCRO UV2 1.25 liters
! CAUTION
Verify part numbers with electronics parts catalogue before placing the order.
8 726-MAT-0012/ Engine Oil- Replace/0.15 HRS
Tools Required
Size Type Quantity
22mm Ring / Socket 01
- Torque wrench 01
Preliminary Activities/Conditions
1. Engine should be hot while draining the oil.
2. Position the Vehicle on level ground /2 post lift/ 4 post lift and turn engine OFF.
3. Fold co-driver seat and hang using the strap provided.
Engine Oil - Replace
P5AMM0003
Engine Oil – "MAHINDRA MAXMILE PREMIUM ECO " GENUINE ENGINE OIL
Capacity – 2 Litres.
8.1 Engine Oil Draining Procedure
1. Open the filler plug.
P5AMM0004
2. Using 22mm ring/socket spanner, remove

the engine oil drain plug located under the oil
sump.
P5AMM0005
3. Allow the entire oil to get drained.
Place a tray under the drain plug to collect

the oil.
8.2 Engine Oil Filling Procedure
1. Refit the drain plug with a new washer. 5. Pull out the dip stick gauge and wipe it clean
with a cloth/paper.
P5AMM0007
P5AMM0010
2. Fill fresh oil recommended to specified
quantity. 6. Insert the dip stick gauge into the dip stick
guide fully till the end.
P5AMM0008
P5AMM0011
3. Refit the engine oil filler cap.
7. Pull out the dip stick slowly and check for
4. Check engine oil level as per the below
the oil level mark between Maximum and
procedure.
Minimum level - if found below minimum level,
top up with recommended oil.
P5AMM0009
MAX
MIN
P5AMM0012
8. Insert the dip stick back and fix properly,

start the engine and check for oil leakage/
seepage at:
• Crankcase joint.
• Crankcase drain plug.
• Oil filter joint.
Nut/ Bolt description Torque Value – Nm
Engine oil drain plug 27.5 ± 2.5
! CAUTION
• Engine oil to be replaced first at 3,000 Kms, then at 10000 Kms, then every 10000 Kms.
• Always use MAHINDRA “MAXIMILE PREMIUM ECO” GENUINE ENGINE OIL.
• For other than Maximile brand, the oil change interval has to be reduced to 5000 kms
provided the oil meets minimum of API CH-4 SAE 15W-40 specification.
9 726-MAT-0013/ Engine Oil Filter- Replace /0.05 HRS
Tools Required
Size Type Quantity

- Oil filter wrench 01
1. Position the Vehicle on 2 post lift.
2. Lift the vehicle and access the oil filter.
Engine Oil Filter- Replace
P5AMM0014
9.1 Engine Oil Filter — Removal
1. Grip the engine oil filter firmly using an oil

filter wrench, rotate in anticlockwise direction
and remove the oil filter from engine assembly.
P5AMM0015
9.2 Engine Oil Filter - Installation
1. Smear a layer of fresh oil on new oil filter O- 6. Start the engine and check for Oil leakage/
ring. seepage at:
2. Place the oil filter in its position. • Crankcase joint.
3. Using hand rotate the oil filter in clockwise • Crankcase Drain Plug.
direction till the O-ring makes contact with the • Oil filter joint.
oil cooler surface.
P5AMM0017
P5AMM0016
• Always tighten the oil filter using hands.

• Never use wrench or filter tool for
installation.
4. Turn the filter another 3/ 4th turn by hand.
5. Check the engine oil level.
! CAUTION
• Never use a wrench/spanner to tighten the oil filter.
• Engine oil filter is to be replaced at at 3,000 Kms, then at 10000 Kms, and thereafter
every 10,000 Kms.
• Recommend to use only the Mahindra genuine oil filter for better engine protection and
lubricant life.
10 726-MAT-0017/ Timing Belt- Inspect/ 0.65 HRS
2. Lift the vehicle and access the timing belt.
3. To access the timing belt refer the procedure given in 726-MAT-0018.
Timing belt
P5AMM0001
10.1 Timing Belts—Inspection
1. PILLING – Belt material is sheared off from 3. CRACKING – Small, yet visible cracks along
the ribs and builds up in the belt grooves. the length of a rib or ribs.
P5AMM0161 P5AMM0163
2. CHUNK OUT – Pieces or chunks of rubber

material have broken off from the belt. When ! CAUTION
chunk-out has occurred, a belt can fall at any
moment. • It is recommended to remove & check
the Timing belts thoroughly if any
abnormality noticed.
• Timing belt need to be inspected at
60,000 kms and 80,000 kms.
P5AMM0162
11 726-MAT-0018/ Timing Belt- Replace/ 0.70 HRS
Tools Required
Size Type Quantity
10mm Socket spanner 01
– Allen key 01
Timing belt
P5AMM0001
11.1 Timing Belts—Removal
1. Fit the special tool Part no - 4. Loosen the 24mm mounting bolt and
(0306GAU00131N) over the alternator drive remove the alternator drive pulley.
pulley.
P5AMM0021
P5AMM0019
5. Loosen the 10mm mounting bolts Qty
2. Rotate the alternator drive pulley in 8no’s & nuts Qty 2 no’s and remove the front
clockwise direction with the help of socket cover.
spanner as shown in the illustration.
P5AMM0022
P5AMM0013
6. Rotate the tensioner bolt in clockwise
3. Remove the alternator drive belt. direction and then remove the timing belt.
P5AMM0020 P5AMM0023
11.2 Timing Belts - Installation
1. Install the new timing belt and tighten the 4. Refit the alternator belt as shown in
tensioner using 6mm Allen key and illustration.
simultaneously tighten the tensioner bolt.
P5AMM0025
P5AMM0024
5. Insert the special tool Part No –
2. Fit the front cover and tighten and the (0306GAU00121N) to the alternator drive
mounting bolts. pulley.
P5AMM0022 P5AMM0026
3. Fit the alternator drive pulley and tighten 6. Rotate the special tool in a clockwise
the bolt to specific torque. direction with the help of socket spanner as
shown in the illustration to fit the belt.
P5AMM0021
P5AMM0027
7. Remove the special tool Part no -

(0306GAU00131N) over the alternator drive
pulley.
P5AMM0028
Front cover mounting bolt 10±2 Nm
Tensioner mounting bolt 35±4 Nm
Alternator drive pulley mounting bolt 125±5 Nm + 60°
! CAUTION
• Timing belt need to be replaced at 100,000kms.
12 726-MAT-0015/ Alternator Belt- Inspect/ 0.05 HRS
Alternator drive belt
P5AMM0029
12.1 Alternator Drive Belts—Inspection
1. ABRASION – Each side of belt appears 5. MISALIGNMENT – Sidewalls of the belt

shiny or glazed. In advanced stages, fabric may appear glazed or the edge cord may
becomes exposed. become frayed and ribs removed. A noise may
result. In severe cases, the belt can jump off the
pulley.
P5AMM0128
2. CRACKING – Small, yet visible cracks along P5AMM0130

the length of a rib or ribs.
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.
P5AMM0129
3. IMPROPER INSTALLATION – A belt rib

begins separating from the joined strands. If left
unattended, the cover will often separate, P5AMM0131
causing the belt to loosen.
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.
P5AMM0137
4. UNEVEN RIB WEAR – Belt shows damage

to the side with the possibility of breaks in the
tensile cord or rough edged ribs. A thumping P5AMM0132
noise may also be heard when running.
P5AMM0134
8. PILLING – Belt material is sheared off from

the ribs and builds up in the belt grooves.
P5AMM0133
! CAUTION
• It is recommended to remove & check
the drive belts thoroughly if any
abnormality noticed.
• Alternator drive belts need to be
inspected at 60,000 kms and 80,000
kms.
13 726-MAT-0016/ Alternator Belt- Replace/ 0.10 HRS
Tools Required
Size Type Quantity
2. Lift the vehicle and access the alternator drive belt.
Alternator drive belt
P5AMM0029
13.1 Alternator Drive Belts—Removal
1. Fit the special tool Part no

-(0306GAU00131N) over the alternator drive
pulley.
P5AMM0019
2. Rotate the alternator drive pulley in

clockwise direction with the help of socket
spanner as shown in the illustration.
P5AMM0027
3. Remove the alternator drive belt.
P5AMM0020
13.2 Alternator Drive Belts - Installation
1. Refit the alternator belt as shown in 4. Remove the special tool Part no -
illustration. (0306GAU00131N) over the alternator drive
pulley.
P5AMM0025
P5AMM0028
2. Insert the special tool Part No –
(0306GAU00121N) to the alternator drive
pulley.
P5AMM0026
3. Rotate the special tool in a clockwise

direction with the help of socket spanner as
shown in the illustration to fit the belt.
P5AMM0027
! CAUTION
• Alternator drive belt need to be replaced at 100,000kms.
14 726-MAT-0021/ Coolant Level & Leak- Inspect/ 0.10 HRS
2. Open the cargo panel assembly cover.
Coolant Level & Leak- Inspect
P5AMM0030
Coolant – MAHINDRA "MAXIMILE ULTRA COOL" Genuine Coolant (READY TO USE COOLANT. NO
NEED TO MIX WATER).
Capacity – 3.0 Litres.
• Check the coolant level when the engine is cold.
1. Check the coolant level in the degassing 5. Check for evidence of coolant leakages at
tank, it should be between MAX and MIN thermostat hoses.
marks.
2. If found below MIN mark then top it up with
MAHINDRA "MAXIMILE ULTRA COOL"
Genuine Coolant.
P5AMM0034
6. Check for evidence of coolant leakage at

radiator assembly.
P5AMM0031
3. Check for evidence of coolant leakages at

the degassing tank outlet hose.
P5AMM0035
! CAUTION
P5AMM0032
• Never remove the degassing tank cap
when the engine is hot.
4. Check for evidence of coolant leakage at
engine coolant inlet. • Never mix MAHINDRA "MAXIMILE
ULTRA COOL" Genuine Coolant with
water.
• Coolant level and leaks to be checked
first at 3,000kms, 10,000kms and
thereafter every 10,000 kms.
P5AMM0032
15 726-MAT-0022/ Coolant- Replace/ 0.20 HRS
2. Open the cargo panel assembly cover.
3. Open the degassing tank guard.
Engine Coolant - Replace
P5AMM0030
Coolant – MAHINDRA "MAXIMILE ULTRA COOL" Genuine Coolant (READY TO USE COOLANT. NO
NEED TO MIX WATER).
Capacity – 3.0 Litres
15.1 Engine Coolant Draining Procedure
1. Open the degassing tank cap.
P5AMM0036
2. Open the drain plug with the help of a flat

end screw driver.
• Place a tray beneath the drain plug to

collect coolant drained.
3. Allow the entire coolant to get drained.
P5AMM0037
4. Refit the drain plug.
P5AMM0037
15.2 Engine Coolant Filling Procedure
1. Fill the recommended coolant in degassing

tank.
P5AMM0031
2. Check and ensure the coolant level in the

degassing tank is between Min and Max marks.
3. Check all the hoses & clips for leakage and
correct fitment.
4. Start the engine and run at approx.
1200rpm for 2-3 min.
5. Check coolant level in degassing tank and
add coolant as per requirement.
6. Close the degassing cap.
P5AMM0038
! CAUTION
• Never remove the degassing cap when the engine is hot.
• Never mix MAHINDRA MAXIMILE ULTRA COOL Genuine Coolant with water.
• Brand specific. Don’t use other coolants / water for top up. In case of emergency, coolant
meeting JIS K-2234 specification should be used (30% concentration diluted with distilled
water) and coolant change period to be reduced as 30,000 kms.
• Coolant to be replaced at every 40,000 kms.
• Do not overfill the system allow free space in the degassing tank for expansion of the fluid.
16 726-MAT-0031/ Air Filter Element- Clean/ 0.10 HRS
2. Lift the vehicle and access the Air filter element.
Air Filter Element - Clean
P5AMM0039
16.1 Air Filter Element — Removal
1. Open the three clips of air filter assembly

cover and then remove the cover.
P5AMM0040
2. Pull out the air filter element gently without

any damage.
P5AMM0041
! CAUTION
Ensure dust should not fall in the clean side
hose while removing the element.
16.2 Air Filter Element — Cleaning
1. Clean the inner side of the air filter housing

and its cover.
2. Clean the sealing area (sealing gasket) with
a dry clean cloth.
Clean Side
Dirty Side
Sealing Area P5AMM0042
3. Cleaning the air filer from inside out.
AIR PRESSURE
CLEAN PLATE
CLEAN PLATE
P5AMM0043
4. Do not blow the air from outside.
AIR
P5AMM0044
! CAUTION
• While cleaning, ensure the air pressure does not exceed 2 bar.
• Always clean the air filter element from inside out.
• Do not tap or hit the filter element.
• Ensure dust should not fall inside the clean hose area while fitting the back cover.
• If required housing should be cleaned only after disconnecting the hoses.
16.3 Air Filter Element — Installation
1. Install the air filter element gently inside the 2. Install the air filter back cover and ensure
filter body ensuring the tight fitment. the cover is properly seated.
P5AMM0045 P5AMM0046
P5AMM0047
Align the back cover with the arrow mark for fixing it on filter main body.
! CAUTION
• Clean air filter element at 3,000 kms, 10,000 kms, 20,000 kms ,40,000 kms, 50,000
kms, 70,000 kms, 80,000 kms and 1,00,000kms .
17 726-MAT-0032 / Air Filter Element - Replace / 0.05 HRS
2. Lift the vehicle and access the Air filter element.
Air Filter Element - Replace
P5AMM0039
17.1 Air Filter Element — Removal
1. Open the three clips of air filter assembly

cover and then remove the cover.
P5AMM0040
2. Pull out the air filter element gently without

any damage.
P5AMM0041
! CAUTION
Ensure dust should not fall in the clean side
hose while removing the element.
17.2 Air Filter Element — Installation
1. Install the air filter element gently inside the

filter body ensuring the tight fitment.
P5AMM0045
2. Install the air filter back cover and ensure

the cover is properly seated.
P5AMM0046
P5AMM0047
Align the back cover with the arrow mark for fixing it on filter main body.
! CAUTION
• Replace filter element earlier if driving in extremely dusty/polluting condition or if any
damage (Tear, Puncture) is observed on filter element.
• Always use recommended genuine air filter element.
• Do not tap or hit the new filter element.
• Replace air filter element at every 30,000 kms.
• Check & replace the air filter if the vehicle is running at dusty conditions.
18 726-MAT-0042/ Fuel Filter- Replace/ 0.10 HRS
Tools Required
Size Type Quantity
2. Lift the vehicle and access the Fuel.
Fuel Filter- Replace
P5AMM0001
18.1 Fuel Filter—Removal
1. Ensure Ignition OFF.
P5AMM0049
2. Disconnect fuel lines (Inlet fuel line, outlet

fuel line and Return line of fuel filter).
All are quick fix connectors, press gently

and remove it carefully; avoid seal damages.
3. Remove the Qty 2no’s mounting bolts of the
fuel filter assembly using 12 mm socket
spanner and remove the fuel filter assembly.
P5AMM0050
18.2 Fuel Filter - Installation
1. Replace the new fuel filter assembly.
P5AMM0050
2. Mount the fuel filter back in its position with

mounting bolts and torque tighten the mounting
bolts to specified value.
3. Connect the inlet fuel line, outlet fuel line
and Return line to fuel filter assembly back.
P5AMM0049
! CAUTION
Check and ensure proper fitment of fuel lines, any leakage can lead to fire.
18.3 Fuel Filter - Bleeding

The fuel filter needs to be bled when there is an air lock. Air lock can happen due to
Various reasons like running out of fuel or fuel filter replacement. Follow the below
Procedure to remove the air lock,
1. Switch the Ignition ON
2. Press the brake pedal and HOLD
3. Press and release the accelerator pedal 3 times
4. Press and HOLD the accelerator pedal on the 4th time
5. The engine check lamp blinks in few seconds
6. Release the brake and accelerator pedals
7. Wait till engine check lamp switches OFF (Approximately 90 secs)
8. Start the engine
Pictorial Representation of bleeding procedure:
Fuel System Ble eding Procedure /

Replace
WHEN (OR(
EMPTY
क ब बदले
. खाली
IGNITION ON BRAKE & HOLD ACCELERAT

OR HOLD ACCELERATOR
HOW X3
4
th
=
कैसे चाल ू
OP
R
पेडल द ब ाइ य े पेडल द ब ाइ य े
ES
ST
ET
T/
STAR
HOUR
1
MIN. SEC.
CHECK ENGINE LAMP RELEASE CHECKENGINE LAMP

START & GO OFF ACCELERATOR RELEASE BRAKE BLINKING
IN CLUSTER IN CLUSTER
ENGINE ! ENGINE !
च के इ जं न ब ंद े ं
Refer Owner’s Manual for more details P5AMM0138
Fuel filter assembly mounting bolts 25 ± 3
! CAUTION
• Always use recommended filters only.
• Before removing the fuel filter, open the fuel tank cap to release the pressure from the
tank and fuel lines.
• It is recommended to replace the fuel filter element at every 30,000kms.
19 726-MAT-0046/ Water Sediment Drain - Fuel Filter/ 0.05 HRS
2. Lift the vehicle and access the fuel filter drain plug.
Water Sediment Drain - Fuel Filter
P5AMM0051
19.1 Water Sediment —Draining
1. Ensure ignition OFF. 5. Turn the ignition ON and check for any
2. Connect the transparent pipe to the drain leaks.
plug outlet.
! CAUTION
• Drain plug requires hand tight only; do
not use any tool and avoid over
tightening.
• Water sediments drain from fuel filter
need to be carried out at every service (
This activity is not required in regular
services where fuel filter element is
replaced)
P5AMM0052
3. Rotate drain plug anti-clockwise till the

water starts flowing from the tube.
P5AMM0053
4. Rotate drain plug in clockwise direction to

stop the flow as soon as water flow stops and
fuel flow starts.
P5AMM0054
20 726-MAT-0056/ Clutch Free Play - Adjust / 0.15 HRS
Tools Required
Size Type Quantity
10mm Open end spanner 02
1. Position the Vehicle on Level Ground.
Clutch Free Play Limits
Clutch Pedal free Play 10 to 20 mm
Clutch Cable Setting Parts
Clut ch Releas e Ar m
Clut ch Cable
Hex Flange Nut
Lock Nut
Sprin g Clut ch Cable

Radius Nut Plain Wash er Rubbe r Bellow
P5AMM0 0 5 5
Procedure to Check the Clutch Pedal Free Play
120
100
P5AMM0056
1. Without pressing the pedal, measure the pedal height from floor to the lowest point of the
clutch pedal pad, it should be 120 mm.
2. Press the clutch pedal up to the point where pedal load is felt. Keeping the pedal in this
position, measure the pedal height from floor to the lowest point of the clutch pedal pad. It
should be100 mm.
3. If the above measurements are correct, then the clutch pedal free play is 10-20mm.
4. If the above measurements are different, set the clutch pedal free play.
Clutch Cable Setting Dimensions

1. With clutch cable in its position, the distance between the bracket bush and release arm = 95 to
115 mm.
95 to115mm P5AMM0057
2. With clutch cable in its position, the distance between the washer and flange nut of release arm
= 15 mm Approximate.
1 5 mm
P5 AMM0 0 5 8
1. Loosen the flange nut and lock nut till the end.
2. Push the clutch release arm towards the front as far as it can go.
3. Holding the clutch release arm in this position, tighten the radius nut towards the trunion nut
so that it just touches the trunion.
4. Now tighten the flange nut till the spring is fully compressed between the washer and the
flange nut and the washer butts against the clutch release arm. This ensures that the spring
is compressed completely.
5. Tighten the lock nut so that the flange nut is firmly locked in its position.
6. Loosen the radius nut by 2 to 5 turns. As the pitch is 1.0 mm, the clutch release arm will
move back by 2 to 5mm.
7. Sitting on the driver’s seat, press fully and release the clutch pedal 10 to 15 times.
8. Check for free play at pedal end as explained above.
9. If the desired clutch pedal free play is not achieved, repeat the clutch pedal free play setting
procedure.
! CAUTION
• Clutch free play need to be adjusted at 3,000kms, 10,000kms and thereafter every
10,000 kms.
21 726-MAT-0062/ Transaxle Oil- Replace / 0.15 HRS
Tools Required
Size Type Quantity
10mm Allen key 01
- Mechanical hand pump 01
1. Position the Vehicle on a2 post lift.
2. Lift the vehicle and access the Transaxle drain plug.
Transmission Oil–Replace
P5AMM0059
Transaxle Oil – "MAHINDRA MAXIMILE SYNCHRO UV2"

Genuine Transaxle Oil.
Capacity – 1.25 Litres.
21.1 Transmission Oil— Draining
1. Remove the filler plug. 4. Install the drain plug and torque tighten to
specified value.
P5AMM0060
P5AMM0063
2. Place a tray underneath the drain plug.
3. Remove drain plug and allow the oil to drain
out into the tray.
• Replace washer with a new one
whenever you remove the drain plug.
P5AMM0061
21.2 Transmission Oil— filling
1. Fill MAHINDRA “MAHINDRA MAXIMILE

SYNCHRO UV2” oil using an oil filling machine or
by clean and transparent pipe attached to the
mechanical hand pump. Ensure that the oil level
is up to lower most point of the filler plug.
P5AMM0062
• Replace washer with a new one

whenever the filler plug is removed.
2. Refit the filler plug with a new washer.
P5AMM0063
Filler plug 27.5 ± 2.5
Magnetic Drain plug 27.5 ± 2.5
! CAUTION
• Recommend to use only Mahindra " MAHINDRA MAXIMILE SYNCHRO UV2" new
generation genuine transmission oil.
• For other than Maximile brand, the oil change interval to be reduced to 20,000 Kms
provided the oil meets minimum of API GL-4 SAE 80W-90 specification.
• Replace the transmission oil at first 20,000 kms, 60,0000 Kms then every 40,0000 Kms.
• Never mix two different oils.
22 726-MAT-0131/ Brake Fluid Level & Leak Inspect / 0.05 HRS
1. Position the vehicle on level ground/2 post lift.
2. Open the Brake fluid reservoir cover.
Brake Fluid – Level & Leak Inspect
P5AMM0065
Brake Fluid – Mahindra "MAXIMILE DOT 3" Genuine brake fluid

Brake System Capacity –
• 0.6 Litres (Excludes bleeding quantity).
22.1 Check For Fluid Leakage In Brake System
1. Check for Brake Fluid Level up to “MAX” 4. Check for brake fluid leakage at Tee joints
mark on the brake fluid reservoir. shown in illustration.
P5AMM0066 P5AMM0069
2. Check brake fluid leakage at brake tube at 5. Check for brake fluid leakage at caliper
reservoir end. flexible hose end on bundy tube (Both RH & LH).
P5AMM0067 P5AMM0070
3. Check for brake fluid leakage at TMC unit. 6. Check for brake fluid leakage at front
caliper inlet and bleeding nipple (Both RH & LH).
P5AMM0068
P5AMM0071
7. Check for brake fluid leakage at rear flexible

hose (Both RH & LH).
P5AMM0072
8. Check for brake fluid leakage at rear

bleeding nipple (Both RH & LH).
P5AMM0073
! CAUTION
• Use recommended fluid & do not mix different brand fluids.
• Brake fluid level & leak check to be done first at 3,000kms, 10,000kms, 20,000kms,
40,000kms, 50,000kms, 70,000kms, 80,000kms, and 1,00000kms.
• Use the same brand fluid for top up; do not top up brake fluid from used and unsealed
brake fluid container.
• The brake fluid reservoir cap/ container should not be opened with dirty hands.
• Always use Mahindra "Mahindra "MAXIMILE DOT 3" genuine brake fluid.
23 726-MAT-0132/ Brake Fluid - Replace / 0.30 HRS
Tools Required
Size Type Quantity
8 mm Ring spanner 01
– Bleeding Transparent Hose & 01

Container
1. Position the vehicle on level ground/2 post lift.
2. Open the Brake fluid reservoir cover.
Brake Fluid — Replace
P5AMM0065
Brake Fluid – Mahindra "MAXIMILE DOT 3" Genuine brake fluid

Brake System Capacity –
• 0.6 Litres (Excludes bleeding quantity).
! CAUTION
• Brake system bleeding is to be done,
1. Whenever Brake fluid is replaced.
2. Removal and Replacement of any of the brake system components.
! CAUTION
• Always use recommended fluid and do not mix different brand fluids.
• Always use fresh and clean fluid from a sealed container.
• Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is
opened). Air in the system will be further compressed into small bubbles and distributed
throughout the hydraulic system and will result in additional bleeding operations.
• Do not reuse the drained fluid.
• Fluid level in the reservoir must be at MAX level at the start of bleeding and should be
checked after bleeding each brake circuit and top up as required.
23.1 Brake Fluid- Draining
1. Open brake fluid reservoir cap. 4. Using 8mm open end spanner loosen all
the bleeding nipples and allow the entire fluid to
get drained.
• Press the brake pedal gently to drain the

fluid completely.
5. Tighten all bleeding screws.
P5AMM0074
2. Pull-out the bleeding nipple dust cap from

both front RH and LH bleeding nipple.
P5AMM0075
3. Pull-out the bleeding nipple dust cap from

both rear RH and LH bleeding nipple.
P5AMM0076
23.2 Brake Fluid- Re-filling
1. Fill recommended brake fluid up to “MAX”

mark on the brake fluid reservoir.
P5AMM0066
2.
P5AMM0077
Press and release brake pedal gently, so that

brake fluid will get circulated throughout the
circuit.
3. Open each bleeding nipple one by one in the
order of bleeding sequence given below, pump
the brake pedal gently and close bleeding nipple
as soon as fluid starts flowing.
23.3 Bleeding
! CAUTION
• During bleeding, that the fluid level in the reservoir does not drop below minimum.
Refer the below illustration for the bleeding sequence for JEETO -
FR RR
4 1
FRONT
REAR
2 3
FL RL
P5AMM0078
1. Connect a transparent tube into rear RH 3. Open the rear RH bleeding screw, allow the
bleeding nipple and insert the other end of tube fluid to flow through the transparent pipe into
in a transparent container with brake fluid. the container.
P5AMM0076 P5AMM0076
! CAUTION
• Ensure other end of tube is submerged in • Air bubbles will escape from brake circuit
liquid, else chances for air entry is high. to container through transparent pipe
and the bubbles will be clearly visible.
• Always use transparent tube for better
visibility of air bubbles. 4. Tighten the bleeder screw as soon as there
is no air bubbles visible in the transparent tube.
2. Press and release the brake pedal 3- 4
times slowly to the full stroke and hold the pedal 5. Continue procedure 2-4 till there is no air
in depressed condition. bubbles visible in the transparent tube.
6. Remove the transparent tube.
7. Tighten the bleeding screw firmly
8. Follow steps from 1-7 for Front LH side
brake.
P5AMM0077
! CAUTION
• Ensure proper quantity of brake fluid in
P5AMM0075
the reservoir throughout the bleeding
procedure.
9. Follow steps from 1-7 for Rear LH side 13. Refit the brake fluid reservoir cap.
brake.
P5AMM0081
P5AMM0160
10. Follow steps from 1-7 for Front RH side

brake.
P5AMM0080
11. Refit the dust cap back on all the bleeding

nipples (both front and rear).
12. Maintain recommended brake fluid up to
MAX mark on the brake fluid reservoir.
P5AMM0066
! CAUTION
• Check brake pedal for sponginess. If found spongy, repeat the entire procedure of bleeding.
• Check and ensure there is no leakage from brake pipes and joints.
• Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does
contact the paint, wash it off immediately with water.
• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
• The brake fluid reservoir cap/ container should not be opened with dirty hands.
• If Maximile brake fluid is not used and in emergency conditions, use BRAKE FLUID MEETING
SAE J1703 FMVSS NO.116 DOT 3 OR IS 8654 TYPE-1 SPECIFICATION.
• During the bleeding operation ensure the container and pipe used is of transparent for
better visual.
• Brake fluid need to be replaced at every 30,000 kms.
24 726-MAT-0133/ Front Brake Pads Or Caliper - Inspect/ 0.40

HRS
Tools Required
Size Type Quantity
- Vernier caliper 01
21mm Wheel spanner/Deep socket 01

spanner
24.1 Brake Pads- Removal
1. Using 21 mm wheel spanner remove 4 3. Lift the caliper upwards and tie it separately
mounting bolts and remove the front RH wheel. as shown in illustration.
P5AMM0082 P5AMM0084
2. Remove front RH caliper lower mounting 4. Remove the brake pads.

bolt using 12mm socket spanner.
P5AMM0085
P5AMM0083
5. Remove the anti-rattle clips.
P5AMM0086
24.2 Brake Pads/Disc- Inspect
Brake Pad Inspection:

Pad t hicknes s
P5AMM0135
Measure the pad lining thickness if it is found to be 1mm or less, it has to be replaced.
Limits :
• New pad thickness: 9.5mm.
• Minimum useful pad thickness: 1mm.
Disc Thickness:
Inspect the disc thickness before assembling the caliper back to the carrier.
P5AMM0136
Limits :
• Actual thickness of disc: 17 mm.
• Minimum useful disc thickness :15 mm.
24.3 Brake Pads- Installation
1. Fix both the anti-rattle clips back in its 2. Refit the brake pads.
position.
P5AMM0085
P5AMM0086
! CAUTION
Ensure both the brake pads are fitted
Replace anti-rattle clips with a new one if properly.
found any damage or crack.
3. Move the caliper and bring back to its 5. Refit the front RH wheel back with the help
original position. of 4 mounting bolts and torque tighten it to
specified torque value.
P5AMM0084
P5AMM0082
! CAUTION 6. Follow the same procedure for front LH

brake pad and caliper inspection.
• For easy movement, pull the caliper
outwards a bit and move it down.
• Chances for piston seal damage is high,
so take adequate precaution while
moving the caliper downwards. • Always replace all four brake pads at a
time. If the pads are to be reused make
• If the pads are changed with a new one, sure pads are assembled back in the
push both the pistons inside before same position as they were when they
moving the caliper downwards. removed. I. e. pad on to the piston side
4. Refit the caliper bottom mounting bolt and and pad on to the outer side. This is
torque tighten to specified torque value. possible only when at the time of removal
of these pads are marked for their
position and kept outside.
• Never lubricate the pad seating areas as
this may lead to jamming.
• After assembly of pads, apply brake
pedal 5 - 6 times in static condition in
order to make the pads align properly.
• It is recommended to apply light braking
during the road test and avoid heavy and
continuous braking during the initial
200kms of run or until the new pads are
P5AMM0083 performing satisfactorily.
Wheel bolts 110±10
Caliper mounting bolt 80±10
! CAUTION
• If any pad is worn out (inboard /outboard) then replace both the pads.
• If pads on one wheel only are worn, even then replace the other wheels also.
• Check brake pads/calipers at every 10,000 kms.
• DO NOT use grease to the pad shims/ anti-rattle shims.
• Always replace anti-rattle shims during brake pad replacement.
25 726-MAT-0135/ Brake Drum & Lining - Inspect/ 0.30 HRS
Tools Required
Size Type Quantity

- Vernier caliper 01
21mm Wheel spanner/Deep socket 01

spanner
1. Position the vehicle on 2 post lift.
25.1 Brake Drum —Removal
1. Using 21mm wheel spanner, remove the 3. Remove drum.

rear LH wheel.
P5AMM0089
P5AMM0087
2. Using a star screw driver, remove drum

mounting screw.
P5AMM0088
25.2 Brake Drum/Lining—Inspection
1. Clean the brakes by blowing compressed 4. The minimum usable thickness of the rear
air. brake liner is 0.75 mm.
2. Check the wheel cylinder for oil leakage. (It
is recommended to check the oil seepage from
wheel cylinder by lifting the dust boots.)
0.75mm
P5 AMM0 1 6 4
P5AMM0090
• The brake shoe must be replaced before

3. Check the brake lining for wear/cracks. the rib starts touching the drum.
• Measure the wear of the brake lining at
the maximum worn out place.
P5AMM0091
25.3 Brake Drum/Lining—Installation
1. Place the drum in its position.
P5AMM0089
2. Refit drum mounting screw.
P5AMM0088
3. Refit rear RH wheel and torque tighten the

wheel nuts to specified torque value.
P5AMM0087
4. Follow the same procedure for rear RH

drum/lining inspection.
Wheel Nut 110±10
! CAUTION
• Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to
prevent vehicle from pulling to one side when braking.
• If there is significant difference in the thickness of the liner on the left and right sides,
check parking brake operation/ wheel cylinders piston for free movement.
• Rear brake drum & liners to be inspected at every 10,000kms.
26 726-MAT-0137/ Parking Brake- Check & Adjust/ 0.15 HRS
Tools Required
Size Type Quantity
1. Position the Vehicle on a 2 post lift.
2. Apply and release the parking brake five times to condition the cables for normal use.
3. Put the parking brake lever into the released position.
26.1 Parking Brake- Adjustment
1. Apply and release the parking brake 5 3. Using 14mm open end spanner, loosen the
times to condition the cables for normal use. lock nut located on back side of the cable
assembly.
P5AMM0092
P5AMM0094
2. Parking brake Cable holder is located under
the vehicle next to the radiator. 4. Position the parking brake lever at 3rd
notch position.
P5AMM0093
P5AMM0093
5. Tighten the adjusting nut till the rear wheels

can no longer be rotated using hands, and
tighten the lock nut as shown in the illustration.
P5AMM0094
6. Pull the parking brake lever up slightly,

press the release button on the lever tip and
lower the parking brake lever completely.
P5AMM0097
7. Check both the rear wheels for free

rotation, if not, loosen the lock nut and then
loosen the adjusting nut gradually until the
wheels can turn freely.
! CAUTION
The parking brake has to be adjusted at every 20,000Kms.
27 726-MAT-0141/ Suspension Bushes - Inspect/ 0.10 HRS
Front Suspension Bushes– Inspect
FW
D
P5AMM0098
1. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear,
cracks & shift. Replace if necessary.
2. Check the ball joint boots for damage, cracks, replace if necessary.
3. Check strut assembly bushes, dust boot, stabilizer bar link bushes for wear & tear, cracks and
shift, replace if necessary.
27.1 Rear Suspension Bushes– Inspect
FW
D
P5AMM0099
1. Check the rear suspension trailing arm rubber bushes for wear, ageing, cracks and metal
sleeve separation.
2. Check the bump stop and pad coil spring for wear and crack.
3. Check shock absorber bushes for wear, crack and shift.
! CAUTION
• While tightening the link & torqueing, ensure that wheels are resting on the ground. If it is
not done, the ride quality will get adversely affected.
• The suspension bushes are to be inspected first at 20,000kms, 40,000kms and
thereafter every 20,000kms.
28 726-MAT-0142/ Suspension Arms & Links - Inspect / 0.10 HRS
Suspension Arms & Links-Inspect
1. Inspect front suspension lower control arm 3. Inspect front suspension stabilizer bar link
for any bend, damage or crack. for any bend, twisting, damage or crack.
P5AMM0100 P5AMM0102
2. Inspect front suspension strut assembly for 4. Inspect front suspension stabilizer bar for
any bend, damage or crack. any bend, twisting, damage or crack.
P5AMM0101 P5AMM0103
5. Inspect rear suspension trailing arm for any

bend, twisting, damage or crack.
P5AMM0104
6. Inspect rear suspension coil spring for any

bend, twisting, damage or crack.
P5AMM0105
7. Inspect rear suspension shock absorber for

any bend, leak, twisting, damage or crack.
P5AMM0106
! CAUTION
• While tightening the link & torqueing, ensure that wheels are resting on the ground. If it is
not done, the ride quality will get adversely affected.
• Suspension arms and links need to be inspected first at 20,000kms, 40,000kms and
thereafter every 20,000 kms.
29 726-MAT-0146/ Wheel Alignment / 0.40 HRS
Tools Required
Size Type Quantity
• Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications.
Vehicle to be run for some distance before starting the wheel alignment. This will settle the load
on each tyre.
• Ensure that the turn table & roller plate move freely to avoid suspension block & no rocking of
turn tables.
• Check for any damage of the rims or bushes & suspension joints/ wheel end for play.
• Ensure that the front turntables & rear plates are at the same level.
• Do the setting of front steering wheel for Straight Ahead Position (SAP) and lock the steering
column rotation.
For setting Straight Ahead Position, Refer the procedure given below
1. Keep the wheels on turntables of the wheel alignment machine.
2. Rotate the steering wheel to LHS lock position.
3. From LHS lock position, rotate steering wheel to RHS Lock position.
4. Count the number of turns of steering wheel from LHS to RHS lock position.
5. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.
6. Lock the steering wheel.
7. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of
the desired side (the number of threads on each side may not be equal).
• Ensure that the silent bushes in the front suspension are in satisfactory condition.
• Ensure that the front suspension fasteners are tightened to specified torque.
• Ensure that there is no play in steering linkages and suspension ball joints.
• Follow instruction manual of wheel alignment machine manufacturer.
29.1 Specification for Wheel Alignment
PARAMETER SPECIFICATION
Camber 0.6°±1°
Caster 4.6°±1°
King pin Inclination 12.8°±2°
Individual Toe 0°10'
Total Toe 0°20'±7'
Difference between LH & RH toe 0°5' Max
29.2 Wheel Alignment —Toe Adjustment
1. Using 17mm open end spanner, loosen the 2. Insert 15mm open end spanner in the tie
ball joint lock nuts 1 on each RH and LH tie rod slot located at the middle and end of the tie
rods. rod, rotate the tie rod to meet the requirements
0°20'±7'.
P5AMM0107
P5AMM0108
• Hold tie rod using 15 mm open end

spanner while loosening the lock nut.
Nut/ Bolt description Quantity Torque Value – Nm
Tie rod Adjustment nut 02 42±5
! CAUTION
• Wheel alignment to be carried if any abnormal conditions are noticed or at 40000kms,
whichever is earlier.
• Wheel alignment procedure to be done in vehicle unladen condition only.
• Do wheel alignment only according to manufacturer's specifications.
• Front tyre should have uniform wear and inflated to recommended pressure.
• Ensure that hub play is correct.
• Ensure that the front suspension fasteners are tightened to specified torque.
• Ensure that there is no play in steering linkages and suspension ball joints.
30 726-MAT-0161/ Battery Electrolyte - Inspect/ 0.05 HRS
Tools Required
Size Type Quantity
10mm Open end or Ring spanner 01
- Eye protector goggles 01
- Flat end screw driver 01
1. Park the vehicle on a level ground.
Battery Electrolyte Level - Inspect
P5AMM0109
1. Ensure the electrolyte level between MIN and MAX marks.

2. If the electrolyte level is less than the MIN mark, top up the electrolyte to the MAX level with
distilled water.
• Topping up should be done with distilled water only.

• Never use normal water or mineral water to top battery electrolyte.
• Vent holes should be clear.
• Clean the terminals.
3. Tighten terminals to specified torques.
30.1 Adding Distilled Water:
P5AMM0110
• Remove the vent plugs.

• Add distilled water to all the cells which require water.
• Refit the vent plugs properly
! CAUTION
• Check battery electrolyte at every 10000kms.
31 726-MAT-0162/ Battery Specific Gravity - Inspect / 0.10 HRS
Tools Required
Size Type Quantity
10mm Open end or Ring spanner 01
- Hydrometer 01
- Eye protector goggles 01
- Flat end screw driver 01
1. Park the vehicle on a level ground.
2. Ensure the electrolyte level between MIN and MAX marks.
3. If the electrolyte level is less than the MIN mark, top up the electrolyte to the MAX level with
distilled water.
Battery Specific Gravity - Inspect
P5AMM0109
31.1 Specific Gravity Readings:

By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully
charged, requires charging, or must be replaced.
The specific gravity for fully charged battery is as follows:
1. EXIDE 1.240
1. Wear suitable eye protectors (goggles). 6. Note the reading for all the cells. The
difference in specific gravity readings should not
be more than 0.05.
P5AMM0110
2. With the help of a flat end screw driver,

remove the vent caps or covers from the
battery.
3. Squeeze the hydrometer bulb and insert
the pickup tube into the cell close to the battery
positive terminal.
4. Slowly release the bulb to draw in only
enough electrolyte to cause the float to rise. Do
not remove the tube from the battery.
5. Read the specific gravity indicated on the
float. Be sure the float is drifting free, and does
not contact with sides of the barrel. Read the
hydrometer at eye level. Disregard the slight
curvature of liquid on the float.
S UCTION
BULB
FLOAT
HYDROMETER
OUTER TUBE
PICKUP ELECTROLYTE
TUBE P5AMM0139
Specific Gravity v/s With% Charge
% C ha rge d Cell Reading (EXIDE) Cell Reading (AMARON)

100 1.280 1.270
75 1.250 1.230
50 1.200 1.190
25 1.140 1.145
0 1.075 1.100
Specific Gravity v/s With OCV
S.NO Specific Gravity OCV

1 1.2 12.3
2 1.21 12.36
3 1.22 12.42
4 1.23 12.48
5 1.24 12.54
6 1.25 12.6
7 1.26 12.66
8 1.27 12.72
9 1.275 12.75
10 1.28 12.78
Battery positive cable 3±1
Battery negative cable 3±1
! CAUTION
• Specific gravity varies with the temperature. If the electrolyte temperature is substantially
above 27 deg. C add seven points (0.007) to the observed specific gravity reading for every
10 deg. C by which the actual temperature is above 27 deg.C.
• Deduct seven points per 10 deg C where the observed reading is below 27 deg. C to obtain
the temperature corrected reading at 27 deg. C.
• Check battery specific gravity at every 10,000kms.
32 726-MAT-0163/ All Light, Horn, Wiper, Washer - Check / 0.05

HRS
1. A - Left Turn Indicator 3. Lamps Off

For inspection, rotate the outer rotary switch on
A the lighting control stalk aligning the “dot” on the
switch to “O” on the stalk to switch OFF all
exterior lamps.
OFF B
OFF
P52H04
P5AMM0111
• For inspection, push the lighting control stalk

anti-clockwise (to stop position A) to indicate
a left turn. The instrument cluster arrow
P52H03
lamp pointing towards the left flashes along P5AMM0112
with the left side turn signal lamps with

chime indicating your intention of turning 4. Parking Lamps On
towards left. For inspection, rotate the outer rotary switch on
• After you have completed your right turn, the the lighting control stalk aligning the “dot” on the
stalk will automatically return to the neutral switch to the “1st detent” position on the stalk
position. Both the right turn lamp and the to switch ON the parking lamps.
right turn signal lamp switch OFF.
2. B- Right Turn Indicator
For inspection, push the lighting control stalk
clockwise (to stop position B) to indicate a right
turn. The instrument cluster arrow lamp
pointing towards the right flashes along with the OFF
right side turn signal lamps with chime
indicating your intention of turning towards
right.
P52H05
P5AMM0113
! CAUTION
The tail lamp, license plate lamp, side
marker lamps and instrument panel
illumination lamps are also activated when
the Parking lamp is switched ON
.
5. Head Lamp On 7. Head Lamp Flash

For inspection, rotate the outer rotary switch on
the lighting control stalk aligning the “dot” on the
switch to the “2nd detent” position on the stalk
to switch ON the head lamps.
OFF
OFF
P52H08
P5AMM0116
• For inspection, pull the lighting control stalk

(from the head lamp low beam position)
towards the steering wheel to
P52H06
P5AMM0114
instantaneously flash the head lamp high
6. Head Lamp High/Low Beam beam.
The head lamp flash works even when the
A head lamp is OFF.(but IGN ON Condition)
OFF
C
P52H07
P5AMM0115
A Head lamp flash/pass

B Low Beam
C High Beam
• For inspection, with the head lamp ON, push

the lighting control stalk down (away) from
steering wheel to switch ON the head lamp
high beam. The head lamp high beam tell-tale
lamp in the instrument cluster illuminates
indicating high beam option selected.
• With the head lamp high beam ON, pull the
lighting control stalk up towards the steering
wheel to switch ON the head lamp low beam.
8. Head Lamp Levelling System 10. Hazard Warning Lamp

100
km
ODO
H F
SET C
AM
E MODE
40 km/h 60
20 80
100
km
ODO
H F
SET C
AM
E MODE
1 0
P5AMM0117 P52H10
P5AMM0119
P52H09
When the vehicle is either fully or partially • The hazard warning lamp switch is located
loaded, it may have an upward inclination on the steering column in front of the
disturbing the head lamp aiming. A correct instrument cluster.
head lamp setting provides good visibility to the • To turn the hazard warning lamp ON, pull the
driver with minimum inconvenience to other
switch up. All the turn signal lamps flash. The
road users.
instrument cluster turn indicator lamps also
To properly aim the head lamp beam, use the flash indicating the same. To turn OFF, push
head lamp levelling switch. This switch is located the switch down.
on the right side of the steering column shroud • Use the hazard warning lamp when your
in the instrument panel. This switch has two vehicle is stationary or to warn other road
positions marked as 0, 1. users to be cautious while passing your
0- Driver only or Driver with Passenger vehicle.
1- Driver + Front passenger + Load occupied 11. WindShield Wiper/Wash Off
The head lamp levelling should be done when

the head lamp low beam is ON. HI
9. Courtesy Lamps LO P ULL
OFF
ON DOOR OFF
P52H14
P5AMM0120
• The image shows the windshield wiper wash

is in OFF position.
P5AMM0118
P22H10
• The courtesy lamp can be switched ON/OFF

by the switch on the lamp. Ensure to switch
off the lamp before locking/getting out the
vehicle.
12. Wiper Low Speed 13. Wiper High Speed
HI HI
LO P ULL LO P ULL
OFF OFF
P52H15
P5AMM0121 P52H15
P5AMM0122
• Rotate the outer rotary switch on the wiper • Pull/Lift the wiper stalk towards the steering
control stalk to align the “dot” on the switch wheel from any position to activate wash
to wiper to operate at low speed. function. The wiper operates simultaneously
• The wipe/wash function can be activated as long as the wash function is active.
only when the ignition is in “ON” position
The wipe/wash function can be activated

only when the ignition is in “ON” position. If
you switch off the ignition before switching
off the wiper, the blades stop at random on
the windscreen. When the ignition is
switched on again, the wiper blades return
to the resting position provided the wipe/
wash stalk is in OFF position.
! CAUTION
Do not operate the wipers when the
windshield is dry. It may lead to scratches
on the glass. It is recommended not to use
the wiper when the windshield glass is
covered with debris, snow or leaves. Clean
the glass before using the wiper to avoid
damage to the wiper blades and glass. Do
not operate the windshield washer for more
than 10 seconds or when the reservoir is
empty.
14. Horn
40 km/h 60
20 80
100
km
ODO
H F
SET C
AM
E MODE
P52H13
P5AMM0123
Press the pad on the steering wheel to blow/

sound the horn. The horn functions even when
the ignition has been switched OFF.
! CAUTION
• Inspect all lights, Warning lights, Horns, Wiper and washers first at 3,000kms,
10,000kms and thereafter every 10,000kms.
33 726-MAT-0122/ Tyre Pressure- Adjust & Inspect/ 0.05 HRS

Proper tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle.
Three primary areas are affected by improper tyre pressure.
• Safety
• Economy
• Ride Comfort and Vehicle Stability
Proper tyre inflation contributes to a comfortable and safe ride. Over inflating produces harsh and
uncomfortable ride. Both under inflation and over inflation affect the stability of the vehicle and can
produce a feeling of sluggish response or over responsiveness in the steering. Unequal tyre
pressures can cause erratic and unpredictable steering response or may cause the vehicle to drift
left or right. Improper inflation pressures can cause uneven wear patterns to develop across the
tyre tread. These abnormal wear patterns will reduce tread life resulting in a need for earlier tyre
replacement. Under inflation also increases tyre rolling resistance and results in higher fuel
consumption.
33.1 Tyre Pressure Value
LD - Laden HD - Laden
Front Rear Front Rear
Kg/cm2 PSI Kg/cm2 PSI Kg/cm2 PSI Kg/cm2 PSI
1.8 26 3.0 43 1.8 26 3.5 50
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 refit dust cap on valve seats after checking tyre pressure.
! CAUTION
• Inspect tyre pressure first at 3,000kms, then at 10,000kms and thereafter every
10,000kms, do adjustment if required.
• Never overload your vehicle. Overloading can cause tire failure, affect vehicle handling, and
increase your stopping distance, resulting in an accident and/or personal injury.
• Improper inflated tires can adversely affect vehicle handling or can fail unexpectedly,
resulting in an accident and/or personal injury.
• Under-inflation is the most common cause of tyre failures and may result in severe tyre
cracking, tread separation or "blowout", with unexpected loss of vehicle control and
increased risk of injury. Under-inflation increases sidewall flexing and rolling resistance,
resulting in heat build-up and internal damage to the tyre. It also may result in unnecessary
tyre stress, irregular wear, loss of vehicle control and accidents.
• Combining radial ply tires with other types of tires on your vehicle will cause your vehicle to
handle poorly, resulting in an accident and personal injury. Always use radial tires in sets of
four. Never combine them with other types of tires.
34 726-MAT-0121/ Tyre Rotation/ 0.20 HRS
1. Position the vehicle on 2 post lift or ground.
34.1 Tyre Rotation

Tyres on the front and rear side of vehicles operate at different loads and perform different steering,
handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular
wear patterns. Rotation will increase tread life, help to maintain mud, snow, and wet traction levels,
and contribute to a smooth, quiet ride. Follow the recommended tyre rotation.
Below illustration shows suggested tyre rotation method:
P5AMM0124
Wheel Nut 120±10
Proper tyre inflation contributes to a comfortable and safe ride. Over inflating produces harsh and
uncomfortable ride. Both under inflation and over inflation affect the stability of the vehicle and can
produce a feeling of sluggish response or over responsiveness in the steering. Unequal tyre
pressures can cause erratic and unpredictable steering response or may cause the vehicle to drift
left or right. Improper inflation pressures can cause uneven wear patterns to develop across the
tyre tread. These abnormal wear patterns will reduce tread life resulting in a need for earlier tyre
replacement. Under inflation also increases tyre rolling resistance and results in higher fuel
consumption.
! CAUTION
• Tyre rotation need to be carried out at every 10,000kms.
35 726-MAT-0182/ Cargo Mounting Bolts - Inspect/ 0.20 HRS
35.1 Inspect and ensure the cargo bottom mounting bolts are with proper
torque as recommended:
P5AMM0125
35.2 Inspect and ensure the cargo top mounting bolts are with proper torque as
recommended.
P5AMM0126
Cargo Mounting Bolts 25±5
! CAUTION
Cargo mounting bolts need to be inspected first at 3,000kms, 20,000kms and thereafter
every 20,000kms.
36 726-MAT-0185/ Door Latches & Door Locks - Lubricate/ 0.05

HRS
1. Position the Vehicle on Flat Surface.
Door latches and locks– Lubrication
P5AMM0127
! CAUTION
Lubricate the door latches & locks first at 3,000kms, 10,000kms and thereafter every
10,000kms.
37 Maintenance Check Sheet
• The task list for scheduled maintenance is available in menu pricing system of DMS.
• The maintenance check list given in the upcoming pages can be used by dealers where
DMS is not available.
37.1 Maintenance Check Sheet @3000Kms
WORK NATURE AC- WORK STATUS Time

TION Allotted
Complete Incom- (Man-hours)
plete
Engine oil R 0.15
Engine oil filter R 0.05
Coolant I 0.10
Air filter element C 0.10
Draining water in fuel filter D 0.05

Clutch free play A
0.15
Brake fluid level & leak I 0.05
All Lights, Horns, Wipers & Washers I 0.05
Tyre pressure I 0.05
Cargo mounting bolts for tightness I 0.20
Door latches, door lock L 0.05
Road Test I
Additional Repair Work carried out, if any -
1)
Observations, Notes if any -
1)
Above Services Performed by – Job Start Time:
Name of the Technician –

TION Allotted
plete
Date of Service – Job End Time:
Repair order No –
Repair order date - Standard Time: 1 man-hrs.
37.2 Maintenance Check Sheet @10,000Kms

TION Allotted
plete
Engine oil R 0.15
Coolant I 0.10
Clutch free play A 0.15
Brake fluid - level & leak I 0.05
Front and rear Brakes I 0.40
Battery electrolyte level I 0.05
Battery electrolyte specific gravity I 0.10
Tyre rotation I 0.20
Road Test I
1)
1)

TION Allotted
plete
Repair order No –
Repair order date - Standard Time: 1.55 man-hrs.

TION Allotted
plete
Engine oil R 0.15
Coolant I 0.10
Transaxle oil R 0.15

Parking brake A 0.15
Suspension bushes I 0.10
Suspension arms & links I 0.10
Road Test I
1)

TION Allotted
plete
1)
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Coolant I 0.10
Air filter element R 0.05
Fuel filter assy. R 0.10
Brake fluid - level & leak R 0.30
Road Test I
1)
1)

TION Allotted
plete
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Coolant R 0.20

Wheel alignment * I 0.40
Road Test I
1)

TION Allotted
plete
1)
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Coolant I 0.10

Clutch free play A
0.15
Road Test I
1)
1)

TION Allotted
plete
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Timing belt I 0.65
Alternator belt I 0.05
Coolant I 0.10
Fuel filter assy R 0.10
Road Test I

TION Allotted
plete
1)
1)
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Coolant I 0.10
Road Test I
1)
1)

TION Allotted
plete
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Timing belt I 0.65
Alternator belt I 0.05
Coolant R 0.20
Wheel alignment * I 0.40
Road Test I

TION Allotted
plete
1)
1)
Repair order No –

TION Allotted
plete
R
Engine oil 0.15
Coolant I 0.10
Fuel filter assy R 0.10
Road Test I
1)
1)

TION Allotted
plete
Repair order No –

TION Allotted
plete
Engine oil R 0.15
Timing belt R 0.70
Alternator belt R 0.10
Coolant I 0.10
Road Test I

TION Allotted
plete
1)
1)
Repair order No –

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Jeeto Maintenance Manual

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Maintenance Manual

1 About the Maintenance Manual

1.1 Maintenance Schedule

1.2 Standard Operating Procedures(SOP)

1.3 Check Sheets

2 Explanation on Colour Codes Used In Illustrations

Fas t ener or s ub component

3 Good Workshop Practices

3.2 Vehicle Protection

3.4 Parts And Tools

3.5 Removed Parts

4 Legend Of The Safety Symbols

Term/ Symbol Denotation

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

Indicates important information relevant to the

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

4.1 Legend Of The Symbols

Dis - assembly Sequence

OIL Lubrication Symbol (oil)

Lubrication Symbol (Semi solid)

5 JEETO Maintenance Schedule

6 JEETO lubrication Chart

System Lubricant Capacity Specification Remarks

7 JEETO Maintenance Parts List

Sl No Part No Description Quantity

1 0311AAC00260N Engine oil drain plug washer 01

2 0303BAU00261N Oil filter 01

3 0306GAU00081N Belt 3PK (Alternator drive Belt) 01

4 0310AAU00231N Timing Belt 01

5 0313AAU02031N Element air filter 01

6 1001CAB00411N Fuel filter assy 01

7 SF0401063 Transaxle Drain plug washer 01

8 0703DK0800N Filler plug (Transaxle filler plug 01

9 EOECOPRE20 MAXIMILE PREMIUM ECO 02 liters

10 TMOUV2SYN20 MAXIMILE SYNCRO UV2 1.25 liters

8 726-MAT-0012/ Engine Oil- Replace/0.15 HRS

Size Type Quantity

22mm Ring / Socket 01

8.1 Engine Oil Draining Procedure

1. Open the filler plug.

2. Using 22mm ring/socket spanner, remove

3. Allow the entire oil to get drained.

Place a tray under the drain plug to collect

8.2 Engine Oil Filling Procedure

8. Insert the dip stick back and fix properly,

Nut/ Bolt description Torque Value – Nm

Engine oil drain plug 27.5 ± 2.5

9 726-MAT-0013/ Engine Oil Filter- Replace /0.05 HRS

Size Type Quantity

9.1 Engine Oil Filter — Removal

1. Grip the engine oil filter firmly using an oil

9.2 Engine Oil Filter - Installation

• Always tighten the oil filter using hands.

10 726-MAT-0017/ Timing Belt- Inspect/ 0.65 HRS

10.1 Timing Belts—Inspection

2. CHUNK OUT – Pieces or chunks of rubber

11 726-MAT-0018/ Timing Belt- Replace/ 0.70 HRS

Size Type Quantity

10mm Socket spanner 01

24mm Socket spanner 01

11.1 Timing Belts—Removal

11.2 Timing Belts - Installation