Repair Manual

MAN-00591
REPAIR MANUAL
MAHINDRA PIKUP E2 E4
LHD
SC/DC Diesel

Revision — 1
MAY - 2018
Published by — Service Engineering
Technical Hub
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Table of Content
1 GENERAL INFORMATION ......................................................................................... 29
1.1 Introduction ................................................................................................................... 29
1.1.1 Important Instructions ......................................................................................... 29
1.1.2 Contents in the manual....................................................................................... 29
1.1.3 Dimensions ............................................................................................................ 32
1.1.4 Technical Specification ....................................................................................... 35
1.1.5 Maintenance Schedule ....................................................................................... 38
1.1.6 Lubrication Chart .................................................................................................. 43
1.1.7 Explanation on Color Codes used in Illustrations ....................................... 44
1.1.8 Good Workshop Practices ................................................................................. 45
1.1.9 Legend of the Safety Symbols ......................................................................... 46
1.1.10 Legend of the Symbols .................................................................................... 47
1.2 General Precautions................................................................................................. 48
1.2.1 Towing your Vehicle During Emergency ........................................................ 50
1.2.2 Towing Equipment ............................................................................................... 52
1.2.3 Service Precautions ............................................................................................ 54
1.3 Jacking and Lifting.................................................................................................... 59
1.3.1 Jacking .................................................................................................................... 60
2 ENGINE - mHAWK .......................................................................................................... 63

2.1 Description & Operation ........................................................................................ 63

2.1.1 Engine System ...................................................................................................... 63
2.1.2 Cylinder Head ....................................................................................................... 64
2.1.3 High Pressure Pump (HPP) .............................................................................. 65
2.1.4 Oils Separators ..................................................................................................... 65
2.1.5 Oil Cooler................................................................................................................ 65
2.1.6 Oil Filter ................................................................................................................... 66
2.1.7 Oil Sump/ Pan ....................................................................................................... 66
2.1.8 Oil Strainer ............................................................................................................. 66
2.1.9 Oil Dipstick ............................................................................................................. 67
2.1.10 Oil Pressure Switch ........................................................................................... 67
2.1.11 Injectors ................................................................................................................ 68
2.1.12 Cylinder Block ..................................................................................................... 68
2.1.13 Piston .................................................................................................................... 69
2.1.14 Connecting Rods ............................................................................................... 70
2.1.15 Crank Shaft.......................................................................................................... 70
2.1.16 Roller Finger (RFF) and Lash Adjuster (HLA) Assembly ....................... 71
2.1.17 Intake and Exhaust Valve ................................................................................ 72
2.1.18 Valve Gear Drive ................................................................................................ 73
2.1.19 Cam Shafts .......................................................................................................... 73
2.1.20 Engine Speed Sensor (Crank Shaft Sensor) ............................................. 74
2.1.21 Glow Plug ............................................................................................................. 74
2.1.22 Cam Phase Sensor ........................................................................................... 75

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 3
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.23 EMS ECU ............................................................................................................. 75

2.1.24 Accessory Drive Belt Auto-tensioner’s ........................................................ 76
2.1.25 Accessory Drive Belts ...................................................................................... 76
2.1.26 Damper Pulley .................................................................................................... 77
2.1.27 Engine Insulator / Mount .................................................................................. 77
2.1.28 Vacuum Pump .................................................................................................... 77
2.1.29 Inlet Manifold ....................................................................................................... 78
2.1.30 Exhaust Manifold ............................................................................................... 78
2.2 Component Location Index .................................................................................. 79
2.2.1 Engine View 1 ....................................................................................................... 79
2.2.2 Engine View 2 ....................................................................................................... 80
2.2.3 Engine View 2 – Euro II ...................................................................................... 81
2.3 Trouble Shooting........................................................................................................ 82
2.4 Engine Cylinder Head Gasket Failure ............................................................. 87
2.4.1 Diagnosis ............................................................................................................... 87
2.5 Engine Overheats ...................................................................................................... 87
2.6 Excessive Oil Consumption ................................................................................. 88
2.7 Standard Checking Procedure ........................................................................... 89
2.7.1 Cylinder Compression Test ............................................................................... 89
2.7.2 Cylinder Head Gasket Failure Test ................................................................. 90
2.7.3 Hydrostatically Locked Engine ......................................................................... 91
2.7.4 Bearing Inspection ............................................................................................... 92
2.7.5 Cam shaft Bearing Journal Diameter ............................................................. 92
2.7.6 Crankshaft End play Inspection ....................................................................... 92
2.7.7 Cylinder Bore Taper Check ............................................................................... 93
2.7.8 Piston Diameter .................................................................................................... 93
2.7.9 Piston Inspection .................................................................................................. 94
2.7.10 Piston Ring-to-groove Clearance .................................................................. 94
2.7.11 Valve Seat Inspection ....................................................................................... 95
2.7.12 Piston Ring End Gap ........................................................................................ 95
2.7.13 Valve Stem Diameter ........................................................................................ 95
2.8 Care of the System .................................................................................................... 96
2.8.1 Service Tips and Precautions ........................................................................... 96
2.8.2 Engine Oil - Replace ........................................................................................... 97
2.8.3 Engine Oil Filter — Replace ............................................................................103
2.8.4 Auto Tensioner & Accessory Drive Belt - Inspect......................................107
2.8.5 Accessory Drive Belts and Auto Tensioner - Replace ............................. 114
2.9 In Car Repairs ............................................................................................................ 117
2.9.1 Engine Assembly R&R ..................................................................................... 117
2.9.2 Damper Pulley R&R .........................................................................................127
2.9.3 Crankshaft Front End Oil Seal R&R .............................................................131
2.9.4 Crankshaft Rear End Oil Seal R&R ..............................................................135

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
4 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.5 Cylinder Head and Gasket R&R ....................................................................139

2.9.6 Cam Shafts R&R ................................................................................................146
2.9.7 Front Timing Chain Cover R&R .....................................................................154
2.9.8 Timing Chain & Sprocket R&R .......................................................................158
2.9.9 Hydraulic Lash Adjuster R&R .........................................................................167
2.9.10 Intake Manifold R&R .......................................................................................170
2.9.11 Oil Sump R&R ...................................................................................................177
2.9.12 Oil Strainer R&R...............................................................................................181
2.9.13 Engine Mountings R&R..................................................................................184
2.9.14 Oil Cooler and Oil Filter Assembly R&R ....................................................188
2.9.15 Glow Plug (Cylinder No. 1) - R&R ...............................................................193
2.9.16 Glow Plugs (Cylinder No. 2,3 & 4) - R&R .................................................197
2.9.17 Vacuum Pump R&R .......................................................................................201
2.9.18 Cam Phase Sensor R&R ..............................................................................205
2.9.19 Crank Shaft Sensor R&R...............................................................................209
2.9.20 Dip Stick Guide R&R .....................................................................................212
2.9.21 Oil Pressure Switch R&R .............................................................................216
2.9.22 EMS ECU R&R ...............................................................................................219
2.10 Disassembly and Assembly ............................................................................222
2.10.1 Cylinder Head Assembly ..............................................................................222
2.10.2 Cylinder Block Disassembly & Assembly .................................................231
2.10.3 Testing: ...............................................................................................................243
2.11 Specification and Wear Data ...........................................................................244
2.12 Lubricants & Sealants.........................................................................................248
2.12.1 Lubricants ..........................................................................................................248
2.12.2 Sealants .............................................................................................................248
2.12.3 Accessory Drive Belts Tension Values ......................................................249
2.12.4 Honing Specifications .....................................................................................250
2.12.5 Oil Cooler Position with respect to Oil Filter Module Mounting
Face .....................................................................................................................251
2.12.6 Sealant Application Pattern ..........................................................................252
2.13 Tightening Specifications & Sequence .....................................................261
2.13.1 Tightening Specifications ..............................................................................261
2.13.2 Tightening Sequence......................................................................................269
2.14 Mahindra Special Tools (MST)........................................................................284
3 AIR INTAKE SYSTEM ..................................................................................................287
3.1 Description & Operation ......................................................................................287
3.1.1 Air intake System ...............................................................................................287
3.1.2 Crank case ventilation system........................................................................288
3.1.3 Air filter element ..................................................................................................289
3.1.4 Oil Separator .......................................................................................................289
3.1.5 Intercooler ............................................................................................................290
3.1.6 Turbo Charger .....................................................................................................290

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 5
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.1.7 HFM Sensor.........................................................................................................291

3.1.8 Boost Pressure Sensor ....................................................................................291
3.2 Component Location Index ................................................................................292
3.2.1 Air intake System View .....................................................................................292
3.3 Trouble Shooting......................................................................................................293
3.3.1 Symptom based Trouble Shooting ................................................................293
3.3.2 Component Inspection and Action Table.....................................................295
3.4 Care of the system...................................................................................................296
3.4.1 Service Tips and Precautions .........................................................................296
3.4.2 Do’s & Don’ts For Turbocharger Assembly ................................................296
3.4.3 HFM Sensor Cleaning ......................................................................................297
3.4.4 Air Filter Element — Replace .........................................................................299
3.5 In Car Repairs ............................................................................................................303
3.5.1 Air Cleaner Duct Dirty Side R&R ...................................................................303
3.5.2 Air Cleaner housing assembly R&R .............................................................307
3.5.3 Air cleaner Clean hose turbo side R&R .......................................................312
3.5.4 Intercooler assembly R&R...............................................................................316
3.5.5 Intercooler Inlet Hose R&R..............................................................................321
3.5.6 Intercooler Outlet Hose R&R ..........................................................................325
3.5.7 Oil Separator assembly R&R ..........................................................................329
3.5.8 Oil Separator Breather Hose R&R ................................................................333
3.5.9 NVH Engine Top Cover R&R ..........................................................................337
3.5.10 Turbo Charger Assembly R&R ....................................................................341
3.5.11 Boost Pressure Sensor R&R ........................................................................350
3.5.12 HFM Sensor R&R ............................................................................................353
3.6 Technical Specification ........................................................................................357
3.6.1 Specification ........................................................................................................357
3.7 Torque Specification ..............................................................................................358
3.7.1 Tightening Specification ...................................................................................358
4 EXHAUST & EMISSION CONTROL SYSTEM ..........................................359
4.1 Description & Operation ......................................................................................359
4.1.1 Exhaust System..................................................................................................359
4.1.2 Major pollutants in diesel engine: ..................................................................360
4.1.3 Emission Control System.................................................................................360
4.1.4 EGR System Layout ..........................................................................................361
4.1.5 EGR System Layout — Euro II.......................................................................362
4.1.6 Crankcase ventilation .......................................................................................363
4.1.7 Exhaust Manifold................................................................................................364
4.1.8 Catalytic Converter (Pre & Post)....................................................................365
4.1.9 Muffler....................................................................................................................365
4.1.10 EGR Valve .........................................................................................................366

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
6 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.11 EGR Cooler .......................................................................................................366

4.1.12 Vacuum Modulator ..........................................................................................366
4.1.13 Turbocharger Oil Outlet (Drain) Pipe .........................................................367
4.1.14 Turbocharger Oil inlet Pipe ...........................................................................367
4.1.15 EGR Pipe ...........................................................................................................367
4.1.16 EGR Pipe — Euro II ........................................................................................368
4.2 Component Index.....................................................................................................369
4.2.1 Exhaust System View .......................................................................................369
4.2.2 Emission Control System View ......................................................................370
4.3 Trouble Shooting......................................................................................................371
4.3.1 Symptom Possible Causes .............................................................................371
4.3.2 Component Inspection and Action Table.....................................................373
4.4 Care of the System ..................................................................................................374
4.4.1 Service Tips & Precautions .............................................................................374
4.5 Exhaust pipe mountings and damage/leakage - Inspect ...................375
4.6 In Car Repairs ............................................................................................................378
4.6.1 Exhaust Manifold R&R .....................................................................................378
4.6.2 Pre Catalytic Converter R&R ..........................................................................383
4.6.3 Post Catalytic Converter R&R ........................................................................387
4.6.4 Exhaust Upper Pipe R&R ................................................................................391
4.6.5 Exhaust Lower Pipe R&R ................................................................................394
4.6.6 Muffler Assembly R&R .....................................................................................397
4.6.7 EGR Valve R&R..................................................................................................401
4.6.8 EGR Cooler R&R ...............................................................................................404
4.6.9 EGR Cooler Long Pipe (Cooler to Intake Manifold) R&R ....................... 411
4.6.10 EGR Long Pipe (EGR Valve to Intake Manifold) R&R — Euro
II ............................................................................................................................416
4.6.11 Cylinder Head Outlet to EGR Cooler Pipe R&R ......................................421
4.6.12 EGR Short Pipe (Exhaust Manifold to EGR Valve) R&R ......................426
4.6.13 EGR Short Pipe (Exhaust Manifold to EGR Valve) R&R — Euro
II ............................................................................................................................429
4.6.14 Vacuum Modulators R&R ..............................................................................432
4.7 Torque Specification ..............................................................................................435
4.7.1 Tightening Specification ...................................................................................435
5 FUEL SYSTEM ..................................................................................................................437
5.1 Description & Operations ....................................................................................437
5.1.1 Fuel Supply System ..........................................................................................437
5.1.2 Fuel supply layout ..............................................................................................438
5.1.3 Injectors ................................................................................................................438
5.1.4 Common rail ........................................................................................................439
5.1.5 High pressure pump ..........................................................................................439

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 7
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.1.6 Fuel filter ...............................................................................................................440

5.1.7 Fuel Rail Pressure Sensor...............................................................................440
5.1.8 Fuel Tank and Strainer .....................................................................................440
5.1.9 High Pressure Fuel Lines (CR to Injectors) ................................................441
5.1.10 High Pressure Fuel Line ( PF Pump to CR) .............................................441
5.1.11 Fuel Filler Pipe ..................................................................................................441
5.2 Component Location Index ................................................................................442
5.2.1 Fuel System View 1 ...........................................................................................442
5.2.2 Fuel System View 2 ...........................................................................................443
5.3 Standard Checking Procedure .........................................................................444
5.3.1 Injector Leak off Test .........................................................................................444
5.4 Trouble Shooting......................................................................................................447
5.4.1 Symptom Possible Causes .............................................................................447
5.4.2 Component Inspection and Action Table.....................................................448
5.5 Care of the system...................................................................................................450
5.5.1 Service Tips and Precautions .........................................................................450
5.5.2 Do’s and Don’ts ..................................................................................................451
5.5.3 IQA Management ...............................................................................................452
5.5.4 Fuel Filter Element — Replace ......................................................................453
5.5.5 Water Sediment Drain– Fuel Filter ................................................................459
5.6 In Car Repairs ............................................................................................................461
5.6.1 Fuel Filter assembly R&R ................................................................................461
5.6.2 Injector R&R ........................................................................................................465
5.6.3 Common Rail (CR) R&R ..................................................................................471
5.6.4 High Pressure Pump R&R ...............................................................................475
5.6.5 Injector Leak-off Pipe R&R ..............................................................................482
5.6.6 High Pressure Pipes (Common Rail to Injector) R&R .............................485
5.6.7 Fuel Pipe (High Pressure Pump to Common Rail) R&R .........................489
5.6.8 Fuel Line (Fuel filter to High Pressure Pump) R&R..................................493
5.6.9 Fuel Pipe Main (Tank to Fuel Filter) R&R ....................................................497
5.6.10 Fuel Return Line (High Pressure pump to Fuel Tank) R&R.................501
5.6.11 Fuel Filler Pipe/ Hose & Breather Hose Assembly R&R.......................505
5.6.12 Fuel Filler Neck Assembly R&R ..................................................................509
5.6.13 Fuel Tank & Strainer Assembly R&R .........................................................513
5.6.14 Fuel Tank Gauge Unit R&R...........................................................................519
5.7 Technical Specification ........................................................................................522
5.7.1 Specification ........................................................................................................522
5.8 Torque Specification ..............................................................................................523
5.8.1 Tightening Specification ...................................................................................523
5.9 Mahindra Special Tools (MST) ..........................................................................524

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
8 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6 COOLING SYSTEM .......................................................................................................525

6.1 Description and Operation..................................................................................525
6.1.1 Radiator ................................................................................................................526
6.1.2 Degassing tank ...................................................................................................526
6.1.3 Coolant Temperature Sensor..........................................................................526
6.1.4 Viscous Fan .........................................................................................................527
6.1.5 Thermostat ...........................................................................................................527
6.1.6 Water Pump .........................................................................................................528
6.1.7 Viscous Fan Logic..............................................................................................528
6.2 Component Location Index ................................................................................529
6.3 Component Location Index — Euro II...........................................................530
6.4 Trouble Shooting......................................................................................................531
6.4.1 Component Inspection Table ..........................................................................534
6.5 Standard Checking Procedures .......................................................................535
6.5.1 Water Pump Leakage Test ..............................................................................535
6.5.2 Thermostat Valve Test ......................................................................................535
6.5.3 Cooling System Leakage Test ........................................................................536
6.6 Care of the System ..................................................................................................537
6.6.1 Coolant Level & Leak - Inspect ......................................................................539
6.6.2 Coolant - Replace ..............................................................................................544
6.7 In Car Repairs ............................................................................................................547
6.7.1 Degassing Tank R&R ........................................................................................547
6.7.2 Viscous Fan R&R ...............................................................................................551
6.7.3 Thermostat R&R.................................................................................................557
6.7.4 Hose Radiator to Degassing tank R&R .......................................................560
6.7.5 Hose assembly radiator outlet R&R..............................................................564
6.7.6 Water Pump R&R ...............................................................................................569
6.7.7 Radiator R&R ......................................................................................................573
6.7.8 Coolant Temperature Sensor R&R ...............................................................581
6.7.9 Thermostat Inlet Hose R&R ............................................................................585
6.7.10 Oil Cooler Inlet Hose R&R ............................................................................588
6.7.11 Oil Cooler Outlet Hose R&R .........................................................................591
6.7.12 EGR Cooler Inlet Hose R&R ........................................................................594
6.7.13 Heater Inlet Hose R&R...................................................................................597
6.7.14 Heater Outlet Hose R&R ...............................................................................601
6.8 Specifications & Wear Data ................................................................................605
6.9 Tightening Specifications & Sequence........................................................606
7 CHARGING SYSTEM ...................................................................................................607
7.1 Description and Operation..................................................................................607

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 9
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.1.1 Charging System Overview ............................................................................607

7.1.2 Battery ...................................................................................................................607
7.1.3 Alternator (With OAP) & Voltage Regulator ................................................607
7.1.4 Alternator Drive Belt ..........................................................................................608
7.2 Component Location Index ................................................................................609
7.2.1 Charging System................................................................................................609
7.3 Trouble Shooting......................................................................................................610
7.3.1 Component Inspection and Action Table..................................................... 611
7.3.2 Diagnosis and Testing.......................................................................................612
7.4 Standard Checking Procedure .........................................................................613
7.4.1 Visual Inspection ................................................................................................613
7.4.2 Open Circuit Voltage Test ................................................................................613
7.4.3 Dark Current Test. ..............................................................................................615
7.5 Care of the System ..................................................................................................616
7.5.1 Do’s and Don’ts of Charging System............................................................616
7.5.2 Service Tips and Precautions .........................................................................617
7.5.3 Maintenance ........................................................................................................617
7.5.4 Factors Affecting Battery Life .........................................................................618
7.5.5 How to Handle the Battery...............................................................................619
7.5.6 How to Recharge a Battery .............................................................................620
7.5.7 Checking Electrolyte Level ..............................................................................621
7.5.8 Specific Gravity Test ..........................................................................................623
7.6 In Car Repairs ............................................................................................................625
7.6.1 Battery R&R .........................................................................................................625
7.6.2 Alternator R&R ....................................................................................................629
7.6.3 Battery separator tray R&R .............................................................................634
7.6.4 Battery Negative Cable R&R ..........................................................................637
7.6.5 Battery Positive Cable R&R ............................................................................640
7.7 Technical Specification ........................................................................................644
7.7.1 Battery Specifications .......................................................................................644
7.7.2 Alternator Specification ....................................................................................644
7.8 Torque Specification ..............................................................................................645
8 STARTING SYSTEM .....................................................................................................647
8.1 Description and Operation..................................................................................647
8.1.1 Starting System Overview ...............................................................................647
8.1.2 Battery ...................................................................................................................648
8.1.3 Starter Motor........................................................................................................648
8.1.4 Ignition Key barrel ..............................................................................................648
8.1.5 Starter Relay........................................................................................................649
8.1.6 TBI Based Immobilizer System ......................................................................649

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
10 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.1.7 ICU & Transponder Ring (Antenna) ..............................................................650

8.1.8 EMS ECU .............................................................................................................650
8.1.9 Immobilizer System Working Flow ................................................................651
8.2 Micro Hybrid Technology (Engine Stop/Start System, ESS)(If
equipped) ................................................................................................................653
8.2.1 Introduction ..........................................................................................................653
8.2.2 How does the Engine Start / Stop System work? .....................................653
8.2.3 The following inputs are required for Start Stop system to
function ...............................................................................................................654
8.2.4 For auto stop to happen the following conditions are to be
met: ......................................................................................................................654
8.2.5 For auto start to happen the following conditions are to be
met .......................................................................................................................654
8.2.6 Frequently Asked Questions (FAQ) ..............................................................654
8.3 Component Location Index ................................................................................657
8.3.1 Starting System Overview 1............................................................................657
8.3.2 Starting System Overview 2............................................................................658
8.4 Trouble Shooting......................................................................................................659
8.4.1 Refer below chart for various symptoms, causes and there
remedial actions - ...........................................................................................659
8.4.2 Component Inspection and Action Table.....................................................661
8.5 Standard Checking Procedure .........................................................................663
8.5.1 Diagnosis and Testing.......................................................................................663
8.5.2 Feed and Earth Checks....................................................................................663
8.5.3 Wiring and Switches ..........................................................................................663
8.5.4 Starting Relay Check ........................................................................................664
8.5.5 Cranking Voltage Test .......................................................................................665
8.5.6 Diagnosis and Testing — Battery Cables....................................................666
8.5.7 Starter Solenoid Testing ...................................................................................668
8.6 Care of the System ..................................................................................................669
8.6.1 Service Tips and Precautions .........................................................................669
8.6.2 Maintenance ........................................................................................................669
8.6.3 Cleaning................................................................................................................670
8.6.4 Jump Starting ......................................................................................................672
8.7 In Car Repairs ............................................................................................................674
8.7.1 Starter Motor R&R .............................................................................................674
8.7.2 Starter Relay R&R .............................................................................................678
8.7.3 Immobilizer Control Unit (ICU) R&R .............................................................681
8.7.4 Key Barrel R&R ..................................................................................................685
8.8 Technical Specification ........................................................................................689
8.8.1 Starter Motor Non - ESS Specification.........................................................689

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 11
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.8.2 Starter Motor ESS Specification ....................................................................689

8.9 Tightening Specifications & Sequence........................................................690
9 CLUTCH .................................................................................................................................691
9.1 Description and Operation..................................................................................691
9.1.1 Clutch System Overview ..................................................................................691
9.1.2 Dual Mass Flywheel ..........................................................................................691
9.1.3 Advantages of DMF ...........................................................................................692
9.1.4 Self Adjusting Technology (SAT) of the Clutch Cover
Assembly............................................................................................................692
9.1.5 Clutch Plate .........................................................................................................693
9.1.6 Clutch Cover ........................................................................................................693
9.1.7 Clutch Master Cylinder .....................................................................................693
9.1.8 Concentric Slave Cylinder ...............................................................................694
9.1.9 Clutch Bundy Tubes ..........................................................................................694
9.1.10 Clutch Pedal Assembly ..................................................................................694
9.1.11 Clutch Sensor....................................................................................................695
9.1.12 Clutch Pedal Return Spring ..........................................................................695
9.1.13 Flywheel Pilot Bearing ....................................................................................695
9.2 Component Location Index ................................................................................696
9.2.1 Clutch Assembly layout 1 ................................................................................696
9.2.2 Clutch Assembly Layout 2 ...............................................................................697
9.2.3 Clutch Assembly Layout 3 ...............................................................................698
9.3 Clutch Master Cylinder .........................................................................................699
9.4 Concentric Slave Cylinder ..................................................................................700
9.5 Trouble Shooting......................................................................................................701
9.5.1 Clutch Problem Causes ...................................................................................701
9.5.2 Clutch misalignment /Clutch Housing Misalignment ................................701
9.5.3 Noisy gearshift ....................................................................................................702
9.5.4 Clutch slippage: ..................................................................................................702
9.5.5 Clutch grab/chatter: ...........................................................................................704
9.5.6 Improper clutch release: ..................................................................................705
9.5.7 Hard gear shift: ...................................................................................................707
9.6 Standard Checking Procedure .........................................................................708
9.6.1 DMF (Dual Mass Flywheel Troubleshooting) .............................................708
9.6.2 DMF Inspection Procedure .............................................................................712
9.6.3 Secondary Flywheel axial play .......................................................................714
9.6.4 DMF run out .........................................................................................................715
9.6.5 DMF — Do’s & Don’ts .......................................................................................715
9.6.6 Clutch cover & Plate run out ...........................................................................716
9.6.7 Clutch Housing Misalignment .........................................................................716
9.6.8 Clutch Pedal Effort .............................................................................................717
9.6.9 Clutch Sensor Setting .......................................................................................719

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
12 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.7 Care of the System ..................................................................................................721

9.7.1 Clutch Fluid Level & Leak – Inspect..............................................................721
9.7.2 Clutch Fluid – Replace .....................................................................................724
9.8 In Car Repairs ............................................................................................................729
9.8.1 Clutch Master Cylinder R&R ...........................................................................729
9.8.2 Clutch Cover/Plate R&R ..................................................................................733
9.8.3 Clutch Concentric Slave Cylinder R&R........................................................738
9.8.4 Dual Mass Fly Wheel (DMF) —R&R ............................................................743
9.8.5 Clutch Bundy Tube R&R ..................................................................................747
9.8.6 Clutch Pedal Assembly R&R ..........................................................................752
9.8.7 Clutch Sensor R&R ...........................................................................................758
9.8.8 Clutch Pedal Return Spring R&R ..................................................................762
9.8.9 DMF Pilot Bearing R&R....................................................................................765
9.8.10 Dust Shield R&R ..............................................................................................768
9.9 Specifications & Wear Data ................................................................................771
9.10 Lubricants & Sealants.........................................................................................774
9.11 Tightening Specifications & Sequence .....................................................775
9.12 Mahindra Special Tools (MST)........................................................................777
10 TRANSMISSION — 6MT .........................................................................................779
10.1 Description & Operations .................................................................................779
10.1.1 Transmission System .....................................................................................779
10.1.2 Shifter Lever Assembly ..................................................................................780
10.1.3 Synchronizers ...................................................................................................780
10.1.4 Shift Fork ............................................................................................................780
10.1.5 Clutch Housing .................................................................................................781
10.1.6 Front Housing ...................................................................................................781
10.1.7 Intermediate Plate ...........................................................................................781
10.1.8 Rear Housing ....................................................................................................782
10.1.9 Input Shaft .........................................................................................................782
10.1.10 Output Shaft ....................................................................................................782
10.1.11 Counter shaft ..................................................................................................783
10.1.12 Drive Gear .......................................................................................................783
10.1.13 Driven Gear .....................................................................................................783
10.1.14 Reverse Idler ..................................................................................................784
10.1.15 Shift Block Actuator ......................................................................................784
10.2 Component Index ..................................................................................................785
10.2.1 Transmission View 1 (Gear Components)................................................785
10.2.2 Transmission View 2 (Casing Components) ............................................787
10.2.3 Transmission View 3 (Shifter Assembly) ..................................................788
10.3 Trouble Shooting ...................................................................................................789
10.3.1 Symptom Possible Causes ...........................................................................789

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 13
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.4 Care of the System ...............................................................................................790

10.4.1 Service Tips & Precautions ...........................................................................790
10.4.2 Transmission Oil Replacement ....................................................................791
10.5 In Car Repairs ..........................................................................................................794
10.5.1 Transmission Gear Shift Lever R&R ..........................................................794
10.5.2 Transmission Gear Shifter Assembly R&R ..............................................797
10.5.3 Transmission Assembly (2WD) R&R .........................................................800
10.5.4 Transmission Assembly (4WD) R&R .........................................................808
10.5.5 Neutral Sensor R&R .......................................................................................818
10.5.6 Vehicle Speed Sensor (2WD) R&R ............................................................822
10.5.7 Vehicle Speed Sensor (4WD) R&R ............................................................826
10.5.8 Reverse Switch R&R ......................................................................................829
10.6 Disassembly and Assembly ............................................................................833
10.6.1 Clutch Housing and Input Shaft Oil Seal ...................................................833
10.6.2 Front Housing ...................................................................................................837
10.6.3 Rear Housing and Rear End Oil Seal R&R ..............................................842
10.6.4 Transmission .....................................................................................................851
10.7 Technical Specifications ...................................................................................887
10.8 Sealant Specification ..........................................................................................888
10.9 Sealant Application Pattern .............................................................................889
10.9.1 Clutch Housing — Front Housing ...............................................................889
10.9.2 Front Housing — Intermediate Plate .........................................................890
10.9.3 Intermediate Plate — Rear Housing .........................................................891
10.9.4 Rear Housing — Lever Assembly Gear Shift ..........................................892
10.10 Torque Specification .........................................................................................893
11 TRANSFER CASE........................................................................................................895
11.1 Description & Operations..................................................................................895
11.1.1 Electronic Transfer Case ...............................................................................895
11.1.2 Transfer Case Controller................................................................................896
11.1.3 Transfer Case Motor .......................................................................................896
11.1.4 Tuner Mass assembly.....................................................................................897
11.1.5 4H – Four Wheel High ....................................................................................897
11.1.6 4L - Four Wheel Low ......................................................................................898
11.1.7 Shifting Procedure ...........................................................................................899
11.2 Component Index ..................................................................................................901
11.2.1 Transfer Case Overview ................................................................................901
11.3 Trouble Shooting ...................................................................................................902
11.3.1 Inspection and Verification ............................................................................902
11.3.2 Symptom Possible Causes ...........................................................................902

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
14 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.4 Care of the System ................................................................................................905

11.4.1 Self diagnosis of ECU .....................................................................................905
11.4.2 Transfer Case Oil Replacement ..................................................................908
11.5 In Car Repairs ..........................................................................................................912
11.5.1 Transfer Case R&R .........................................................................................912
11.6 Disassembly and Assembly ............................................................................925
11.6.1 Transfer Case ..................................................................................................925
11.7 Technical Specifications....................................................................................943
11.8 Sealant Specification ...........................................................................................943
11.9 Torque Specification ............................................................................................944
11.10 Mahindra Special Tools (MST) .....................................................................944
12 PROPELLER SHAFT .................................................................................................945
12.1 Description and Operation ...............................................................................945
12.2 Component Location Index .............................................................................946
12.2.1 Refer below illustration for rear propeller shaft layout
(2WD)– ...............................................................................................................946
12.2.2 Refer below illustration for propeller shafts layout
(4WD)– ...............................................................................................................947
12.3 Trouble Shooting ...................................................................................................948
12.3.1 Component Inspection and Testing Table ................................................949
12.4 Standard Checking Procedure.......................................................................950
12.4.1 Propeller Shaft Imbalance - Check .............................................................950
12.4.2 Propeller Shaft Run out – Check .................................................................952
12.4.3 Propeller Shaft Greasing ..............................................................................953
12.5 In Car Repairs ..........................................................................................................954
12.5.1 Propeller Shaft (2WD) R&R ..........................................................................954
12.5.2 Rear Propeller Shaft (4WD) R&R ...............................................................958
12.5.3 Front Propeller Shaft (4WD) R&R ...............................................................962
12.5.4 Universal Joint (UJ) R&R...............................................................................966
12.5.5 Centre Bearing — Dismantling ....................................................................969
12.6 Tightening Specifications & Sequence .....................................................972
13 FRONT AXLE ...................................................................................................................973
13.1 Description and Operation ...............................................................................973
13.1.1 Automatic Locking Hub ..................................................................................973

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 15
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.2 Component Location Index .............................................................................974

13.3 Trouble Shooting ...................................................................................................975
13.3.1 Inspection and Verification ............................................................................975
13.3.2 Mechanical ........................................................................................................975
13.3.3 Refer below chart for various symptoms, causes and there
remedial actions of system ...........................................................................975
13.3.4 Noise when the vehicle is coasting .............................................................977
13.3.5 Intermittent Noise ............................................................................................978
13.3.6 Noise when the vehicle is turning................................................................978
13.3.7 Constant Noise .................................................................................................978
13.3.8 Vibration .............................................................................................................979
13.3.9 Oil leakage from Differential carrier leakage ............................................979
13.3.10 Axle case oil leakage....................................................................................979
13.4 Standard Checking Procedure.......................................................................981
13.4.1 Ring Gear & Pinion Assembly Theory: ......................................................981
13.4.2 Shim Selection Procedure: ...........................................................................982
13.4.3 Measuring Pinion & Gear Depth Using Service Tools & Gauges
“Pinion Shim Selection: (If Old Shim Not Available) ..............................984
13.4.4 Interpretation of Contact Pattern .................................................................986
13.5 Care of the System ...............................................................................................988
13.5.1 Front Differential Oil Replace - Procedure ...............................................988
13.5.2 Front Wheel Bearings Inspection ................................................................991
13.6 In Car Repairs ........................................................................................................1000
13.6.1 Half Shaft Assembly R&R ...........................................................................1000
13.6.2 Front Axle R&R ..............................................................................................1009
13.6.3 Auto Locking Hub R&R ................................................................................1013
13.6.4 Rubber Boot R&R ..........................................................................................1016
13.7 Disassembly and Assembly ..........................................................................1019
13.7.1 Removal: ..........................................................................................................1020
13.7.2 Inspection.........................................................................................................1027
13.7.3 Installation........................................................................................................1028
13.8 Specifications & Wear Data ...........................................................................1037
13.9 Lubricants & Sealants.......................................................................................1037
13.10 Torque Specification .......................................................................................1038
14 REAR AXLE ....................................................................................................................1039
14.1 Description and Operation .............................................................................1039
14.2 Component Location Index ...........................................................................1040
14.3 Trouble Shooting .................................................................................................1041

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
16 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.3.1 Rear Axle Noise Diagnosis .........................................................................1041

14.4 Care of the System .............................................................................................1046
14.4.1 Differential Oil Replace ................................................................................1046
14.5 In Car Repairs ........................................................................................................1050
14.5.1 Axle Shaft R&R ..............................................................................................1050
14.5.2 Axle Shaft Inner Oil Seal R&R ...................................................................1054
14.5.3 Axle Shaft Wheel Bearing R&R .................................................................1056
14.5.4 Rear Axle R&R ...............................................................................................1060
14.6 Disassembly and Assembly ..........................................................................1066
14.6.1 Rear Axle Assembly......................................................................................1066
14.7 Specifications, Wear Data & Tightening Specifications ................1086
14.8 Lubricants & Sealants.......................................................................................1087
14.9 Mahindra Special Tools (MST)......................................................................1088
15 WHEELS & TYRES ...................................................................................................1089
15.1 Description and Operation .............................................................................1089
15.1.1 Wheels & Tyres ..............................................................................................1089
15.2 Structure of Tyre ..................................................................................................1089
15.2.1 Tread .................................................................................................................1090
15.2.2 Shoulder ...........................................................................................................1090
15.2.3 Sidewall ............................................................................................................1090
15.2.4 Bead ..................................................................................................................1090
15.2.5 Carcass ............................................................................................................1090
15.2.6 Belt .....................................................................................................................1090
15.3 Tyre Information ...................................................................................................1091
15.4 Tyre Rating ..............................................................................................................1092
15.5 Speed Rating..........................................................................................................1092
15.6 Tyre Label (Vehicle Placard) ..........................................................................1093
15.7 Tyre Pressure.........................................................................................................1093
15.8 Component Index ................................................................................................1094
15.8.1 Wheels & Tyres View ....................................................................................1094
15.9 Trouble Shooting .................................................................................................1095
15.9.1 Symptom Possible Causes .........................................................................1095
15.10 Care of the system ...........................................................................................1100

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 17
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.10.1 Service Tips and Precautions ..................................................................1100

15.10.2 Wheel Balancing..........................................................................................1101
15.10.3 Tyre Inspection and Rotation ...................................................................1103
15.11 In Car Repairs......................................................................................................1104
15.11.1 Wheels R&R..................................................................................................1104
15.11.2 Tyre & Valve R&R ........................................................................................1108
15.11.3 Spare Wheel & Winch R&R ...................................................................... 1113
15.11.4 Wheel Hub (2WD) R&R ............................................................................. 1116
15.11.5 Wheel Hub (4WD) R&R .............................................................................1121
15.12 Technical Specification .................................................................................1129
15.12.1 Specification .................................................................................................1129
15.13 Torque Specification .......................................................................................1130
15.13.1 Tightening Specification ............................................................................1130
16 SUSPENSION ...............................................................................................................1131
16.1 Description and Operation .............................................................................1131
16.1.1 Suspension System ......................................................................................1131
16.1.2 Upper Arm .......................................................................................................1132
16.1.3 Lower Arm .......................................................................................................1132
16.1.4 Front Stabilizer Bar Assembly....................................................................1133
16.1.5 Knuckle .............................................................................................................1133
16.1.6 Ball Joint ...........................................................................................................1134
16.1.7 Front Suspension Shock Absorber ...........................................................1134
16.1.8 Torsion Bar ......................................................................................................1135
16.1.9 Rear Suspension Stabilizer Bar Assembly.............................................1135
16.1.10 Rear Suspension Shock Absorber .........................................................1136
16.1.11 Leaf Spring Assembly ................................................................................1136
16.2 Component Location Index ...........................................................................1137
16.2.1 Front Suspension ..........................................................................................1137
16.2.2 Rear Suspension ...........................................................................................1138
16.3 Trouble Shooting .................................................................................................1139
16.3.1 Symptom possible causes remedy ...........................................................1139
16.3.2 Components inspection and action table ................................................1142
16.4 Standard Checking Procedure.....................................................................1144
16.4.1 Ball joint checking ..........................................................................................1144
16.4.2 Steering Straight Ahead Setting Procedure: ..........................................1144
16.5 Care of the System .............................................................................................1145
16.5.1 Service Tips and Precautions ....................................................................1145
16.5.2 Front suspension bushes inspect .............................................................1146
16.5.3 Rear Suspension Bushes Inspection Procedure ..................................1147

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
18 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.5.4 Suspension arms & Links inspect .............................................................1148

16.6 Wheel Alignment procedure..........................................................................1151
16.6.1 Camber Adjustment Procedure .................................................................1156
16.6.2 Caster Adjustment Procedure ....................................................................1157
16.6.3 Toe-in Adjustment Procedure .....................................................................1158
16.6.4 Ride Height ......................................................................................................1160
16.7 In Car Repairs ........................................................................................................1162
16.7.1 Upper Control Arm R&R ..............................................................................1162
16.7.2 Upper Control Arm Ball Joint R&R...........................................................1166
16.7.3 Lower Control Arm R&R .............................................................................1170
16.7.4 Lower Control Arm Ball Joint R&R ............................................................1174
16.7.5 Front Suspension Stabilizer Bar Links R&R ..........................................1177
16.7.6 Front Stabilizer Bar and Bushes R&R .....................................................1181
16.7.7 Knuckle R&R ...................................................................................................1185
16.7.8 Front Shock Absorber R&R ........................................................................1192
16.7.9 Torsion Bar R&R ............................................................................................1196
16.7.10 Rear Stabilizer Bar and Bushes R&R ....................................................1203
16.7.11 Rear Suspension Shock Absorber R&R ..............................................1207
16.7.12 Rear Suspension Leaf Spring R&R .......................................................1211
16.7.13 Leaf Spring Pivot End Bush Replacement ...........................................1217
16.7.14 Leaf Spring Shackle End Bush Replacement .....................................1219
16.8 Technical Specification ....................................................................................1221
16.8.1 Front Suspension ..........................................................................................1221
16.8.2 Rear Suspension ...........................................................................................1221
16.9 Torque Specification..........................................................................................1222
16.9.1 Tightening Specification...............................................................................1222
17 BRAKES ............................................................................................................................1223
17.1 Description and Operation .............................................................................1223
17.1.1 Brake System .................................................................................................1223
17.1.2 Hydraulic Control Unit ..................................................................................1224
17.1.3 Electronic Control Unit .................................................................................1225
17.1.4 Normal Braking...............................................................................................1225
17.1.5 Anti-lock Braking ............................................................................................1225
17.1.6 Electronic Stability Program .......................................................................1226
17.1.7 ABS Hydraulic Schematic ...........................................................................1228
17.1.8 Non ABS Hydraulic Schematic ..................................................................1229
17.1.9 Brake Pad ........................................................................................................1230
17.1.10 Brake Caliper ................................................................................................1230
17.1.11 Brake Disc .....................................................................................................1230
17.1.12 EHCU (Electronic Hydraulic Control Unit) ............................................1231
17.1.13 Tandem Master Cylinder/ Brake Booster Assembly ..........................1231
17.1.14 Brake Pedal ..................................................................................................1231
17.1.15 Brake Drum ...................................................................................................1232

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 19
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.16 LSPV ( Load Sensing Proportionating Valve) .....................................1232

17.2 Component Index ................................................................................................1233
17.2.1 Brake System Layout View 1 (ABS) .........................................................1233
17.2.2 Brake System Layout View 2 (Non ABS) ................................................1234
17.3 Symptom Possible Causes Remedy.........................................................1235
17.4 Troubleshooting of Vacuum Booster Assembly ................................1238
17.5 Vacuum Leak Test ...............................................................................................1239
17.6 Standard Checking Procedure.....................................................................1240
17.6.1 Brake switch adjustment..............................................................................1240
17.7 Care of the System .............................................................................................1242
17.7.1 Service Tips and Precautions ....................................................................1242
17.7.2 Brake Fluid Level & Leak Test....................................................................1243
17.7.3 Brake Fluid Replace or Bleeding ...............................................................1249
17.7.4 Brake Pad Inspect & Replace ....................................................................1267
17.7.5 Brake Liner Inspect & Replace ..................................................................1272
17.7.6 LSPV Height Setting Procedure ................................................................1277
17.7.7 Inspection of Brake & Clutch Pedal for free play &
operation ..........................................................................................................1281
17.8 In Car Repair ..........................................................................................................1282
17.8.1 Caliper Assembly R&R ................................................................................1282
17.8.2 Brake Disc (2WD) R&R ................................................................................1286
17.8.3 Tandem Master Cylinder (TMC) and Reservoir R&R ..........................1299
17.8.4 Brake Booster R&R .......................................................................................1303
17.8.5 Brake Pedal R&R...........................................................................................1310
17.8.6 EHCU Unit R&R .............................................................................................1315
17.8.7 Vacuum Reservoir and Hoses R&R .........................................................1320
17.8.8 Rear Brake Drum R&R.................................................................................1324
17.8.9 Wheel Cylinder R&R .....................................................................................1327
17.8.10 Front Brake Flexible Hose R&R ..............................................................1332
17.8.11 Rear Brake Flexible Hose (ABS) R&R ..................................................1335
17.8.12 Front Brake Caliper Stem R&R ...............................................................1338
17.8.13 Bundy Tube TMC to EHCU R&R ............................................................1341
17.8.14 Bundy Tube EHCU to Front LH Caliper R&R ......................................1345
17.8.15 Bundy Tube EHCU to Front RH Caliper R&R .....................................1350
17.8.16 Bundy Tube EHCU to Rear RH Wheel Cylinder R&R ......................1355
17.8.17 Bundy Tube EHCU to Rear LH Flexible hose R&R ...........................1359
17.8.18 Bundy Tube Rear Flexible Hose to Wheel Cylinder R&R ................1364
17.8.19 Bundy Tube Primary TMC to Four Way Tee Part 1 (Non ABS)
R&R ...................................................................................................................1367
17.8.20 Bundy Tube Primary TMC to Four Way Tee Part 2 (Non ABS)
R&R ...................................................................................................................1371
17.8.21 Bundy Tube Secondary TMC to LSPV Part 1 (Non ABS)
R&R ...................................................................................................................1374

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
20 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.22 Bundy Tube Secondary TMC to LSPV Part 2 (Non ABS)

R&R ...................................................................................................................1378
17.8.23 Bundy Tube Secondary TMC to LSPV Part 3 (Non ABS)
R&R ...................................................................................................................1381
17.8.24 Bundy Tube Four Way Tee to LH Flexible Hose 2WD (Non ABS)
R&R ...................................................................................................................1385
17.8.25 Bundy Tube Four Way Tee to LH Flexible Hose 4WD (Non ABS)
R&R ...................................................................................................................1389
17.8.26 Bundy Tube Four Way Tee to RH Flexible Hose (Non ABS)
R&R ...................................................................................................................1393
17.8.27 Bundy Tube LSPV to Four Way Tee (Non ABS) R&R ......................1397
17.8.28 Rear Flexible Hose (Non ABS) R&R .....................................................1401
17.8.29 Bundy Tube 3 way Tee to Rear RH Wheel Cylinder (Non ABS)
R&R ...................................................................................................................1405
17.8.30 Bundy Tube 3 Way Tee to Rear LH Wheel Cylinder (Non ABS)
R&R ...................................................................................................................1409
17.8.31 LSPV Unit (Non ABS) R&R ......................................................................1413
17.8.32 Hand Brake lever Assembly R&R...........................................................1418
17.8.33 Hand Brake Front Cable R&R .................................................................1421
17.8.34 Hand brake Rear cable Assembly R&R................................................1424
17.8.35 Front Wheel Speed Sensor R&R ............................................................1427
17.8.36 Rear Wheel Speed Sensor R&R ............................................................1430
17.8.37 Brake Switch R&R.......................................................................................1433
17.9 Specifications ........................................................................................................1436
17.9.1 Technical Specifications ..............................................................................1436
17.9.2 Tightening Specifications ............................................................................1441
18 STEERING SYSTEM ................................................................................................1443
18.1 Description and Operation .............................................................................1443
18.1.1 Steering System .............................................................................................1443
18.1.2 How rack & pinion power steering system work ...................................1444
18.1.3 Steering Wheel ...............................................................................................1445
18.1.4 Power Steering Rack ....................................................................................1445
18.1.5 Clock Spring ....................................................................................................1445
18.1.6 Intermediate Shaft .........................................................................................1446
18.1.7 Power Steering Pump ..................................................................................1446
18.1.8 Combination Switch ......................................................................................1446
18.2 Component Location Index ...........................................................................1447
18.2.1 Steering System Layout...............................................................................1447
18.3 Trouble Shooting .................................................................................................1448
18.3.1 Visual Inspection ............................................................................................1448
18.3.2 Trouble shooting chart..................................................................................1449
18.3.3 Component Inspection and Remedy Action: .........................................1454
18.4 Standard Checking Procedure: ...................................................................1456

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 21
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.4.1 Check for Power Steering Fluid Leaks ....................................................1456

18.4.2 Free Play Check.............................................................................................1456
18.4.3 Clock Spring Setting Procedure. ...............................................................1458
18.5 Care of the System .............................................................................................1459
18.5.1 Service Tips and Precautions ....................................................................1459
18.5.2 Power Steering Fluid Level & Leak — Inspect ......................................1460
18.5.3 Power Steering Fluid — Replace ..............................................................1462
18.6 In Car Repairs ........................................................................................................1467
18.6.1 Steering Wheel R&R.....................................................................................1467
18.6.2 Clock Spring R&R ..........................................................................................1473
18.6.3 Combination Switch R&R ............................................................................1477
18.6.4 Steering Column R&R ..................................................................................1481
18.6.5 Intermediate Shaft Upper R&R ..................................................................1485
18.6.6 Intermediate Shaft Lower R&R ..................................................................1488
18.6.7 Tie-Rod End Ball Joint R&R .......................................................................1491
18.6.8 Power Steering Rack Assembly R&R ......................................................1494
18.6.9 Bellow R&R .....................................................................................................1501
18.6.10 Power Steering Pump R&R ......................................................................1503
18.6.11 Suction Hose (Power Steering Reservoir to Pump) R&R ................1508
18.6.12 Reservoir R&R .............................................................................................1511
18.6.13 Inner Ball Joint (IBJ) R&R .........................................................................1514
18.6.14 Tube Pump to Rack R&R ..........................................................................1517
18.6.15 Tube Return (Rack to Reservoir) R&R ..................................................1520
18.7 Technical Specifications .................................................................................1523
18.8 Tightening Specifications ...............................................................................1525
19 HEATING, VENTILATION AND AIR CONDITIONING
(HVAC) ..........................................................................................................................1527
19.1 Description and Operation .............................................................................1527
19.1.1 HVAC.................................................................................................................1527
19.1.2 Centre / Side Vents .......................................................................................1531
19.1.3 Second Row Floor Vents .............................................................................1531
19.1.4 HVAC Controls ...............................................................................................1531
19.1.5 Air Distribution Control .................................................................................1532
19.1.6 Blower Speed Control ..................................................................................1533
19.1.7 Temperature Control .....................................................................................1534
19.1.8 AC Compressor Assembly ..........................................................................1535
19.1.9 Condenser .......................................................................................................1535
19.1.10 The Receiver/ Drier.....................................................................................1536
19.1.11 Thermal Expansion Valve .........................................................................1536
19.2 Component Location Index ...........................................................................1537
19.2.1 HVAC Overview .............................................................................................1537
19.3 Standard Checking Procedure.....................................................................1538

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
22 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.3.1 AC PERFORMANCE TEST .......................................................................1538

19.3.2 AC Working Logic ..........................................................................................1539
19.4 Care of the System .............................................................................................1540
19.4.1 Service Tips and Precautions. ...................................................................1540
19.4.2 Refrigerant Recovery Recycling and Recharging ................................1544
19.4.3 Discharging the system................................................................................1544
19.4.4 Evacuation of the system ............................................................................1545
19.4.5 Purging – if required ......................................................................................1546
19.4.6 Preliminary Charging and High Pressure Leak Test ............................1546
19.4.7 Charging the System ....................................................................................1547
19.4.8 Contaminated Refrigerant Handling .........................................................1548
19.4.9 HVAC Filter R&R ............................................................................................1549
19.4.10 HVAC System Do’s & Dont’s ....................................................................1551
19.5 In Car Repairs ........................................................................................................1552
19.5.1 HVAC Unit R&R..............................................................................................1552
19.5.2 Temperature Actuator R&R.........................................................................1556
19.5.3 Heater Coil R&R.............................................................................................1560
19.5.4 Mode Actuator R&R ......................................................................................1564
19.5.5 Fresh/Recirculation Actuator R&R............................................................1568
19.5.6 Blower Motor R&R .........................................................................................1572
19.5.7 Field Effect Transistor (FET) R&R ............................................................1576
19.5.8 Blower Resistor R&R ....................................................................................1580
19.5.9 Water Drain Hose R&R ................................................................................1584
19.5.10 Evaporator R&R ..........................................................................................1587
19.5.11 Expansion Valve R&R ................................................................................1591
19.5.12 AC Compressor R&R .................................................................................1595
19.5.13 AC Condenser R&R ...................................................................................1598
19.5.14 AC High Pressure Hose (Compressor to Condenser) R&R ...........1603
19.5.15 AC High Pressure Hose (Expansion Valve to Compressor)
R&R ...................................................................................................................1607
19.6 Technical Specifications .................................................................................1611
19.7 Tightening Specifications & Sequence ...................................................1613
20 RESTRAINT SYSTEM.............................................................................................1615
20.1 Description and Operation .............................................................................1615
20.1.1 Driver and Passenger Airbag .....................................................................1615
20.1.2 Airbag System Malfunction Lamp .............................................................1616
20.1.3 Airbag Inflation/Deployment .......................................................................1618
20.1.4 Child Restraint and Airbag ..........................................................................1619
20.1.5 Airbag Non-Deployment ..............................................................................1620
20.1.6 Driver Airbag Module ....................................................................................1623
20.1.7 Passenger Airbag Module ...........................................................................1623
20.1.8 Seat Belt Pre-tenioner / Load Limiter .......................................................1624
20.1.9 Clock Spring ....................................................................................................1624
20.1.10 Front Crash Sensor ....................................................................................1625

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 23
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.2 Component Location Index ...........................................................................1626

20.3 Care of the System .............................................................................................1627
20.4 In Car Repairs ........................................................................................................1629
20.4.1 Driver Airbag Module R&R..........................................................................1629
20.4.2 Passenger Airbag Module (PAB) R&R ....................................................1632
20.4.3 Seat Belt Assembly Driver R&R ................................................................1635
20.4.4 Driver Seat Belt Buckle R&R ......................................................................1640
20.4.5 Co - Driver Seat Belt Buckle R&R .............................................................1644
20.4.6 Second Row RH Seat Belt Assembly R&R ............................................1647
20.4.7 Second Row seat Lap and Buckle Assembly R&R ..............................1652
20.4.8 Second Row Seat Twin Buckle Assembly R&R ....................................1655
20.4.9 Airbag ECU R&R ...........................................................................................1658
20.5 Tightening Specifications ...............................................................................1661
21 INSTRUMENT PANEL ............................................................................................1663
21.1 Description and Operation .............................................................................1663
21.2 INSTRUMENT CLUSTER OVERVIEW .......................................................1663
21.2.1 Instrument Cluster .........................................................................................1663
21.2.2 Warning Lamps Overview ...........................................................................1664
21.2.3 Warning Lamps .............................................................................................1665
21.3 Component Location Index ...........................................................................1668
21.3.1 Refer below illustration for Instrument Panel .........................................1668
21.4 Service Tips and Precautions.......................................................................1669
21.5 In Car Repairs ........................................................................................................1670
21.5.1 Centre Console R&R ....................................................................................1670
21.5.2 Glove Box R&R ..............................................................................................1677
21.5.3 Instrument Panel R&R .................................................................................1681
21.5.4 Cross Car Beam R&R ..................................................................................1690
21.5.5 Instrument Cluster R&R ...............................................................................1696
21.5.6 MBFM R&R .....................................................................................................1699
21.5.7 Crash Sensor R&R ........................................................................................1702
21.6 Torque Specifications & Sequence ...........................................................1706
22 DOORS,BONNET & TAIL GATE .....................................................................1707
22.1 Description and Operation .............................................................................1707
22.2 Component Location Index ...........................................................................1707
22.2.1 Refer below illustration for Doors. .............................................................1707
22.3 Outside Rear View Mirror ................................................................................1708

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
24 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.4 Tip-Tap ORVM Adjustment .............................................................................1708

22.5 Manual (Joystick) ORVM Adjustment (if equipped) .........................1708
22.6 Power Window (if equipped) .........................................................................1709
22.7 Power Window Lock Switch ..........................................................................1710
22.8 In Car Repairs ........................................................................................................1711
22.8.1 Outside Rear View Mirror (ORVM) ...........................................................1711
22.8.2 Front Door R&R .............................................................................................1715
22.8.3 Front Door Window Glass R&R .................................................................1719
22.8.4 Door Outer Handle R&R ..............................................................................1722
22.8.5 Front Door Inner Handle ..............................................................................1725
22.8.6 Rear Door Window Glass ............................................................................1728
22.8.7 Tail Gate R&R ................................................................................................1733
22.9 Torque Specifications .......................................................................................1738
23 SEATS .................................................................................................................................1739
23.1 Description and Operation .............................................................................1739
23.1.1 Sitting in correct position — Driver Seat .................................................1739
23.1.2 Front Seat Slide .............................................................................................1740
23.1.3 Front Seat Recline .........................................................................................1740
23.1.4 Driver Seat Height Adjust (If Equipped) ..................................................1741
23.1.5 Head Restraint................................................................................................1742
23.2 Component Location Index ...........................................................................1744
23.2.1 Refer below illustration for Seating System ...........................................1744
23.3 In Car Repairs ........................................................................................................1745
23.3.1 Driver Seat R&R.............................................................................................1745
23.3.2 Co — Driver Seat R&R ................................................................................1748
23.3.3 Second Row Seat R&R................................................................................1751
23.4 Torque Specifications .......................................................................................1755
24 INTERIOR TRIMS .......................................................................................................1757
24.1 Description and Operation .............................................................................1757
24.1.1 Interior Trims ...................................................................................................1757
24.2 In Car Repairs ........................................................................................................1758
24.2.1 Driver Sun Visor R&R ...................................................................................1758
24.2.2 Co - Driver Sun Visor R&R ..........................................................................1761
24.2.3 A-Pillar Upper Trim R&R..............................................................................1764
24.2.4 A-Pillar Lower Trim R&R..............................................................................1768
24.2.5 B-Pillar Upper Trim R&R..............................................................................1772
24.2.6 B-Pillar Lower Trim R&R..............................................................................1776

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 25
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.7 Front Scuff Plate R&R ..................................................................................1779

24.2.8 Rear Scuff Plate R&R ...................................................................................1782
24.2.9 C-Pillar Upper Trim R&R .............................................................................1785
24.2.10 C-Pillar Lower Trim - R&R ........................................................................1788
24.2.11 Front Door Trim R&R ..................................................................................1791
24.2.12 Roof Liner R&R ............................................................................................1796
24.2.13 Inner Grab Handle - R&R ..........................................................................1802
24.3 Tightening Specifications ...............................................................................1805
25 EXTERIOR TRIMS .....................................................................................................1807
25.1 Component Location Index ...........................................................................1807
25.1.1 Refer below illustration for Exterior Trims ...............................................1807
25.1.2 Component Location Index .........................................................................1808
25.2 In Car Repairs ........................................................................................................1809
25.2.1 Front Bumper Mesh R&R ............................................................................1809
25.2.2 Front Splash shield R&R .............................................................................1812
25.2.3 Foot Step Assembly R&R............................................................................1815
25.2.4 Bezel Fender R&R ........................................................................................1818
25.2.5 Rear Splash Shield Cover R&R.................................................................1821
25.2.6 Rear Bumper Anti Skid Pad - R&R ...........................................................1824
25.3 Torque Specifications & Sequence ...........................................................1826
26 INTERIOR LIGHTING ..............................................................................................1827
26.1 Description and Operation .............................................................................1827
26.1.1 Front Courtesy/Map Reading .....................................................................1828
26.1.2 Second Row Courtesy Lamp......................................................................1829
26.1.3 Puddle Lamps .................................................................................................1829
26.2 Component Location Index ...........................................................................1830
26.2.1 Refer below illustration for Interior Lighting ............................................1830
26.3 In Car Repairs ........................................................................................................1831
26.3.1 Front Courtesy/Map Reading Lamp R&R ...............................................1831
26.3.2 Second Row Courtesy Lamp R&R ...........................................................1834
26.3.3 Roof Lamp Bulb R&R ...................................................................................1837
26.3.4 High Mount Stop Lamp R&R ......................................................................1840
26.3.5 Puddle Lamp R&R .........................................................................................1843
27 EXTERIOR LIGHTING ............................................................................................1847
27.1 Description & Operation ..................................................................................1847
27.1.1 Follow-Me Home (FMH) with Rain Light Sensor (RLS) ......................1847
27.1.2 Follow-Me Home (FMH) Non RLS ............................................................1847
27.1.3 Lead Me to Vehicle (LMV)(if equipped) ...................................................1848

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
26 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.2 Component Location Index ...........................................................................1850

27.2.1 View 1: ..............................................................................................................1850
27.2.2 View 2: ..............................................................................................................1851
27.3 Care of the System .............................................................................................1852
27.3.1 All Light, Horn, Wipers & Washer - Check .............................................1852
27.3.2 Head Lamp Aiming ........................................................................................1858
27.4 In Car Repairs ........................................................................................................1863
27.4.1 Head Lamp R&R ............................................................................................1863
27.4.2 Fog Lamp R&R ...............................................................................................1866
27.4.3 Side Marker Lamp R&R ...............................................................................1870
27.4.4 Registration Plate Lamp R&R ....................................................................1873
27.4.5 Tail Lamp R&R................................................................................................1876
27.5 Technical Specifications .................................................................................1880
27.5.1 Bulb Specification ..........................................................................................1880
27.6 Torque Specifications .......................................................................................1881
28 IN CAR ENTERTAINMENT..................................................................................1883
28.1 Description and Operation .............................................................................1883
28.1.1 Level 1 Audio Infotainment System ..........................................................1883
28.1.2 Level 3 Audio Infotainment System ..........................................................1885
28.2 Component Location Index ...........................................................................1886
28.2.1 Refer below illustration for In-car Entertainment ..................................1886
28.3 Service Tips and Precautions.......................................................................1888
28.4 In Car Repairs ........................................................................................................1889
28.4.1 Infotainment Unit R&R .................................................................................1889
28.4.2 GPS Antenna R&R ........................................................................................1893
28.4.3 Front Door Speaker R&R ............................................................................1897
28.5 Tightening Specifications ...............................................................................1900
29 BUMPERS ........................................................................................................................1901
29.1 Description and Operation .............................................................................1901
29.1.1 Refer below illustrations for front bumper exploded view: .................1901
29.1.2 Refer below illustrations for rear bumper exploded view: ..................1902
29.2 Component Location Index ...........................................................................1903
29.2.1 Refer below illustration for front bumper layout ....................................1903
29.2.2 Refer below illustration for rear bumper layout .....................................1904
29.3 In Car Repairs ........................................................................................................1905

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 27
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.1 Front Bumper Grill R&R ...............................................................................1905

29.3.2 Front Bumper Assembly R&R ....................................................................1909
29.3.3 Rear Bumper Assembly R&R.....................................................................1915
29.4 Tightening Specifications & Sequence ...................................................1920
30 WIPERS & WASHERS ............................................................................................1921
30.1 Description and Operation .............................................................................1921
30.1.1 Front Nozzle ....................................................................................................1921
30.1.2 Washer Tank and Washer Motor ...............................................................1921
30.1.3 Front Wiper Arms/Blade ..............................................................................1922
30.1.4 Wiper Control Stalk .......................................................................................1922
30.1.5 Auto Wipe (if equipped) ...............................................................................1923
30.1.6 Wipe/Wash ......................................................................................................1923
30.2 Component Location Index ...........................................................................1924
30.2.1 Refer below illustration for front wiper assembly layout. ....................1924
30.2.2 Refer below illustration for wiper washer assembly layout. ...............1925
30.3 Care of the System .............................................................................................1926
30.3.1 Windshield Washer Fluid Top-up ..............................................................1926
30.3.2 Checking the Wiper Blades ........................................................................1926
30.4 In Car Repairs ........................................................................................................1927
30.4.1 Front Wiper Blade R&R ...............................................................................1927
30.4.2 Front Wiper Rubber R&R ............................................................................1931
30.4.3 Front RH Wiper Arm R&R ...........................................................................1935
30.4.4 Front LH Wiper Arm R&R ............................................................................1938
30.4.5 Plenum Applique R&R .................................................................................1941
30.4.6 Front Wiper Assembly R&R ........................................................................1945
30.4.7 Front Wiper Motor R&R ...............................................................................1950
30.4.8 Front Washer Nozzle R&R ..........................................................................1954
30.4.9 Wiper Washer tank R&R..............................................................................1957
30.4.10 Wiper Washer Motor R&R ........................................................................1961
30.5 Specifications & Wear Data ...........................................................................1964
30.6 Tightening Specifications & Sequence ...................................................1965
31 CHASSIS ...........................................................................................................................1967
31.1 Chassis — Side View .........................................................................................1967
31.2 Chassis — Top View ..........................................................................................1968
31.3 Under Body Inspection ....................................................................................1969

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
28 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1 GENERAL INFORMATION

1.1 Introduction
This Workshop/Repair manual is designed to assist technicians to repair and maintain
Mahindra PIKUP vehicles. This manual provides general information on removal and
installation, disassembly and assembly, inspection and adjustment and trouble shooting. It
also provides functioning of the system in brief.

1.1.1 Important Instructions

Individuals who undertake repairs should have essential skills or training. Following correct
service methods and repair procedures are essential for the safe, reliable operation of all
motor vehicles as well as the personal safety of the individual while carrying out the work. This
manual cannot possibly predict all such variations and offer warnings or cautions as to each.
Deviation from the instructions provided in this manual could lead to personal injury or damage
to the vehicle.
DANGER, WARNING, CAUTION and NOTICE symbols are given right through this manual to
alert the service technician to an area of potential hazard or to note something of importance.

DANGER Indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.

WARNING Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION used with the safety alert symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.

Notice is used to highlight information useful to the technician to properly complete

the work.
The danger, warning, caution and notice are included wherever it is required. Anyone
using the service procedures or tools must make sure that neither personal safety nor
vehicle safety is compromised.

1.1.2 Contents in the manual

This manual contains the procedures for performing the required service operations. The
procedures are separated into the following important operations.
• Description and Operation
• Component Location Index
• Service Tips and Precautions

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 29
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Troubleshooting Chart
• In car Repairs
• Assembly and Disassembly
• Component Inspection and Action Table
• Mahindra Service Tools (MST)
• Technical Specification
• Torque Specification
Description and Operation
This section provides brief information of the system construction, description and operation.
Component Location Index
This section contains overview illustrations of the system with color codes for identifying the
system components.
Service Tips and Precautions
These are the general service tips and precautions that need to be followed while servicing the
parts, working in the workshop or during assembling and disassembling the parts.
Trouble Shooting Chart
Diagnosis test steps are used in the section to identify the source of concern in a step-by-step
approach. Diagnosis tests have three columns: symptom, possible causes and remedy. The
first column is used exclusively for indication of a concern, the second column for possible
causes and the third column for remedies or the direction to another analysis step.
In car Repairs
This section gives information on removal and refit of components from a vehicle.
Disassembly and Assembly
This section gives information on disassembling and assembling a component or a system,
wherever applicable.
Component Inspection and Action Table
The table has three columns. The first column names the component. The second column
suggests the tests that need to be carried out on the component. The last column suggests
possible actions.
Mahindra Service Tools (MST)
The special tools table lists the Mahindra Service Tools (MST) required to repair the vehicle.
Illustrations are provided to support identifying the special tool.
Technical Specification
This section gives the technical specification of the system/component, wherever necessary.
Torque Specification
This section gives the torque values applicable to the specified components while tightening
them, wherever applicable.
Fuel Handling Precautions
• Always disconnect the vehicle battery before working on the fuel system.

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
30 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Avoid prolonged and frequent skin contact with oils, particularly engine oils.
• Properly ventilate the area so that the flammable fumes do not become concentrated.
• Never smoke or have an open flame in the work area.
• Always check for leaks after fuel system repairs.
• Clean up fuel spills immediately with absorbent materials, by using proper disposal
procedures.
• Wear protective clothing, including resistant gloves wherever required.
• Avoid wearing contaminated clothes.
• First-aid treatment must be given immediately for open cuts and wounds.
Do not operate the engine for unlimited period of time without proper exhaust ventilation. Keep
the work area well ventilated and free of any flammable materials. Special care should be
taken when handling any flammable or toxic materials such as gasoline, refrigerant gas, etc.

Fuels and vapors are extremely flammable. Use extreme caution when working with
fuel, fire or explosion may occur causing severe personal injury or death.

Petrol and diesel fuels are irritants. Wash hands thoroughly after handling the fuels.

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 31
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.3 Dimensions

Dimensions
Wheel Base 3040 mm

Overall Length 5175 mm

Overall Width 1820 mm

1860 mm (SC)
Overall Height
1915 mm (DC)

Track Width (Front) 1450 mm

Track Width (Rear) 1450 mm

Minimum Ground Clearance 210 mm

2294 mm (SC)
Cargo Length
1489 mm (DC)

Cargo Width 1520 mm

Cargo Height 550 mm

The specifications are for reference only. Subject to change without prior notice.

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
32 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.3.1 Front View

1.1.3.2 Rear View

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 33
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.3.3 Side View

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
34 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.4 Technical Specification

Technical Specifications

ENGINE - 2.2L mHawk EII & EIV LHD

Displacement/Cubic Capacity 2179 cc

4 Stroke, Turbocharged, Common Rail Direct Injection

Type
Engine

Bore x Stroke 85.0 X 96.0 mm

No of Cylinders 4 In-line

Max. Engine Output (kW @ rpm) 103 kW @ 3750 rpm

Max. Torque (Nm @ rpm) 320 Nm @ 1500 to 2800 rpm

CLUTCH

Single Plate, Dry Type, Hydraulic Actuation, Dual Mass

Type
Flywheel

TRANSMISSION

Type Manual, Synchromesh in all Forward Gears

No. of Gears 6 Forward, 1 Reverse

SHIFT MECHANISM

Type Manual

GEAR RATIOS

I 3.777 : 1

II 2.214 : 1

III 1.425 : 1

IV 1.00 : 1

V 0.791 : 1

VI 0.71 : 1

Reverse 3.559 : 1

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 35
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

TRANSFER CASE (4X4 ONLY)

Type Electric Shift

Ratio 1 : 1 (High), 1 : 2.48 (Low)

AXLES

2WD — Non-drive, Stub Axle

Front
4WD — Full Floating, 4.55:1

Single Reduction Semi Floating Hypoid type

Rear 2WD – 4.55 : 1
4WD – 4.55 : 1

WHEELS & TIRES

Rim 6.5 J x 16"

Tires P245/75 R16 111S

STEERING

Type/Description Rack & Pinion, Power Assisted - Hydraulic

Turning Circle Diameter 13.4 m

SUSPENSION

Independent, wishbone type suspension with torsion

Front bar at both side, front stabilizer bar.

Leaf Spring with shock absorber assy, Rear stabilizer

Rear
bar

Shock Absorber Hydraulic, Double Acting, Telescopic

BRAKES

Hydraulic, Vacuum Assisted Servo, Front Disc, Rear

Service Brake Drum, with ABS & EBD (if equipped)

Front Ventilated Disc and Caliper Type

Rear Drum type, Internally Expanding with Auto Adjuster

Internal expanding with auto adjuster on rear wheels,

Parking Brake
hand lever and cable type.

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
36 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

FUEL

Fuel Capacity 80 liters

ELECTRICAL SYSTEM

System Voltage 12V

Battery 90 AH

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 37
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.5 Maintenance Schedule

Distance Covered in km / Months in service

whichever is earlier

3- 4-
0- 0- 6- 7-
1- 20- 50- 80- 90- 10-
Description 5- 0- 0- 0- 0-
0- 00- 00- 00- 00- 00-
0- 0- 0- 0- 0-
0- 0/ 0/ 0/ 0/ 00/
00/ 0/ 0/ 00/ 00/
00/ 12- 30- 48- 54- 60-
3M 1- 2- 3- 4-
6M M M M M M
8- 4- 6M 2M
M M

A = Adjust as Necessary I = Inspect and correct. Replace if worn out or

faulty R = Replace L = Lubricate C = Clean

ENGINE & COOLING SYSTEM

Engine Oil I R R R R R R R R R R

Engine Oil Filter I R R R R R R R R R R

Check Engine Oil Level and

| | | | | | | | | | |
Leakage

Auto Tensioner and Belt -

| | R
Compressor/Water Pump

Auto Tensioner and Belt -

| | R
Alternator/Power Steering

Engine Coolant I I I I R I I I R I I

AIR, FUEL AND EXHAUST

Air Cleaner Element A R R R

Fuel Filter Element R R R R R

Water In Fuel Filter D I I I I I I I I I I I

Exhaust Pipe Mountings

and Damage / Leakage I I I I I I I I I I I

CLUTCH ,TRANSMISSION&TRANSFER CASE

Clutch Fluid I I R I I R I I R I

Transmission Oil I R I I R I I R I I R

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
38 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Distance Covered in km / Months in service

whichever is earlier

3- 4-
0- 0- 6- 7-
1- 20- 50- 80- 90- 10-
Description 5- 0- 0- 0- 0-
0- 00- 00- 00- 00- 00-
0- 0- 0- 0- 0-
0- 0/ 0/ 0/ 0/ 00/
00/ 0/ 0/ 00/ 00/
00/ 12- 30- 48- 54- 60-
3M 1- 2- 3- 4-
6M M M M M M
8- 4- 6M 2M
M M

A = Adjust as Necessary I = Inspect and correct. Replace if worn out or

faulty R = Replace L = Lubricate C = Clean

Transfer Case Oil ( For

4WD Models Only) I I R I I I R I I I R

PEDALS & CONTROLS

Brake & clutch for free play

& operation I I I I I

STEERING

Check Power Steering

Reservoir Fluid Level And
I I I I I I I I I I I
Hose Connection For
Leaks

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 39
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Distance Covered in km / Months in service

whichever is earlier

3- 4-
0- 0- 6- 7-
1- 20- 50- 80- 90- 10-
Description 5- 0- 0- 0- 0-
0- 00- 00- 00- 00- 00-
0- 0- 0- 0- 0-
0- 0/ 0/ 0/ 0/ 00/
00/ 0/ 0/ 00/ 00/
00/ 12- 30- 48- 54- 60-
3M 1- 2- 3- 4-
6M M M M M M
8- 4- 6M 2M
M M

A = Adjust as Necessary I = Inspect and correct. Replace if worn out or

faulty R = Replace L = Lubricate C = Clean

FRONT AXLE (4WD Models)

Differential Oil (Front) I R I I R I I R I I R

Check And Repack Front

Axle 4wd Wheel Bearing
Grease & Replace Seals & R R
Also Check For Smooth
Rotation.

REAR AXLES

Check, Top-Up If Required

& Replace Rear Axle I R I I R I I R I I R
Differential Gear Oil

WHEELS & TYRES

Tyre Rotation I I I I I I I I I I I

Tyres Inflation Pressure

(Including Spare Tyre) I I I I I I I I I I I

Wheel Alignment* I I I I I I I I I I I

PROPELLER SHAFT

Check & Grease Propeller

Shaft Sliding Yoke I I I I I I I I I I
Assembly

BRAKES

Brake Fluid I I I R I I R I I R I

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
40 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Distance Covered in km / Months in service

whichever is earlier

3- 4-
0- 0- 6- 7-
1- 20- 50- 80- 90- 10-
Description 5- 0- 0- 0- 0-
0- 00- 00- 00- 00- 00-
0- 0- 0- 0- 0-
0- 0/ 0/ 0/ 0/ 00/
00/ 0/ 0/ 00/ 00/
00/ 12- 30- 48- 54- 60-
3M 1- 2- 3- 4-
6M M M M M M
8- 4- 6M 2M
M M

A = Adjust as Necessary I = Inspect and correct. Replace if worn out or

faulty R = Replace L = Lubricate C = Clean

Brake Pads, Disc & Other

Brake Components For I I I I I I I I I I I
Wear, Deterioration

Rear Brake Lining, Drums

& Other Brake Components I I I I I I I I I I I
For Wear, Deterioration

Parking Brake I I I I I I I I I I I

SUSPENSION(Replace bushes if necessary)

Suspension Bushes I I I I I

Suspension Arms and

I I I I I
Links

ELECTRICALS

All instruments, gauges,

lights and accessories I I I I I I I I I I
operation

Battery fluid level, specific

gravity and conditions of I I I I I I I I I I
battery terminals

Headlights (High & Low

beam) & levelling I I I I I I I I I I
mechanism operation

HVAC

Mesh Element R R R R R

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 41
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Distance Covered in km / Months in service

whichever is earlier

3- 4-
0- 0- 6- 7-
1- 20- 50- 80- 90- 10-
Description 5- 0- 0- 0- 0-
0- 00- 00- 00- 00- 00-
0- 0- 0- 0- 0-
0- 0/ 0/ 0/ 0/ 00/
00/ 0/ 0/ 00/ 00/
00/ 12- 30- 48- 54- 60-
3M 1- 2- 3- 4-
6M M M M M M
8- 4- 6M 2M
M M

A = Adjust as Necessary I = Inspect and correct. Replace if worn out or

faulty R = Replace L = Lubricate C = Clean

UNDER BODY INSPECTION

Differential, propeller
shafts, drive shafts, body
mounting bolts, engine
mounting bolts, suspension I I I I I I I I I I
mounting bolts for any
damage

A- Under Extremely
Dusty Conditions
*Charges to be paid by customer Interval To Be
Reduced At Every
10,000 kms

D- Check and clean as per kms or when indicator glows

A = Adjust as Necessary; I = Inspect and correct.; Replace if worn out or faulty ;R =

Replace L = Lubricate ;C = Clean

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
42 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.6 Lubrication Chart

PERFORMANCE
VISCOSITY GRADE SAE
SPECIFICATION
FILLING
SYSTEM DIESEL DIESEL
–10° C & VOLUME
ENGINES (up ENGINES (up Upto -10° C
to Euro IV) to Euro V) below

API CH4, MB
228.3, VDS-2,
Engine DHD-1 and / or ACEA C3 15W- 40 5W-30 6 Litres
ACEA A5/B5;
A3/B4
BASF MAKE "GLYSANTIN" G 30 #
Engine Note: # Mix non-conductive (de mineralized) water with coolant
Radiator externally & fill upto the max level. 7.5 Litres
Coolant
Ratio : 30% Coolant + 70% water for temperatures up to -10°C,
Below -10°C use 50% Coolant + 50% water
Transmis-
Manual Transmission Fluid 75W-90 75W-90 2.25 Litres
sion
Electronic
Transfer ATF MEETING THE SPEC. OF DEXTRON III 1.2 Litres
Case
API GL-5, Meeting LS Rear Axle: 1.8
Axles specification80W-90 80W-90 Litres & Front
Axle: 1.25 Litres
Power SHELL SPIRAX S3 ATF MD3 / CALTEX MAKE "TEXAMATIC" 0.8 Litres
Steering 1888 (approx)
Brake & Fluid Meeting SAE J 1703 FMVSS No.116; DOT 4 0.9 Litres
Clutch specifications (approx)
Wheel
Hub &
Chassis NLGI 3 NLGI 2
Lithium Complex Grease As Required
Lubrica- (Mineral) (Synthetic)
tion
Points

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 43
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.7 Explanation on Color Codes used in Illustrations

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.

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
44 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.8 Good Workshop Practices

ATTIRE/DRESS
1. Always wear clean uniform
2. Wear safety shoes
3. Wear gloves, when required
4. Wear belt cover
VEHICLE PROTECTION
1. Put seat cover, fender cover, steering wheel cover, before starting the operations.
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.
PARTS AND TOOLS
1. Before starting the operation, prepare tool stand, MST (Special Tools), gauges, oils and
parts for replacement.
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 re-usable 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.
The removed parts should be packed in clean bags and handed over to the customer.

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 45
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.9 Legend of the Safety Symbols

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

Term/ Symbol Denotation

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in
death or serious injury.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.

CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.

Indicates important information relevant to

the vehicle, the vehicle's use or to sections of
this manual to which particular attention must
be paid for optimum use of the vehicle.

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

“do not,” “do not do this,” or “never”.

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
46 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.1.10 Legend of the Symbols

Symbol Denotation

Inspection

Wrong practice

Right Practice

Sealant Application

Dis - assembly Sequence

Assembly Sequence

Torque Tightening

Tightening Sequence

Lubrication Symbol (Soap oil)

Lubrication Symbol (oil)

Lubrication Symbol (Semi solid)

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 47
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.2 General Precautions

When working on the vehicle in the workshop, always follow the below mentioned procedures:
• Make sure that the area has adequate ventilation to disperse exhaust gases such as
carbon monoxide and other fumes.
• When the engine is running, use adequate ventilation or an extraction hose to remove
exhaust fumes.
• Make sure that there is no oil or fuel spillage in the floor. Spilled fluids can cause fire
hazard, besides increasing the risk of personnel slipping.
• Make sure that the work area such as floors, workbenches, tools are clean and free from
debris.
• Be sure that all necessary tools and measuring equipment are available before starting any
work.
• Use Mahindra Service Tools when they are required.
• Do not allow other people near the vehicle during servicing.
• Always engage the parking brake and/or use wheel chocks to prevent the vehicle from
moving.
• Ensure there is adequate room to raise the vehicle and remove the wheels, if necessary.
• Do not let fuel, coolant and other fluids spill over electrical and hot vehicle parts.
• Avoid repeated contact with fluids.
• Do not disconnect battery when not required.
• If battery disconnected then relearning- if any to be done.
• The battery should be disconnected while, working on the starter motor, alternator, ECU’s
and during such similar critical activities.
• Cover seats and carpets, wear clean overalls and wash hands or wear gloves before
working inside the vehicle.
• Avoid spilling hydraulic fluid or battery acid on paint work. Wash off with water immediately
on contact. Use plastic sheets to protect carpets and seats.
• Protect temporarily exposed screw threads by fitting plastic caps.
• While using the welding equipment on the vehicle, keep a suitable fire extinguisher readily
available.
• Before using the welding equipment always disconnect the battery negative terminal.
Failing to do so will result in ECU failures..
Preparation before dismantling the vehicle parts
• Clean components and surrounding area prior to removal.
• Blank-off any openings exposed by component removal using grease proof paper and
masking tape.
• Use plastic caps or plugs immediately to seal fuel, oil or hydraulic lines when separated to
prevent loss of fluid and entry of dirt.
• Close the open ends of oil ways, exposed by component removal with tapered hardwood
plugs or readily visible plastic plugs.
• After a component is removed, place it in a suitable container/tray. Use a separate
container/tray for each component and its associated parts.

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
48 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Dismantling of the vehicle parts

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

• Fitment of non-approved accessories could lead to vehicle not performing as

intended resulting in personal injury or death in case of an accident.
• Improper maintenance, including incorrect removal and installation of the SRS, will
lead to personal injury caused by accidental activation of the system.

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 49
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.2.1 Towing your Vehicle During Emergency

If a towing service is unavailable in an emergency, the vehicle may be temporarily towed by a
cable or chain secured to the towing eyelet under the front bumper, welded with the front cross
member. Use only the eyelet for towing in an emergency. Otherwise the vehicle may get
damaged.

• A driver must be present in the vehicle being towed to steer and operate the brakes.
Towing in this manner must be done only on hard surfaced roads for short
distances and at low speeds. Also, the wheels, axles, drive train, steering and
brakes must all be in good condition.
• Avoid sudden starts or erratic driving maneuvers, which would place excessive
stress on the towing eyelet and towing cable or chain, and result in breaking of the
eyelet or the chain.
• If the engine is not running, the power assist for the steering and brakes will not
work and it will be much harder than usual.
• When lifting the rear wheels, take care to ensure adequate ground clearance for
towing at the front end of the raised vehicle. The bumper and/or underbody of the
vehicle may be damaged during towing.

• Use only a cable or chain specifically intended for use in towing vehicles. Securely
fasten the cable or chain to the towing eyelets provided.
• Do not tow with sling type truck, either from the front or rear. Doing so may cause
body damage.
Front Tow Hook

Front tow hook is welded to front cradle

assembly.
The front self recovery tow hook is in the tool
pouch located under the second row seat.
Remove/Pry out the tow hook cover in the
front LHS bumper using a screwdriver. Screw
in the recovery hook and tighten. Fasten a
cable or chain specifically intended for use in
towing vehicles to the towing hook.

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
50 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Rear Tow Hook

The vehicle comes with a rear welded self

recovery tow hook.

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 51
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.2.2 Towing Equipment

Towing Equipment’s are of different Types
Sling-type equipment: The tow truck uses metal cables with hooks on both ends. These
hooks go around parts of the frame or suspension and lift the end of the vehicle off the ground.
This is not a good method of towing as it may damage the vehicle's suspension and body.
Avoid tow with sling type equipment.

Flat-bed equipment: The vehicle is loaded on the back of a truck. This is the safest and best
way of towing.

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
52 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Front/Rear - lift equipment: The tow truck uses two pivoting arms that go under the tyres
(front or rear) and lift them off the ground. The other two tyres remain on the ground.
• For Mahindra Pikup vehicles equipped with MT, only Rear lift equipment is
recommended.
• Never tow Mahindra Pikup vehicles using front lift equipment.

Improper towing procedure will damage the transmission. Follow the towing
instructions precisely.

4WD vehicles:
While towing on two wheels, propeller shaft needs to disconnect in order to protect the
coupling. Propeller shaft need not be disconnected while towing on all four wheels.

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 53
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.2.3 Service Precautions

Removal of Parts
While correcting a problem, try to determine its cause. Begin to work only after first learning
which parts and subassemblies need to be removed and disassembled for replacement or
repair. After removing the part, plug all holes and ports to prevent entering of foreign materials.
Disassembly of Parts
If the disassembly procedure is complex and requires many parts to be disassembled, all parts
should be temporarily marked in a place that will not affect their performance or external
appearance and identified so that reassembly can be performed with ease and efficiency.
Inspection during Removal/ Disassembly
When removed, each part should be carefully inspected for malfunctioning, deformation,
damage, and other problems.
Arrangement of Parts
All disassembled parts should be carefully arranged for reassembly. Be sure to separate or
otherwise identify the parts to be replaced from those that will be reused.
Cleaning of Parts
All parts to be reused should be carefully and thoroughly cleaned by using the appropriate
cleaning agent and method.

Using compressed air will cause dirt and other particles to fly out, and cause injury to
the eyes, wear protective goggles to avoid probable injury.
Reassembly
• Standard values, such as torques and certain adjustments, must be strictly adhered to while
reassembling the parts.
• If removed, these parts should be replaced with new ones:
1. Oil seals
2. O-rings
3. Cotter pins
4. Lock washers
5. Nylon nuts
• Specified oil/lubricant should be applied to the moving components or parts.
• Specified oil or grease should be applied at the prescribed locations such as oil seals
before reassembly.
Adjustment
Use recommended/appropriate gauges and testers while making adjustments.
Rubber Parts and Tubing
Prevent fuel or oil from spilling on rubber parts or tubing.

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
54 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Vise
When using a vise, use protective padding in the jaws of the vise to prevent damage to parts.
Component Cleaning
To prevent the ingress of dirt, accumulation of loose dirt and greasy deposits should be
removed before disconnecting or dismantling components or assemblies. Components should
be thoroughly cleaned using appropriate cleaning agent before inspection and prior to
reassembly.

Wear eye protection while cleaning vehicle components with compressed air, a steam
cleaner or power washer. Failure to follow this instruction will result in personal injury.

• To prevent damage to the electrical connectors in the engine compartment, do not

use a steam cleaner or power washer to clean the engine compartment.
• When testing sensitive components and electrical circuits with an ohmmeter or
voltmeter, make sure that the vehicle electrical system is not getting damaged by
improper use of tool.
ECU and electrical parts precautions
• Never reverse the polarity of battery terminals.
• Install only the parts specified for that particular vehicle.
• Do not apply too much force while disconnecting the connector.
• Do not apply excessive shock to the ECU by dropping or hitting it.
• Be careful to prevent condensation in the ECU due to rapid temperature changes and do
not allow water or rain to enter the ECU.
• Be careful not to let oil into the ECU connector.
• Avoid cleaning the ECU with volatile oil.
• Do not disassemble the ECU, do not remove the upper or lower covers.

During normal operation, batteries generate dangerous explosive gases that may
explode if exposed to open flames or sparks resulting in personal injury or death.

Do not reverse the negative (-) and positive (+) battery cable
connections. This may lead to serious damage to the vehicle electrical system.
Electrical Parts
Battery Cable
• Before disconnecting connectors or removing electrical parts, switch OFF the ignition and
disconnect the negative battery cable, unless battery voltage is required to perform
diagnosis or repair.

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 55
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Connectors

Inserting a jumper wire probe into the data link connector terminal may damage the
terminal.
• When disengaging the electrical connectors, never pull on the wire. Always pull the
connector apart by disengaging the locking tab and pulling on the connector body.
Disconnecting Connector
• When disconnecting two connectors, grasp the connectors not the wires.
• Connectors should be disconnected by pressing or pulling the lock lever.
Locking Connector
• When locking connectors, listen for a click that will indicate that they are securely
locked.
Connector Inspection
• When a tester is used to check for continuity or to measure voltage, insert the tester
probe from the wiring harness side.
• Check the terminals of waterproof connectors from the connector side, as they
cannot be accessed from the wiring harness side.

To prevent damage to the terminal, wrap a thin wire around the lead before inserting it
into the terminal.
Terminals Inspection
• Pull individual wires lightly to check that they are secured firmly in the connector.
Precautions for Engine Control Unit (ECU)
Before connecting or disconnecting ECU harness connector:
• Turn ignition switch to “OFF” position.
• Disconnect the negative battery terminal and wait for at least 2 minutes before
disconnecting the ECU connector. Ensure the battery negative terminal is disconnected
while connecting the ECU connector.
• Do not forcefully pry off the ECU connector.

Avoid touching the terminals and connectors of sensitive electrical components, static
electricity may damage the vehicle ECU and other sensitive electrical components.
This may cause electric shock and cause personal injury.

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
56 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Do not expose the ECU or other sensitive electrical components to water, heat, or
shock of any type, leading to component damage.

Sensors, Switches, and Relays

• Handle the sensors, switches, and relays with care. Do not drop them or strike them against
other objects.
Fuse Replacement
• While replacing a fuse, be sure to replace it with the specified capacity. Check the circuit
before replacing the fuse.
• Be sure that the negative battery terminal is disconnected before replacing a main fuse.
• While replacing a pullout type fuse, use the fuse puller.
Efficient diagnosis
1. Obtain detailed information about the conditions and the environment when the incident
occurred.
The following key information provides a good study of the incident:
• WHAT - Vehicle Model, Engine, Transmission and the System.
• WHEN - Date, Time of Day, Weather Conditions, Frequency, speed of the vehicle,
Engine rpm, which gear, Whether 2WD or AWD.
• WHERE - Road Conditions, Altitude and Traffic Situation.

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 57
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• HOW - System Symptoms, Operating Conditions. Service History and if any

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

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
58 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.3 Jacking and Lifting

Front jack up point — B - On the chassis long member just behind the front wheels.
Rear jack up point — A - under the rear axle.
Jacking & Lifting Points

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 59
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1.3.1 Jacking
Position the jack at the correct jacking point. Make sure the jack is positioned on a level and
solid ground. Ensure no one is in the vehicle.
Block the wheel diagonally opposite the flat tyre to keep the vehicle from rolling when it is
jacked up. When blocking the wheel, place a wheel block in front of one of the front wheels or
behind one of the rear wheels.

A Flat Tyre B Chock Blocks

To raise the vehicle, insert the jack handle end along with the extension into the jack and turn it
clockwise with the jack handle. As the jack touches the vehicle and begins to lift, check that it
is properly positioned.

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
60 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Make sure to set the jack properly in the jacking point. Raising the vehicle with an
improperly positioned jack will damage the underbody of the vehicle or may allow the
vehicle to fall off the jack and cause personal injury.
• Use the jack only for lifting your vehicle during wheel changing.
• Do not raise the jack with someone in the vehicle.
• When raising the vehicle, do not place any objects on top of or underneath the jack.
• Raise the vehicle only high enough to remove and change the wheel.
• Usable extended height of jack is up to the yellow line/mark. Do not raise the jack
above the yellow line.
• Follow jacking instructions.
• Do not start or run the engine while the vehicle is supported by the jack.

Never get under the vehicle when the vehicle is supported by the jack alone.

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 61
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
62 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2 ENGINE - mHAWK

2.1 Description & Operation

2.1.1 Engine System

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

The 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 63
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

The fuel economy and emission has been optimized at source by means of low engine friction,
faster engine warm up, centralized injectors, optimized combustion, catalytic converter, closed
loop operation of the turbocharger (VGT) etc.
The engine NVH is optimized by means of stiffened engine components, optimized engine
mounts (Hydro mounts), multiple injection strategy etc.

2.1.2 Cylinder Head

A diesel engine cylinder head performs

several functions.
• They provide the top seal for the cylinders
bore.
• They provide structure holding the Valves,
fuel injectors, cam shafts, glow plugs and
other components.
• The cylinder head even consists of ports
which are used to allow air in to the
combustion chamber & allows the exhaust
gases to move out.
The cylinder head is bolted on top of the
cylinder block to form the roof of the
combustion chamber. The cylinder head:
• Seals the top of the cylinder block.
• Holds the glow plugs, fuel rail and
injectors.
• Provides seats, guides and ports for the
intake and exhaust valves.
• Holds the valve train.
• Provides mountings for the intake and
exhaust manifold.
The intake and exhaust manifolds are
mounted to the cylinder head against the
valve ports. The top part of the cylinder head
is designed such that the rocker arm and
other parts of the valve train can be mounted
on it. The aluminium alloy gives the head
superior heat dissipating capability to that of
the cast iron head. The coolant and oil
passages are incorporated in the head for
cooling and lubrication purposes.
The cylinder head gasket forms the gas and
watertight junction between the cylinder head
and block. It also offsets any minor
irregularities in the mating surfaces. Thus the
gasket is made up of flexible material.

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
64 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.3 High Pressure Pump (HPP)

The HPP is driven by the engine timing

chain. The sprocket bolted to the main shaft
of the HPP is also marked while setting the
timing of the engine. The HPP pumps in the
required quantity of the fuel into the common
rail. The HPP should be replaced as a whole
assembly.

2.1.4 Oils Separators

The oil separator separates oil from the blow

by of the engine and sends it back to engine
oil sump. The remaining air and other gases
are sent to the inlet manifold.
There is also a spring loaded diaphragm
valve provided on the oil separator outlet to
the inlet manifold. This prevents the flow of
excessive of blow by from the oil separator to
the inlet manifold in case the air filter is
chocked and high suction starts acting on
outlet port of oil separator.
No leakage past diaphragm or top cover of
oil separator is permitted. Replace the
assembly if there is any leakage or found
defective.

2.1.5 Oil Cooler

The engine oil becomes hot and has to be

cooled else it loses its properties. The hot oil
rejects heat to the coolant in the oil cooler.
The oil thus maintains its temperature at
optimum level.

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 65
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.6 Oil Filter

The oil filter traps the impurities and foreign

particles are present in the oil.

2.1.7 Oil Sump/ Pan

The oil pan is the reservoir for the oil and

also cover the crank case. It is secured to the
engine block by bolts. A sealant is used to
provide a leak proof joint.

2.1.8 Oil Strainer

Oil strainer is the first stage in the filtration of

the lubricant. It filters the coarse particles
present in the oil before it enters the oil
pump.

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
66 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.9 Oil Dipstick

Oil dipstick is used to measure the level of oil

in the pan. It has two marks on it specifying
MIN and MAX levels.

2.1.10 Oil Pressure Switch

Oil Pressure switch operates the low oil

pressure indicator in the cluster. This serves
as a warning indicator to the driver, indicating
a decrease in the oil pressure which might
harm the engine if he continues running the
engine.

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 67
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.11 Injectors

It is an electro — mechanical device, which is

used to inject the fuel it to the combustion
chamber. The quantity of fuel injected in the
combustion chamber is controlled by an
electronic control module.

2.1.12 Cylinder Block

The Cylinder block is the basic building of an

engine. It is the place where the power is
produced and delivered. Essentially the
cylinder block forms a housing for most of the
components of the engine like crank shaft,
connecting rod, piston, piston pin etc. it's also
houses the water jacket and main oil
galleries. Which takes away the excess heat
and disperses it to the atmosphere.
Together with the compression chamber in
the cylinder head and the piston crown, the
cylinder forms the combustion chamber. The
cylinder's task is to guide the piston and to
dissipate surplus heat which occurs during
combustion. In addition, the cylinders,
together with the piston rings, have a sliding
and sealing function.

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
68 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.13 Piston

The task of the piston is to receive the

pressure forces that arise as a result of the
combustion of the air/fuel mixture and to
transfer them via the piston pin and the
connecting rod to the crankshaft.
The piston has to provide the moving seal
between the combustion chamber and the
crank case. Due to its up and down
movement it creates vacuum to induce the
air and then compress it. The main task
however is to transmit the pressure of the
combustion gases through the connecting
rod to the crank shaft. Accordingly the piston
has to be light in weight in order to minimize
the inertia forces and also be able to
withstand the combustion heat and dissipate
it. Its thermal expansion should not be too
high as otherwise it could stick to the cylinder
bore.
The piston has the following components, the
crown, the ring zone, the skirt and the pin
bore. The crown is the top most part of the
piston which is subjected to the greatest
thermal and pressure loads. The crown also
has the combustion chamber incorporated
into it. It also has grooves cut on it to make
way for the valves when they are fully open.
In the ring zone 3 rings ensure a good
sealing in the cylinder. It minimizes the
quantity of the combustion gasses that is
escaping to the crank case. The piston skirt
guides the piston in the bore. The rings also
prevent the lubricating oil from getting into
the combustion chamber. The piston bore
accommodates the piston pin which
connects piston to the connecting rod.
There are two types of rings, one is the
compression rings and other one is oil ring.
Compression rings are located at the top on
the piston. They are intended to ensure the
gas-tight seal possible to the combustion
chamber. Compression rings include the
plain compression ring at the top and second
is having an inside bevel and taper-face. The
lower piston rings are the oil scraper rings.
These prevent oil from penetrating into the
combustion chamber. The oil scraper rings
include the slotted oil control ring (with oil
passage to the insides of the piston) and the
oil ring with an expander or spiral-type

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 69
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

expander (narrow running surface to

increase pressure force). The three rings are
mounted on the pistons at a phase difference
of 120 degrees to each other. The piston
cooling is by an oil jet mounted on the
crankcase and on the main oil gallery.

2.1.14 Connecting Rods

The connecting rod transfers the movement

of the piston to the crank pin on the crank
shaft. A steel piston pin connects the piston
to the connecting rod. Since it is subjected to
very severe alternating tensile, compressive
and buckling loads. its “I” cross section gives
the connecting rod the required stiffness. The
piston pin allows the piston to pivot the small
end of the connecting rod with the piston.
The large end of the connecting rod is
connected to the crank shaft with a bearing
cap.

2.1.15 Crank Shaft

The crankshaft receives the power in linear

direction and convert it into rotatory motion.
The flywheel is mated at the rear end and
transmits the power through the clutch and
transmission to the wheels.
The front end is having a vibration dampener
and also is used to drive the critical
camshaft.
The drive through the vibration dampener is
used for accessories like water pump, power
steering and AC compressor.

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
70 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.16 Roller Finger (RFF) and Lash Adjuster (HLA) Assembly

The RFF and HLA assembly together

provide zero clearance between the valve
stem and roller follower. The HLA damps the
spring return force when the valve closes
(comes back to original position). This will
result in noiseless and smooth operation of
valve opening and closing.
The HLA is operated by hydraulics (oil). Oil
for the HLA is provided from the oil gallery.
During valve closing the cam force initially
presses the HLA down, then the valve is
opened. When the valve opens the HLA
dampens the spring force by moving HLA up
and down. As the valve stem gets worn off
the HLA moves up and maintains the zero
clearance between valve stem and roller
follower. Thus by this actions RFF and HLA
provides noiseless the valve closing and
opening operation.

A. Intake camshaft.
B. Exhaust camshaft.
C. HLLA (Hydraulic Lash Limiting Adjuster).
D. Exhaust valve.
E. Intake valve.
F. Valve Spring.
G. RFF (Roller Finger Follower).

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 71
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.17 Intake and Exhaust Valve

The main function of the valve is opening and

closing the ports in the cylinder head during
the exchange of gases. The four valves per
cylinder design is more precise and efficient.
Two inlet valves are bigger in diameter when
compared to the two exhaust valves. Valves
are subjected to extremely high pressure and
temperatures. Although the inlet valves are
cooled by the intake air it still heats up to high
temperatures since it lies in the path of hot
combustion gases. The valves are solid and
heat treated. The valve face is the contact
point between the valve and its seat. Both
A. Hydraulic Lash Adjuster these surfaces are machined to form a tight
seal when closed. Maximum contact is
B. Valve Spring Retainer Top essential for better heat transfer.
C. Valve Lock The valve guides keep the valves in precise
D. Valve Spring alignment in the cylinder head. They allow
the valve stem to go through the combustion
E. Valve Spring Retainer Bottom chamber to the upper cylinder head area,
F. Intake Valve where the valve springs are mounted. The
guides are soft alloy inserts that are pressed
G. Exhaust Valve into the head. The valve springs are
responsible for closing the valve firmly on to
the valve seat. This is installed on to the
cylinder head around the valve stem. The
upper and lower spring seats prevent wear
and keep the spring in place. When the valve
moves it must seated firmly again the valve
seat. There must not be any pressure on the
stem side of the valve.

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
72 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.18 Valve Gear Drive

The main function of the engine timing is to

coordinate the induction of the fresh gases
and expulsion of the exhaust gases. The
valve gear drives the camshafts by taking
drive from the crankshaft via a timing chain.
The timing chain transmit the motion with
comparatively less noise and better
efficiency. The chain and the tensioner are
subjected to minimal wear and maintenance
is unnecessary. In extreme cases when the
chain wears out it is replaced.
The timing chain is tensioned using an auto
tensioner. There is no need to constantly
reset or service the timing chain or the
tensioner or the crankshaft sprocket. The
camshaft sprocket bolted to the camshaft is
having mark which must be aligned
appropriately during the assembly to
maintain proper valve timing.

2.1.19 Cam Shafts

The camshaft controls the valve opening and

closing events. It is driven by the crankshaft
through a chain connection. The camshaft
rotates at half the speed of the crankshaft to
maintain proper timing of the four cycle of
combustion. The opening and closing of the
valves are done by lobes on the camshaft.
The engine has two camshafts one for
operating intake valves and the other for
exhaust. The exhaust camshaft is identified
by the presence of a ring for the purpose of
operating a cam phase sensor.
The timing of the valve depends on the
position of the camshaft and shape of the
lobes on it.
The valve lift is the distance the valve is lifted
off its seat when fully opened. This is
determined by the height of the cam lobe.
The valve need enough lift to allow air to flow
freely into the cylinder and for exhaust gases
to flow out of the cylinder, without interfering
with piston or binding the spring.
The duration is the length of time the cam
lobe keeps the valve open. it is measured in
degrees of camshaft rotation and is
determined by the shape of the cam lobe.

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 73
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.20 Engine Speed Sensor (Crank Shaft Sensor)

The crankshaft speed sensor is an inductive

type sensor. It measures the speed of the
trigger wheel mounted on the crankshaft.
During engine cranking and running, the
EMS ECU receives the output signal from
crankshaft speed sensor.

2.1.21 Glow Plug

A glow plug is a heating device used to aid in

cold starting. In cold weather, high speed
diesel engines can be difficult to start
because the mass of the cylinder block and
cylinder head absorb the heat of
compression, preventing ignition due to the
higher surface-to-volume ratio.
The glow plug is a pencil-shaped piece of
metal with a heating element at the tip. This
heating element, when electrified, heats due
to its electrical resistance and begins to emit
light in the visible spectrum, hence the term
glow-plug.
The heat generated by the glow plugs is
directed into the cylinders and serves to
warm the engine block immediately
surrounding the cylinders. This aids in
reducing the amount of thermal diffusion
which will occur when the engine attempts to
start.
The fuel injector spray pattern then impinges
directly upon the hot tip of the glow plug
during the injection of fuel at top dead center.
This enables the fuel to ignite even when the
engine is insufficiently hot for normal
operation. This reduces the cranking time
needed to start the diesel engine.
The glow plugs are controlled by the EMS
ECU. The ECU decides the actuation of the
glow plugs based on operating conditions,
engine temperature and environment
temperature.

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
74 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.22 Cam Phase Sensor

The cam phase sensor is located on the cam

cover and senses the trigger wheel of the
exhaust cam shaft.
The camshafts control engine intake and
exhaust valves. They rotate at half the
engine speed. When a piston travels up
towards 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 words, it means, that if the camshaft
sensor fails while the engine is running, the
ECU will receive information on the engine
status from the crankshaft sensor.
The cam phase sensor utilizes the Hall-Effect
for establishing the camshaft position. A
tooth of ferromagnetic is attached to the
exhaust 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 wafer.
This result in a brief voltage signal (Hall
voltage) that informs the ECU that cylinder 1
has entered the compression phase.

2.1.23 EMS ECU

EMS (Engine Management System) ECU is

an electronic control unit which is used to
ensure optimal engine performance. It does
this by analyzing values or signals from
various sensors and other ECU’s and
adjusting the actuators accordingly.
EMS ECU is mounted in Passenger
compartment on front right side below
Instrument panel.

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 75
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.24 Accessory Drive Belt Auto-tensioner’s

This vehicle is equipped with two auto-

tensioner’s. One auto-tensioner for
Alternator/Power steering pump drive belt
and other for Water pump/AC compressor
drive belt.
It is mandatory to maintain belt tension
through out the belt life in-order to have
maximum efficiency and life. A tensioner is a
device that applies a force to create or
maintain recommended belt tension.

2.1.25 Accessory Drive Belts

In this vehicle there is two accessory drive

belts
1. Alternator/Power Steering Pump
Drive Belt.
This drive belt connects the damper
pulley with Alternator and Power
steering pump pulley, and thus
transfers drive required for the
operation of alternator and power
steering pump from engine via
crankshaft damper pulley.
2. AC Compressor/Water pump Drive
Belt.
This drive belt connects the damper
pulley with AC compressor & Water
pump pulley, and thus transfers drive
required for the operation of AC
compressor & Water pump from engine
via crankshaft damper pulley.

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
76 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.26 Damper Pulley

The damper pulley is mounted on the front

end of the crank shaft. The power stroke tend
to twist the engine crankshaft. Each power
stroke applies a huge force on the crank pin.
This force tries to push the crank pin ahead
of the rest of the crankshaft. Then as the
force on the crank pin recedes, the
crankshaft untwists. This twist-untwist action
repeats with every power stroke. Then action
tends to create an oscillating motion on
crankshaft. This is torsional vibration. It can
break the crankshaft.
The vibration damper helps to control
torsional vibration.

2.1.27 Engine Insulator / Mount

Two Engine mounts are used in this vehicle.

The function of engine mount is to isolate
engine vibrations from getting transferred to
chassis and thus improving the comfort
inside the passenger compartment.

2.1.28 Vacuum Pump

Vacuum pump is fitted on the rear part of the

engine, it receives drive from exhaust cam
shaft. the function of vacuum pump is to
create vacuum for the Turbo actuation, EGR
actuation and Brake booster functioning.

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 77
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.1.29 Inlet Manifold

It is a structure of a pipe, which carries air

into the combustion chamber in an engine.
The primary function of the intake manifold is
to evenly distribute the air to each intake port
in the cylinder head (s). Even distribution is
important to optimize the efficiency and
performance of the engine.

2.1.30 Exhaust Manifold

The exhaust manifold collects the exhaust

gases from multiple cylinders into exhaust
pipe. It may also serve as a mount for the,
turbo charger and other components of the
engine.

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
78 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.2 Component Location Index

2.2.1 Engine View 1
Refer below illustrations for mHAWK engine accessory and component location -

A. Crank Case Ventilation B. Oil filler Cap

C. Injector D. Timing Cover

E. Water Pump Assembly F. Viscous Fan

G. Auto Tensioner H. Accessory Drive Belt

I. Damper pulley J. Power Steering Pump pulley

K. Cam Cover L. Intake pipe

M. Intake manifold N. Dipstick

O. Oil filter P. Oil Cooler

Q. Alternator R. Power Steering Pump

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 79
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.2.2 Engine View 2

Refer below illustrations for mHAWK engine accessory and component location -

A. Leak Off Pipe G. EGR Cooler.

B. EGR long pipe H. EGR Short Pipe.

C. Vacuum pump I. Exhaust Manifold

D. Cylinder head outlet pipe J. AC Compressor

E. Dual mass flywheel K. Turbocharger

F. EGR Valve L. Oil Sump

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
80 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.2.3 Engine View 2 – Euro II

Refer below illustrations for mHAWK engine accessory and component location -

A. Leak off pipe B. EGR Long pipe

C. Vacuum Pump D. Cylinder head outlet pipe

E. Dual Mass Flywheel F. EGR Valve

G. EGR Short pipe. H. Exhaust manifold

I. Turbocharger J. AC Compressor

K. Oil Sump

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 81
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.3 Trouble Shooting

Refer below chart for various symptoms, causes and there remedial actions –

Symptom Causes Remedial action

Engine will not 1. Air intake obstructed. • Replace the air filter element.
start & emit
black smoke • Check for free operation of
Turbocharger.

2. Defective injectors • Replace the defective injectors.

3. Lack of compression. • Check compression pressure - if

low check for valve seat, rings and
liner wear.

4. Cylinder head gasket failure • Replace the cylinder head gasket.

5. Engine timing- Valve • Check engine timing.

6. CR system • Refer diagnostic manual.

Noisy engine & 1. Faulty injectors. • Replace the defective injectors.

black smoke.
2. Loose main bearings • Tighten the main bearings.

3. Broken parts • Inspect and replace the broken

parts.

4. EGR valve stuck open • Check the EGR valve & replace if
mechanically required.

Engine does 1. Air intake restricted. • Replace air cleaner element if

not give full required.
power.
2. Clogged fuel filter. • Replace filter element.

3. Defective injectors. Replace the defective injectors.

4. Air leaks in pressure line after • Plug the leaks, replace hose or
turbocharger ( Turbo to intercooler, clip if required.
intercooler & intercooler to intake
manifold)

5. Fuel return pipe to tank blocked. • Locate the kink/block in return

pipe and rectify.

6. Valve leak • Check the compression pressure,

re-lap if required.

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
82 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

7. Turbocharger damaged • Get the turbocharger repaired at

authorized TEL dealer.

8. Gas leaks between exhaust • Replace gaskets.

manifold & cylinder head.

9. Leaking exhaust system. • Tighten the TC mounting bolts.

Replace gasket if required.

10. Exhaust gas leak between turbo • Correct the leak.

& manifold.

11. Gas leak between EGR pipe • Change the gasket or the hose.
and joints

12. EGR pipe leak. • Replace the pipe.

13. Fuels supply line kink creating • Remove the restriction.

restriction.

14. Compression leak. • Check compression and carry-out

necessary action.

15. Jammed piston rings • Replace piston rings.

16. Vacuum leak to the turbo • Check the vacuum leak and
actuator causing the delayed turbo rectify. Please note that the turbo
operation operation is sensitive to vacuum
leak.

17. Check CR system • Refer the diagnostic manual

Noisy engine & 1. Cylinder head gasket defective. • Replace the cylinder head gasket.
high smoke (
White/ Grey) 2. Worn out or damaged valve • Lap the valve seats or regrind.
seats.

3. Leakage between injector and • Tighten the injector holder

cylinder head. mounting bolt.

Black smoke. 1. Clogged air filter element • Replace the air filter element.

2. Restriction in air intake to • Locate & remove restriction.

compressor duct.

3. Air leak between the • Locate the leaks, change hose or

turbocharger to intake manifold. clamp if required.

4. Excess oil. • Correct the oil level.

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 83
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

5. Wear in valve seal. • Check the valve stem seals,

replace if required.

6. Wear in piston rings & liner. • Check the compression pressure,

replace rings & liners.

7. Turbocharger oil seal leaks • Check the Turbocharger if

defective get it attended.

8. Defective Injectors. • Check Injectors.

White smoke. 1. Improper timing. • Check sprockets & chain for wear.
Rectify

2. Defective cylinder head gasket. • Replace the cylinder head gasket.

3. Restriction in fuel supply • Remove the restrictions.

Starter will not 1. Electrical complaints. • Rectify.

work or only
cranks slightly 2. Hydrostatic lock. • Remove the water in the cylinder
and find the cause for water entry.
• Check and rectify any damage if
happened.

Starter will not 1. Weak battery. • Check the battery specific gravity.
crank the
engine. 2. Corroded or loose battery • Clean & tighten battery
connection. connections.

3. Faulty starter motor. • Repair starter motor or replace.

4. Improper earthing. • Rectify earthing issue.

Noisy valves 1. Thin or diluted engine oil. • Change the engine oil with
recommended specifications.

2. Low oil pressure. • Check the oil level.

3. Worn HLLA • Replace the HLLA.

4. Worn valve guides. • Replace the valve guides.

5. Excessive run out of valves seats • Grind valve seats and valves.

6. Oil thickening • Replace oil & find the reasons of

thickening, rectify.

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
84 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

7. Aeration in oil • Follow the de-aeration procedure.

Oil pressure 1. Low oil level. • Check engine oil level.

drop
2. Defective oil pressure sensor. • Install new sensor.

3. Clogged oil filter. • Replace filter.

4. Clogged oil cooler. • Clean/replace the oil cooler.

5. Clogged oil strainer. • Clean/replace the strainer.

6. Pressure relief valve in oil pump • Rectify.

stuck open.

7. Oil leaks - internal • Check the gasket between the

block and front cover for leakage.

8. Worn parts in oil pump. • Replace the pump.

9. Excessive bearing clearances • Check bearing clearances.

10. Thin or diluted oil. • Change oil to correct viscosity.

11. Oil pump suction tube loose, • Remove sump, inspect the parts &
bent or cracked. replace.

Oil leaks 1. Worn oil seals • Replace the defective seals.

2. Misaligned or deteriorated • Replace gasket.

gaskets.

3. Loose fastener, broken or porous • Tighten fastener

metal parts
• Repair or replace.

Excessive oil 1. Cracked vacuum line hoses. • Check and correct.

consumption
2. Clogged air filter element. • Replace air filter element.

3. Restriction in air intake to • Locate and remove restriction.

turbocharger duct.

4. Restrictions in turbocharger oil • Remove the restriction in drain

drain line. pipe.

5. Restriction in crankcase • Check the crankcase ventilation

breather. and rectify.

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 85
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

6. Damaged oil separator. • Replace the cam cover assembly.

7. Turbocharger damaged. • Change oil, filter, service the

Turbocharger and use
recommended oils and drain
intervals or replace the
turbocharger.

8. Worn out rings, liners, and • Overhaul engine.

valves.

9. External oil leak. • Stop the external oil leakages.

10. Leakages through inlet manifold • Change the manifold O-ring or

mounting face allowing dust entry. replace the manifold.

11. Bend/kink in any of the oil return • Remove the bend or kinks.
pipe’s/ vacuum hoses.

12. Defective vacuum pump. • Replace the vacuum pump.

1. Excess oil. • Correct the oil level.

2. Wear in valve seal. • Check the valve stem seals,

replace if required.
Blue smoke 3. Wear in piston rings and liner. • Check the compression pressure,
replace rings and liners.

4. Turbocharger seal leaks. • Check the turbocharger if

detective get it attended.

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
86 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.4 Engine Cylinder Head Gasket Failure

2.4.1 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 of two ways:
A. Between adjacent cylinders.
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 leakage in engine water jackets.

2.4.1.1 Cylinder to Cylinder Leakage Test

Check the cylinder compression pressure. For additional information refer to Cylinder
compression pressure inspection procedure. Leakage between cylinders will be result in drop
of compression pressure by nearly 50 to 70% in the affected cylinders, thus cylinder to cylinder
leakages can be identified.

2.4.1.2 Cylinder to Water jacket Leakage Test

1. Remove the degassing tank cap.
2. Warm up the engine and till the engine thermostat valve opens.
3. If large combustion /combustion pressure leak exist, bubbles will be visible in coolant.
4. If bubbles are not visible, install a pressure tester on degassing tank 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.

2.5 Engine Overheats

Most over heating is caused by loss of coolant due to leaks in the cooling system. Other
causes are as below: ,
1. Inoperative fan,
2. Defective water pump,
3. Clogged water jacket or radiator,
4. Defective radiator hose,
5. Defective thermostat,
6. Improper valve timing,
7. Lack of engine oil,
8. Usage of non-recommended coolant,

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 87
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.6 Excessive Oil Consumption

An engine loses oil in three ways:
1. An engine gasket, seal may fail, allowing drops of oil to fall on the ground. This is
external leak.
2. Excessive blowby or crankcase air flow may carry oil through the PCV system into the
combustion chamber to be burned.
3. High speed driving along with worn intake valve guides and worn piston oil-rings allow oil
to pass into the combustion chambers.
Smoky exhaust gas indicates the engine is burning oil, Air-fuel mixture is too rich, or water or
coolant has leaked into the combustion chamber.
The colour of the exhaust gas can tell us which condition exists.
• If the exhaust gas has a bluish tinge, the engine is burning oil.
• If the exhaust gas is more black then blue, indicates incomplete combustion of fuel. The air-
fuel mixture may be too rich.
• Whitish exhaust smoke while the engine is cold may be considered normal. But after warm-
up, white smoke may indicate water or coolant has turned to steam in the combustion
chamber. The engine may have a cracked cylinder head or blown head gasket.

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
88 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.7 Standard Checking Procedure

Tests and inspection procedures are necessary for specific engine malfunctions that cannot be
is isolated with the Service Diagnosis charts. In-formation concerning tests and Inspection is
provided within the following
1. Cylinder Compression Pressure Test
2. Cylinder Combustion Pressure Leakage Test.
3. Engine Cylinder Head Gasket Failure Test.
4. Intake Manifold Leakage Test.
5. Engine Oil Leak Test.
6. Inspection for oil seal area leaks.
7. Hydrostatically Locked Engine.

2.7.1 Cylinder Compression Test

The cylinder compression test is performed to determine the compression pressure of
individual cylinders. The test is performed in two stages.
1. Dry Test.
2. Wet Test
The results of the cylinder compression test can be utilized to diagnose several engine
malfunctions.
Before carrying out the compression test ensures that the battery is in good working condition.
Otherwise the indicated pressures may not be valid for diagnostic purpose.

• Check engine oil level and add oil if necessary.

• Drive the vehicle until engine reaches normal operating temperature.

The recommended compression pressures are to be used only as a guide to

diagnosing engine problems. An engine should not be disassembled to determine the
cause of low compression unless some malfunction is present.

2.7.1.1 Dry Test:

1. Remove the respective injector whose compression pressure need to check.
2. Fit the dummy injector and connect it with the compression gauge.
3. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical
connector.
4. Crank the engine for 10–15 seconds.
5. Note down the max value the gauge indicates.
6. Repeat the procedure for all the other cylinders.

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 89
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Tabulate the results.

8. Refer to the specification for the value.

2.7.1.2 Wet Test:

1. Spray 10 to 20 ml of engine oil inside the bore through the injector port with the help of
an oil can.
2. Fit the dummy injector and connect it with the compression gauge.
3. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical
connector.
4. Crank the engine.
5. Note the maximum value the gauge indicates.
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results.
8. Refer to the specification for the value.
Compare both the dry and the wet values with the specifications. The wet test values should
always be higher than the dry test values. If the reading does not change during wet test this
can hint towards compression leakage from cylinder head or through the valves. If the wet and
dry test values vary considerably between cylinders then the piston rings can be suspected.

2.7.2 Cylinder Head Gasket Failure Test

The cylinder head gasket failure can be easy to determine. A large stream of white smoke
blowing from the exhaust and an overheating engine are sure signs. However, more suitable
cylinder head gasket failure signs may be more difficult to diagnose. The engine may
experience mysterious coolant loss, or only lose coolant when the engine is driven under
heavy load. You may even experience a rough running engine when you first start the vehicle.
An initial inspection of cooling system components and a comprehensive test drive may be
necessary to confirm the customer's complaint of coolant loss or overheating. Check for the
presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust
may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign
that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil
residue in the coolant reservoir.
It is important to confirm actual engine running temperature and accuracy of the temperature
gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non
intrusive method used by most repair shops to verify temperature gauge accuracy and actual
engine running temperature.
Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant
loss), checking for proper operation of the cooling fan, and checking radiator efficiency are
important before jumping to the conclusion that the head gasket is defective.
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.
Cylinder to Water jacket Leakage Test
• Remove the degassing pressure cap.

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
90 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Warm up the engine and allow it to warm up until the engine thermostat opens.
• If large combustion pressure leak exist, bubbles will be visible in coolant.
• If bubbles are not visible, install a 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.

2.7.3 Hydrostatically Locked Engine

Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This
occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder
at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly
incompressible the piston cannot complete its travel; either the engine stop rotating or a
mechanical failure occurs.
When an engine is suspected to be hydrostatically locked, regardless of what caused the
problem, the following steps should be used

DO NOT use starter motor to rotate the engine, severe damage may occur.
1. Inspect air cleaner, air intake system and intake manifold to ensure system is dry and
clear of water and foreign material.
2. Place a shop towel around the injectors when removing them from the engine. This will
catch any fluid that may possibly be in the cylinder under pressure.
3. With all injectors removed, rotate engine crankshaft.
4. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
5. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.
e., connecting rods, pistons, valves, etc.)
6. Repair engine or components as necessary to prevent this problem from recurring.

Squirt approximately one teaspoon of oil into the cylinders, rotate engine to
lubricate the cylinder walls to prevent damage on restart.
7. Drain engine oil and remove oil filter.
8. Install a new oil filter.
9. Fill engine with specified amount of approved oil.
10. Connect negative battery cable.
11. Start engine and check for any leaks.

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 91
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.7.4 Bearing Inspection

Inspect Bearing for the following defects:

A. Cratering - fatigue failure
B. Spot polishing - incorrect seating
C. Imbedded dirt engine oil
D. Scratching - dirty engine oil
E. Based exposed - poor lubrication
F. Both edges worn - journal damaged
G. One edge worn - journal tapered or
bearing not seated
H. Tin coating - bearing excessive wear

2.7.5 Cam shaft Bearing Journal Diameter

1. Using a micrometer measure the

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

2.7.6 Crankshaft End play Inspection

1. Place the dial indicator and bracket.

2. Determine the end float by raising the
crankshaft with the aid of a screwdriver.

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
92 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.7.7 Cylinder Bore Taper Check

Measure the cylinder bore with an internal micrometer

• Carry out the measurements in different directions and at different heights to determine if
there is any out-of-roundness or tapering.
• If the measurement is out of the specified range, install a new block or hone out the cylinder
block.

2.7.8 Piston Diameter

1. Using a Micrometer measure the piston

Diameter.

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 93
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.7.9 Piston Inspection

Do not use any aggressive cleaning fluid

or a wire brush to clean the piston.
1. Clean the piston skirt, pin bush, ring
grooves and crown and check for wear
or cracks.
2. If there are signs of wear on the piston
skirt, check whether the connecting rod
is twisted or bent.

2.7.10 Piston Ring-to-groove Clearance

The piston ring must protrude from the piston groove. To determine the piston ring
clearance, insert the feeler gauge right to the back of the groove, behind the wear
ridge.

1. Using feeler gauge, measure the piston

ring clearance.

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
94 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.7.11 Valve Seat Inspection

1. Measure the valve seat width using the

valve seat width micrometer.
• Check for pitting.
• Check for valve seat insert
looseness (Engine overheat
conditions).

2.7.12 Piston Ring End Gap

1. Take the piston ring and use a piston

without Rings to push the piston ring
about xx mm into the cylinder bore.
2. Do not mix up the piston rings. Install
the piston rings in the same position
and location.

2.7.13 Valve Stem Diameter

1. Using a micrometer measures the

diameter of the valve stems.
2. If the measurements are not to
specification, install a new valve.

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 95
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8 Care of the System

2.8.1 Service Tips and Precautions
Observe the following precautions when disassembling or servicing the engine system and its
components.
• Ensure a dust free environment before starting the work on the engine.
• Carefully assemble the disassembled parts in the correct order. If work is interrupted, the
disassembled parts must be covered with clean cover/paper cloth.
• Carefully disconnect all the electrical connection in the engine compartment before
commencing the work.
• Carefully unscrew the high pressure pipe nut from the high pressure connector. Always use
two spanners or socket wrench set while tightening it.
• Ensure that there are no contacts between hard materials and critical head’s, eccentric
shaft, LP connectors and flange.
• Handle the High Pressure Pump (HPP) with extreme care. If the HPP falls down it must be
changed though it is not damaged.

• Do not work on the cooling system until the engine is OFF and cooled down
considerably, because the pressure within the system is extremely high and will
cause personal injury
• Eye protection must be worn while working near the engine system, failure to follow
this may cause personal injury.
• Use Extreme Caution while the engine is running. Do not put your hands near hot
components, near the turbocharger in the engine compartment. Failure to follow
these instructions may lead to serious personal injury.
• Care to be taken while working with heavy parts, failure to follow this instruction will
lead to personal injury and damage to the parts.

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
96 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.2 Engine Oil - Replace

2.8.2.1 Component Location Index

Engine Oil –Engine Oil Specification API CH4, MB 228.3, VDS-2, DHD-1 and / or ACEA A5/
B5; A3/B4 (Viscosity Grade (Upto -10°C : SAE 15W-40) and (-10°C & below : SAE 5W-30))
Capacity – 6 Liters.

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 97
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Engine should be hot while draining the • Check for the oil level, which should be in
oil. between the MAX & MIN level.
• Position the Vehicle on level ground /2
post lift/ 4 post lift and turn engine OFF.

Tools Required:

Size Type Quantity

22 mm Socket spanner 01

— Tray 01

2.8.2.3 Engine Oil Draining Procedure:

1. Open the filler plug. 2. Using 22 mm ring/ socket spanner,

remove the engine oil drain plug located
under the oil sump.

3. Allow the entire oil to get drained.

Place a tray under the drain plug to

collect the oil.

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
98 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.2.4 Engine Oil Filling Procedure

1. Always refit the drain plug with a new

washer.

2. Fill fresh oil recommended to specified

quantity.

3. Refit the engine oil filler cap.

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 99
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.2.5 Engine Oil Level Inspection

Preliminary Activities/Conditions
1. Wait for about 10 minutes for oil in circulation to drain down.
Engine Oil Level - Inspect

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
100 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Pull out the dip stick gauge and wipe it 4. Insert the dip stick back and fix properly.
clean with a cloth/paper.

5. start the engine and check for oil

2. Insert the dip stick gauge into the dip leakage/ seepage at:
stick guide fully till the end.
• Oil sump & crankcase joint.
• Oil sump drain plug.
• Oil filter joint.

3. Pull out the dip stick slowly and check for

the oil level mark between Maximum and
Minimum level - if found below minimum
level, top up with recommended oil.

Nut/ Bolt description Torque Value – Nm

Engine oil drain plug 27.5 ± 2.5

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 101
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Engine oil is to be inspected at 5000/3Months (Distance Covered in kms/Months in

service whichever is earlier).
• Engine oil is to be replaced first at 10,000 Kms/6Months and then every 10,000 Kms/
6Months (Distance Covered in kms/Months in service whichever is earlier).
• Always use Engine Oil Specification of API CH4, MB 228.3, VDS-2, DHD-1 and / or
ACEA A5/B5; A3/B4, Viscosity Grade (Upto -10°C : SAE 15W-40) and (-10°C & below :
SAE 5W-30))
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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
102 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.3 Engine Oil Filter — Replace

2.8.3.1 Component Location Index

2.8.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Check for the oil level and top up.
• Open the bonnet.

Tools Required:

Size Type Quantity

- Oil filter wrench 01
- Universal joint, extension rod 01 each
& ratchet

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 103
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.3.3 Engine Oil Filter Removal Procedure

• Insert the cup oil filter removal tool from LH wheel arch area.
• Using a universal joint, suitable extension rod and ratchet loosen and remove the oil
filter.

1. Grip the engine oil filter firmly using an oil

filter removal universal cup tool, rotate in
anti-clockwise direction and remove the oil
filter from engine assembly.

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
104 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.3.4 Engine Oil Filter Installation Procedure

1. Smear a layer of fresh oil on new oil filter 3. Using hand rotate the oil filter in
O-ring. clockwise direction till the O-ring makes
contact with the oil cooler surface.

2. Place the oil filter in its position.

• The oil filter should be only hand

tightened. No special tool or spanner
to be used.
• Never use wrench or filter tool for
installation. If the oil filter is
overtightened then it cause O ring
distortion or damage, resulting in
engine seizure.

4. Turn the filter another 3/ 4th turn by

hand.

5. Check the engine oil level. For additional

information refer to Engine oil level
inspection section.

6. Start the engine and check for Oil

leakage/ seepage at:
• Oil pan & crankcase joint.
• Oil pan drain plug.
• Oil filter joint.

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 105
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Engine oil filter is to be Inspected at 5000/3Months (Distance Covered in kms/

Months in service whichever is earlier).
• Engine oil filter is to be replaced first at 10,000 Kms/6Months and then every 10,000
Kms/6Months (Distance Covered in kms/Months in service whichever is earlier).
• Recommend to use only the Mahindra genuine oil filter for better engine protection
and lubricant life.
• For Non – ABS vehicles, if the activity is done on a 2 post lift, ensure that the LSPV
spring is disconnected before lifting the vehicle. After lowering, reconnect the LSPV
spring and ensure the correct LSPV setting height.

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
106 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.4 Auto Tensioner & Accessory Drive Belt - Inspect

2.8.4.1 Component Location Index

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 107
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.4.1 Accessory Drive Belt Inspection

1. Random Cracking Across the Ribs

Appearance:
Small yet visible cracks along the length of a
rib or ribs.

Causes:
Continuous exposure to high temperatures
and the stress of bending around the pulleys
leads to cracking.
Cracks begin at the rib top and grow to the
cord line. As a rule, if cracks appear 1 or 2
cm apart, 80% of the life is gone and the belt
should be replaced.

2. Chunk-Out
Appearance:
Pieces or chunks of rubber material have
come off the belt. When chunk-out has
occurred, a belt can fail at any moment. Belt
should be replaced immediately.

Causes:
Chunk-out can happen when several cracks
in one area move parallel to the cord line.
Heat, age and stress are the primary
contributors.

3. Pilling
Appearance:
Belt material wears off from the ribs and
builds up in the belts grooves.

Causes:
There are a number of causes, including
misalignment, new belt on worn pulleys, lack
of tension or a combination of these factors.

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
108 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Gravel Penetration
Appearance:
Small pinholes are visible on the backside of
the belt. Bumps may be visible and fabric
around the holes can be frayed.

Causes:
Granular gravel or pebble gravel is wedged
between the belt groove (s) and pulley ridge
(s).

5. Damaged Outermost Ribs

Appearance:
Sidewalls of the belt may appear glazed or
the edge-cord may become frayed and ribs
removed. A noticeable noise may result.

Causes:
Pulley misalignment is a common cause of
premature belt failure. Misalignment forces
the belt to twist while running, causing
premature wear.

6. Oil Contamination
Appearance:
The belt surface is flaky, sticky or swollen.

Causes:
Oil and grease are a rubber compound’s
worst enemies, weakening the compound’s
bonds and making the belt soft and spongy.
Eventually, such a belt will slip, create heat
and fail.

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 109
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Abrasion
Appearance:
The backside of the belt appears very shiny
or glazed. In advance stages, the fabric or
even the cord becomes exposed and gets
damaged.

Causes:
When in motion, the belt makes contact with
the foreign objects in its path such as a
flange or bolt. This may be caused by
improper belt tension or by belt flutter
(vibrations) on longer span lengths between
two pulleys.

8. Rib Separation
Appearance:
The belt rib shears off or begins to separate
from the belt base.

Causes:
The belt is not correctly positioned. One of
the belt ribs is placed outside the pulley
groove, causing a belt rib to run without a
supporting or aligning pulley groove.

9. Uneven Rib Wear

Appearance:
Wear that is more severe on one rib than on
the others or one rib that exhibits a different
wear pattern than the others. A thumping or
grinding noise may also be heard.

Causes:
A foreign object — such as a pebble — in the
pulley will cause uneven wear and cut into
the belt and break the tensile cords.

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
110 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10. Broken Belt

Appearance:
The belt is broken.

Causes:
A large foreign object between the belt and
pulley can cut into the belt and break the
tensile cords. Tensile break may occur but go
unnoticed when the belt is forced or pried on
during installation. Other possible causes
may be severe shock loads or a blocked
pulley and/or accessory.

11. Belt Noise

Inspection:
Run the engine and inspect for Chirping,
squealing. tapping, ticking or grinding noise
coming from the belt.

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 111
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.4.1.2 Auto - Tensioner Inspection

1. Rust bleed and cracks

Appearance:
Rust bleeding between arm and base or
dripping from the tensioner. Also, check the
tensioner for cracks or damage to arm,
housing and bracket.

Causes:
Rust bleeding or dripping is a sign of internal
component wear. Most common crack
damage occurs at tensioner “Stops” and
mounting bolts.

Solution:
Replace the auto-tensioner.

2. Pulley bearing wear

Appearance:
With the engine off and the belt removed,
manually rotate the pulley. If you notice,
resistance or roughness, the problem is likely
to be pulley bearing wear.

Causes:
Defective bearing and/or pulley.

Solution:
Replace the complete tensioner. Do not
attempt to replace a worn pulley in a used
tensioner assembly but always replace the
entire tensioner assembly, as part failure will
inevitably follow quickly.

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
112 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Tensioner assembly misalignment

Appearance:
Abnormal belt tracking on tensioner pulley.

Causes:
Bent or misaligned mounting bracket,
improper tensioner installation or corrosion/
contamination between tensioner base and
mounting surface. A small amount of
contamination results in a large amount of
misalignment at tensioner pulley.

3. Tensioner Noise Appearance:

Squeaks and rattles coming from the
tensioner.

Causes:
Failure of bearings or pivot are will cause
excessive noise.

Solution:
Replace the tensioner assembly.

Accessory drive belt and auto-tensioner needs to be inspected at 60,000 kms or

36months and 80,000 kms or 48 months (Distance Covered in kms/months in service
whichever is earlier).

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 113
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.5 Accessory Drive Belts and Auto Tensioner - Replace

2.8.5.1 Component Location Index

2.8.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Open the bonnet. • Refit the Viscous fan.
• Remove the NVH Cover. • Refit the NVH Cover.
• Remove the Viscous fan. • Close the bonnet

Tools Required

Size Type Quantity

14 mm Ring spanner 1

12 mm Socket spanner 1

17 mm Open end spanner 1

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
114 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.5.3 Removal

1. Remove the Viscous fan. For additional 4. Using a 15 mm ring spanner rotate the
information refer to Viscous fan R&R section. auto tensioner in clock wise direction and
remove the drive belt.
2. Using 17 mm open end spanner rotate
the tensioner in clock wise direction and
remove the drive belt.

5. Using 12 mm socket spanner, remove

the mounting bolts of water pump/AC
Compressor auto tensioner and remove the
3. Using 12 mm socket spanner remove the tensioner.
alternator/power steering auto tensioner
mounting bolts and remove the tensioner.

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 115
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.8.5.4 Installation

1. Install the water pump/AC Compressor 5. Rotate the auto tensioner in clock wise
auto tensioner mounting bolts and Torque direction & place the drive belt.
tighten the bolts to specified value.
6. Later release the auto tensioner.

2. Rotate the auto tensioner in clock wise

direction & place the drive belt. 7. Refit the Viscous fan. For additional
information refer to viscous fan R&R section.
3. Later release the auto tensioner.

Accessory drive belt and auto-tensioner

needs to be replaced at 1,00,000 kms or
60 months. (Distance Covered in kms/
months in service whichever is earlier).

4. Install the alternator/power steering auto

tensioner mounting bolts and Torque tighten
the bolts to specified value.

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
116 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9 In Car Repairs

2.9.1 Engine Assembly R&R

2.9.1.1 Component Location Index

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 117
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the transmission assembly.
• Remove the bonnet. • Refill the engine oil if required, Check for
the oil level.
• Drain fluids Coolant, steering & engine oil
if necessary. • Install the HVAC system & recharge the
• Recover the AC gas & disconnect the AC gas.
HVAC and condenser lines. • Refill coolant & steering oil.
• Remove the transmission assembly.

Tools Required

Size Type Quantity

10 mm / 13 mm / 14 mm / 16 Socket spanner 1
mm / 19 mm

12 mm / 13 mm / 14 mm / 16 Combination spanner 1
mm / 17 mm & 18 mm

7 mm & 8 mm ‘T’ spanner 1

- Hose clip pillar 1

- Screw driver – Flat & Star 1

- Torque wrench 1

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
118 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.1.3 Removal

1. Remove the Battery. For additional 9. Using a hose clip plier unclip the spring
information refer to Battery R&R section. band clamp and detach the thermostat bye
pass hose.
2. Remove the Intercooler assembly. For
additional information refer to intercooler
R&R section.

3. Remove the transmission assembly. For

additional information refer to Transmission
R&R section.

4. Remove the transmission assembly

(4WD). For additional information refer to
Transmission (4WD) R&R section.

5. Remove the bonnet assembly. For

additional information refer to Bonnet R&R
section. 10. Using a hose clip plier unclip the spring
band clamp and detach the radiator outlet
6. Drain the coolant. For additional hose.
information refer to coolant draining section.

7. Recover the A/C gas from HVAC system.

For additional information refer to Refrigerant
recovery recycling and recharging section.

8. Using a hose clip plier unclip the spring

band clamp and detach the radiator inlet
hose.

Ensure that the coolant is not in hot

condition.
11. Remove the Radiator. For additional
information refer to Radiator R&R section.

12. Drain the power steering fluid. For

additional information refer to Power steering
fluid draining. section.

13. Using a hose clip plier, unclip the spring

band clamp and then disconnect the fluid
inlet hose to pump.

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 119
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14. Using a 17 mm open end spanner 17. Remove the breather hose.
loosen the mounting nut and disconnect the
fluid outlet tube from pump.

18. Using a flat screw driver, loosen the

securing clip and remove the turbocharger
15. Remove the fuel filter assembly. For inlet hose.
additional information refer to Fuel filter R&R
section.

16. Disconnect the fuel lines from the high

pressure pump.

Ensure the fuel outlet in the HPP is

protected dust free.

19. Using a hose clip plier, unclip the spring

band clamp and disconnect the vacuum hose
from vacuum pump.

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
120 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20. Disconnect vacuum hose from 23. Using a hose clip plier, unclip the spring
turbocharger. band clamp and then disconnect the HVAC
heater inlet & outlet hose.

21. Disconnect vacuum hose from EGR

valve. 24. Disconnect the exhaust connection
from the turbo charger using 13 mm spanner.

22. Disconnect the HVAC hoses from the

AC compressor using 12 mm combination 25. Disconnect engine compartment and
spanner. engine wiring harness connectors, all injector
connectors and cam phase sensor
connector.

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 121
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26. Remove the LH engine mounting nut

using 19 mm socket spanner.

27. Remove the RH engine mounting nut

using 19 mm socket spanner.

28. Using a rope chain, hook the engine

carefully at its lifting brackets and further
remove the engine.

Improper tie-up of the lifting rope chain

will cause damage to the vehicle and the
persons involved.

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
122 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.1.4 Installation

1. Position the engine with the help of lifting 3. Mount the LH engine mounting insulator
crane. on chassis using mounting bolts. Torque
tighten the bolts to specified value.

Improper tie-up of the lifting rope chain

will cause damage to the vehicle and the
persons involved.

4. Connect engine compartment and

engine wiring harness connectors, all injector
connectors and cam phase sensor
connector.
2. Mount the RH engine mounting insulator
on chassis using mounting bolts. Torque
tighten the bolts to specified value.

5. Install the exhaust mounting on the turbo

charger and Torque tighten the bolts& nut to
specified value.

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 123
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Install the heater inlet and outlet hoses. 9. Connect vacuum hose onto the
turbocharger.

7. Install the AC Suction and discharge

hoses and Torque tighten the nuts to 10. Connect vacuum hose onto EGR valve.
specified value.

11. Refit the turbocharger inlet hose fasten

8. Connect the vacuum hose of vacuum the hose with mounting clamp.
pump and fasten using spring band clamp.

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
124 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Install the breather hose of crank case 16. Refit the Radiator. For additional
ventilation and fasten using spring band information refer to Radiator R&R section.
clamp.
17. Install the radiator outlet hose and
fasten using spring band clamp.

13. Install the fuel lines on the high

pressure pump.
18. Install the thermostat bypass hose and
fasten using spring band clamp.

14. Refit the fuel filter assembly. For

additional information refer to Fuel filter R&R
section. 19. Install the radiator inlet hose and fasten
using spring band clamp.
15. Install the inlet and outlet hoses on the
steering pump.

20. Refit the Battery. For additional

information refer to Battery R&R section.

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 125
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21. Refit the Intercooler assembly. For

additional information refer to intercooler
R&R section.

22. Refit the transmission assembly (2WD).

For additional information refer to
Transmission R&R section.

23. Refit the bonnet assembly. For

additional information refer to Bonnet R&R
section.

24. Refill the power steering fluid. For

additional information refer to Power steering
oil filling section.

25. Fill the coolant. For additional

information refer to Coolant filling section.

26. Recharge the A/C freon gas to the

HVAC system. For additional information
refer to Refrigerant recovery recycling and
recharging section.

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
126 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.2 Damper Pulley R&R

2.9.2.1 Component Location Index

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 127
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Check for the drive belt seating.
• Remove the viscous fan. • Refit the viscous fan.

Removal Steps:
1. Remove Alternator & steering pump drive belt.
2. Remove Water pump & Ac compressor drive belt.
3. Remove Crank shaft damper pulley bolt & Damper pulley.
Tools Required

Size Type Quantity

15 mm Ring spanner 1

24 mm Ring spanner 1

17 mm Open end spanner 1

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
128 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.2.3 Removal

1. Remove the viscous fan. For additional 6. Using 24 mm ring spanner loosen and
information refer to Viscous fan R&R section. remove the damper pulley mounting bolt and
take out the pulley.
2. Using 17 mm open end spanner rotate
the tensioner in clock wise direction and
remove the drive belt.

3. Using a 15 mm ring spanner rotate the

auto tensioner in clock wise direction and
remove the drive belt.

4. Remove the starter motor. For additional

information refer to Starter motor R&R
section.

5. Lock the flywheel using appropriate tool.

2.9.2.4 Inspection
1. Inspect the damper pulley for any physical damage. If found replace.
2. Inspect for any foreign materials, clean if found.
3. Inspect the accessory drive belts.

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 129
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.2.5 Installation

1. Install the damper pulley assembly and 7. Later release the auto tensioner.
Torque tighten the bolts to specified value.

• Damper pulley bolt not to be reused.

• Always use new bolt once removed.

8. Refit the viscous fan. For additional

information refer to Viscous fan R&R section.

2. Remove the locking tool for the flywheel.

3. Refit the starter motor. For additional

information refer to Starter motor R&R
section.

4. Rotate the auto tensioner in clock wise

direction & place the drive belt.

5. Later release the auto tensioner.

6. Rotate the auto tensioner in clock wise

direction & place the drive belt.

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
130 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.3 Crankshaft Front End Oil Seal R&R

2.9.3.1 Component Location Index

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 131
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Check for the drive belt seating.
• Remove the viscous fan. • Check for any oil leakage.
• Top up engine oil if required.
• Refit the viscous fan.

Removal Steps:
1. Remove Alternator & steering pump drive belt.
2. Remove Water pump & AC compressor drive belt.
3. Remove Crank shaft damper pulley bolt & Damper pulley.
4. Remove Crank shaft front end oil seal.
Tools Required

Size Type Quantity

15 mm/ 24 mm Ring spanner 1

17 mm Open end spanner 1

- Socket wrench/ Screw driver Each 1

flat

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
132 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.3.3 Removal

1. Remove the damper pulley assembly.

For additional information refer to Damper
pulley R&R section.

2. Using a suitable tool remove the crank

shaft front end oil seal.

2.9.3.4 Inspection
1. Check and clean the oil seal seating area thoroughly for any damage.

The oil seals should never be reused.

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 133
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.3.5 Installation

1. Refit the front end oil seal using the

suitable dolly MST.

Apply the oil on the oil seal lip prior to

installation.

2. Refit the damper pulley assembly. For

additional information refer to Damper pulley
R&R section.

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
134 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.4 Crankshaft Rear End Oil Seal R&R

2.9.4.1 Component Location Index

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 135
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Install the clutch assembly.
• Open the bonnet. • Install the transmission assembly.
• Remove the transmission assembly. • Check for any oil leakage.
• Remove the clutch assembly. • Top up engine oil if required.
• Close the bonnet.

Removal Steps:
1. Remove fly wheel mounting bolts
2. Remove fly wheel mounting bolt washers.
3. Remove fly wheel assembly.
4. Remove rear end oil seal.
Tools Required

Size Type Quantity

13 & 19 mm Socket spanner 1

MST 0301BM0008ST Flywheel Locking tool 1

- Screw driver – Flat & Star 1

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
136 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.4.3 Removal

1. Remove the transmission. For additional 4. Using a suitable tool remove the rear end
information refer to Transmission (4WD) oil seal.
R&R section.

2. Remove the pressure plate mounting

bolts and the pressure plate/Clutch disc by
using 13 mm socket spanner.

Ensure that the crank shaft is arrested

with the locking tool (MST
0301BM0008ST), before removing.

The oil seals should never be reused.

3. Remove the flywheel mounting bolts

using 19 mm socket spanner and the remove
the flywheel assembly.

2.9.4.4 Inspection
1. Check and clean the oil seal seating area thoroughly for any damage.

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 137
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.4.5 Installation

1. Place the rear end oil seal and mount the 4. Refit the pressure plate/clutch disc & the
MST. mounting bolts, tighten to the sequence
mentioned below and Torque tighten the
bolts to specified value.

2. Press fit the rear end oil seal.

5. Refit the transmission assembly. For

additional information refer to Transmission
(4WD) R&R section.

3. Install the flywheel washers and the

mounting bolts and torque tighten to
specified value.

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
138 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.5 Cylinder Head and Gasket R&R

2.9.5.1 Component Location Index

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 139
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.5.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Check and ensure proper functioning of
• Open the bonnet engine.
• Check for engine oil and coolant
leakages.

Tools Required

Size Type Quantity

10 mm/ 12 mm/ 13 mm/ 14 Socket spanner 1

mm/ 15 mm

8 mm Deep socket spanner 1

— Hose clip pillar 1

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
140 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.5.3 Removal

1. Remove the HLA’s from the engine. For 6. Using 12 mm ring spanner, loosen and
additional information refer to Hydraulic Lash remove common rail mounting bolts and then
Adjuster (HLA) removal and installation detach and remove the common rail.
section.

2. Remove the Exhaust Manifold. For

additional information refer to Exhaust
Manifold R&R section.

3. Remove the Intake Manifold. For

additional information refer to Intake Manifold
R&R section.

4. Using 10 mm socket spanner remove the

cylinder head outlet pipe and remove the
heater inlet hose using hose clip plier.

7. Remove glow plug pigtail and By using a

8 mm deep socket spanner, loosen and
remove the glow plugs.

5. Using 12 mm socket spanner remove the

EGR long pipe .

8. Using a 15 mm socket spanner remove

the cylinder head mounting bolts & remove
the head assembly .

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 141
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Remove the cylinder head gasket from

the engine block.

2.9.5.4 Inspection

Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are
found.

1. Check the Cylinder Head for external 3. Check the Cylinder Head bottom face for
damages. distortion.

2. Check the cylinder head height and if not

meeting the specified value, replace the
cylinder head assembly.

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
142 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Check the cylinder head flatness, if any

misalignment or bend found replace the
cylinder head assembly.

5. Check the cylinder head for warpage.

6. Check the length of the Cylinder Head

bolts.

7. Check the valve seat area for leakages.

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 143
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.5.5 Installation

1. Align a new cylinder head gasket on the 3. Insert the glow plugs, torque tighten the
engine block. glow plugs to specified value and Connect
glow plug pigtail connectors on glow plugs.

Replace the cylinder head gasket with a

new one. Failure to follow this will lead to
compression failure.

4. Refit the common rail using mounting

bolts. Torque tighten the bolts to specified
value.

2. Firmly hold and carefully align the

cylinder head assembly on crankcase. Insert
the mounting bolts and torque tighten the
bolts to specified value in recommended
sequence.

Always replace the new cylinder head

bolts during installation.

5. Install the EGR long pipe and Torque

tighten the bolts to specified value .

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
144 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Install the cylinder head outlet pipe and

Torque tighten the bolts to specified value,
refit the heater inlet hose.

7. Refit the Exhaust Manifold. For

additional information refer to Exhaust
Manifold R&R.

8. Refit the Intake Manifold. For additional

information refer to Intake Manifold R&R.

9. Refitl the HLA’s. For additional

information refer to Hydraulic Lash Adjuster
(HLA) R&R.

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 145
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.6 Cam Shafts R&R

2.9.6.1 Component Location Index

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
146 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.6.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the timing chain and sprocket.
• Open the bonnet. • Check and ensure proper functioning of
engine.
• Remove the timing chain and sprocket.
• Check for engine oil and coolant
leakages.

Tools Required

Size Type Quantity

10 mm / 12 mm Socket spanner 1

14 mm/ 17 mm Open end spanner 1

— Hose clip pillar 1

MST – 0301BM0001ST Camshaft locking Tool 1

MST –0301BM0004ST TDC lock pin 1

MST – 0301BM011ST Cam chain tensioning tool 1

MST – 0301BM0002ST Camshaft locator / camshaft 1

linear alignment tool

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 147
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.6.3 Removal

1. Remove the timing chain and sprocket 4. Remove the injector leak off pipe.
assembly. For additional information refer to
Timing Chain and Sprockets removal and
installation section.

2. Remove the injector electrical

connections.

5. Using 12 mm socket spanner remove

the injector holder nut.

3. Using 14 mm and 17 mm open end

spanner remove the High pressure fuel lines
from the injector to common rail .

6. Remove the injectors.

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
148 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Remove the connector & By using 10 10. Remove the stefa plug at rear side of
mm socket spanner remove the cam phase the camshaft (intake manifold side).
sensor .

8. Remove blow by hose and by using 10 11. Using 10 mm socket spanner remove
mm socket spanner remove the oil separator. the cam cover mounting bolts .

9. Remove the vacuum hose and by using

12 mm socket spanner remove the vacuum
pump assembly . Handle the cam cover carefully such that
the cam phase sensor is not damaged
during the removal and installation.

12. Remove the cam shaft assembly.

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 149
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.6.4 Inspection
1. Check the inlet camshaft and the exhaust camshaft for any damage and replace it if
necessary.
2. Inspect the camshaft bearing journals for scoring or excessive wear.
3. Inspect the camshaft lobes for scoring or excessive wear.
4. Inspect the threaded bolt holes in the front of the camshaft for damaged threads or
debris.

2.9.6.5 Installation

Check and confirm the TDC Position of the piston for cylinder-1 before installation, in
case the same was not followed while removing the timing chain.
Cam shafts should not be interchanged during the installation. Exhaust camshaft has
the trigger wheel for the cam phase sensor mounted on it.

1. Install both the cam shafts on the 2. Install the camshaft locator / camshaft
cylinder head assembly. linear alignment tool (Special Tool No:
0301BM0002ST) and align the camshafts to
properly fix in its position.

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
150 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Rotate the crankshaft such that the key 5. Lock the front end timing tool for
slot reaches 12’O clock position. camshaft (Special Tool No: 0301BM0001ST)
on the camshaft key slot located at back part
of the sprocket.

4. Locate the crankshaft TDC lock pin

through the cylinder block using special tool
No: 0301BM0004ST at the bottom of starter
motor. 6. After aligning the cam lobes properly on
the Hydraulic lash adjuster (HLA), remove
the camshaft locator / camshaft linear
alignment tool (Special Tool No:
0301BM0002ST) placed on the top of
camshafts.

The front end timing tool for camshaft

(Special Tool No: 0301BM0001ST) as
shown in the image above, should not be
removed till the cam cover is installed on
to the engine.

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 151
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Install the cam cover and Torque tighten 10. Install the oil separator and Torque
the bolts to specified value. tighten the bolts to specified value and refit
the blow by hose.

Apply loctite 5188 over the surface

before installing.

11. Install the cam phase sensor and

Torque tighten the bolts to specified value
and connect the connector.

8. Install the vacuum pump and Torque

tighten the bolts to specified value and refit
the vacuum hose.

12. Install the injectors.

9. Insert the stefa pin locator (Special Tool

No: 0301BM009ST) at the rear side of the
camshaft (intake manifold side).

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
152 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Install the injector holding clamps and 16. Install the injector electrical connectors.
Torque tighten the bolts to specified value.

17. Refit the timing chain and sprocket from

14. Install the injector leak off pipe. the engine assembly. For additional
information refer to Timing Chain and
Sprockets removal and installation section.

15. Install the high pressure pipe lines and

HPP on injector and Torque tighten the bolts
to specified value.

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 153
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.7 Front Timing Chain Cover R&R

2.9.7.1 Component Location Index

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
154 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.7.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift, open • Install the assembly feed system & the
the bonnet. crank shaft dampener pulley.
• Remove the assembly feed system and • Install the thermostat bye pass hose &
the crank shaft dampener pulley. refill the coolant to the required level.
• Remove the thermostat bypass hose. • Refill the Engine Oil
• Drain the Engine Oil

Tools Required

Size Type Quantity

12 mm/ 24 mm Socket spanner 1

17 mm Open end spanner 1

— Hose clip pillar 1

15 mm Ring spanner 1

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 155
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.7.3 Removal

1. Drain the engine oil. For additional 6. Using 12 mm socket spanner remove the
information refer to Engine Oil Draining timing cover bottom mounting bolts on oil
procedure. sump & remove the timing cover.

2. Remove the inter cooler. For additional

information refer to intercooler R&R section. .

3. Remove the damper pulley. For

additional information refer to Damper pulley
R&R section.

4. Remove the thermostat bye pass hose.

5. Using 12 mm socket spanner remove the

timing cover mounting bolt.

2.9.7.4 Inspection
1. Check for any damages or cracks in timing cover. If found replace the new.

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
156 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.7.5 Installation

1. Refit the timing cover bottom mounting 4. Refit the inter cooler assembly. For
bolts, torque tighten the same to specified additional information refer to intercooler
value. R&R section.

5. Refill the engine oil. For additional

information refer to Engine Oil Filling
procedure.

2. Refit the timing cover assembly and

Torque tighten the bolts to specified value.

Use only the recommended sealant,

failure to follow the instruction may lead
to leakages. While tightening the timing
cover mounting bolts follow torque
sequence as shown in the illustration.

Apply loctite 5900 to the timing cover.

3. Refit the damper pulley. For additional

information refer to Damper pulley R&R
section.

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 157
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.8 Timing Chain & Sprocket R&R

2.9.8.1 Component Location Index

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
158 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.8.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift, open • Install the assembly feed system & the
the bonnet. crank shaft dampener pulley.
• Remove the assembly feed system and • Install the thermostat bye pass hose &
the crank shaft dampener pulley. refill the coolant to the required level.
• Remove the thermostat bypass hose. • Refill the Engine Oil
• Drain the Engine Oil

Tools Required

Size Type Quantity

10 mm / 12 mm/ 15 mm/ 22 Socket spanner 1

mm/ 24 mm

5 & 6 mm Allen key 1

17 mm Open end spanner 1

— Hose clip pillar 1

15 mm Ring spanner 1

MST – 0301BM0001ST camshaft locking Tool 1

MST – 0301BM011ST Cam chain tensioning tool 1

MST –0301BM0004ST TDC lock pin 1

MST – 0305BAM0007ST HPP removal tool 1

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 159
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.8.3 Removal

1. Remove the front timing chain cover. For 4. Install the TDC lock plug and insert the
additional information refer to Front timing TDC locking pin (Special Tool No:
chain cover R&R section. 0301BM0004ST)

2. Using 10 mm socket spanner remove the

oil filler elbow & cap.

5. Using a 6 mm allen key, loosen the

timing chain top guide allen bolts and remove
the top guide bracket
3. Rotate the crankshaft sprocket such that
the key slot reaches 12’O clock position.

6. Lock the front end timing tool for

camshaft (Special Tool No: 0301BM0001ST)
on the inlet and exhaust camshaft key slot
located on back of the camshaft sprocket

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
160 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Loosen the 22 mm center mounting bolts 10. Remove the camshaft secondary timing
of the left primary and secondary timing chain between the pump and the sprocket.
chain guide.

11. Remove the 10 mm primary timing

8. Remove the 12 mm secondary timing chain auto tensioner mounting bolts , remove
chain auto tensioner mounting bolts and auto tensioner and detach the primary chain
remove the auto- tensioner guide.

9. Release the right secondary chain guide 12. Using 5 mm allen key, remove the allen
mounting circlip locks and remove the right key bolts and remove the right primary chain
secondary chain guide. guide.

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 161
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Remove the primary timing chain 15. Install the cam chain tensioning tool
between the crankshaft and HPP. (Special Tool No: 0301BM011ST) into the
inlet & exhaust camshaft sprocket holes and
hold it. Remove the 15 mm camshaft
sprocket mounting bolt and detach inlet &
exhaust camshaft sprocket.

14. Fix the HPP removal tool (Special Tool

No: 0305BAM0007ST) to match the HPP
shaft to the tool centre mounting bolt and
tighten the 22 mm centre mounting bolt.
Detach the HPP sprocket and pump.

Perform the same action on the other

camshaft sprocket and remove it.

16. Remove the key & remove the crank

shaft sprocket.

Remove the Crankshaft sprocket lock

key while removing Crankshaft sprocket
and keep it in a secured place.

2.9.8.4 Inspection
1. Check for any damages or cracks in timing chain, sprockets, tensioner and timing chain
cover post installation. If found replace the affected components

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
162 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.8.5 Installation

Check and confirm the TDC Position of the piston for cylinder-1 before installation, in
case the same was not followed while removing the timing chain

• Do not remove the camshaft locking tool & the Crankshaft TDC plug from its
location, else the engine timing could get disturbed.
• It is always recommended to replace the timing chain as kit, if to be replaced.
• Clean the outer and inner surface of the timing chain area of the engine and timing
cover.

1. Ensure the TDC locking pin (Special Tool 3. Install the inlet, exhaust camshaft
No: 0301BM0004ST) in lock position sprocket on the camshaft and tighten the
15mm mounting bolt, install the HPP
sprocket and tighten the 22 mm mounting
nut.

2. Ensure the front end timing tool for

camshaft (Special Tool No: 0301BM0001ST)
is on the both camshaft key slot located on
back of the sprocket.
Inlet and exhaust camshaft sprocket
mounting nut should be tightened only
after installing the chain guides and auto
tensioner.

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 163
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Install primary timing chain connecting 7. Install the primary chain auto tensioner
HPP pump and Crankshaft. and tighten 10mm mounting bolts of primary
chain auto- tensioner.

5. Install the right primary chain guide and

using 5 mm allen key, tighten the right
primary chain guide allen key bolts. Tighten the guide center mounting bolt
after installing primary and secondary
timing chain auto-tensioner..

8. Engage the tensioner lock pin into the

tensioner. Release the tension of the
tensioner by disengaging the tensioner lock
pin from the tensioner.

6. Install left primary and secondary chain

guide and secure its 22mm center mounting
bolt.

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
164 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Install the secondary timing chain 11. Install the cam chain tensioning tool
connecting HPP pump sprocket and (Special Tool No: 0301BM011ST) into the
camshaft sprocket. camshaft sprocket holes and hold it. Tighten
both 15 mm camshaft sprocket mounting bolt
to the specified torque.

Install the right secondary chain guide.

Secure the mounting circlip locks of the right
chain guide.
12. Using sprocket and wrench, tighten the
22 mm mounting nut of the HPP sprocket to
specified torque.

10. Install the secondary chain guide and

auto-tensioner. Tighten 12mm mounting bolt
of secondary timing chain auto-tensioner.
13. Remove the front end timing tool for
camshaft (Special Tool No: 0301BM0001ST)
on the camshaft key slot located near to the
sprocket.

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 165
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14. Remove the crankshaft TDC locking pin

(Special Tool No: 0301BM0004ST) at bottom
of the starter motor and install the TDC plug.

15. Install the top support bracket. Using 6

mm allen key, tighten allen key bolts of the
timing chain top support bracket to the
specified torque.

16. Refit the front timing chain cover

assembly. For additional information refer to
Front timing chain cover R&R section.

17. Install the oil filler elbow assembly and

Torque tighten the bolts to specified value.

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
166 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.9 Hydraulic Lash Adjuster R&R

2.9.9.1 Component Location Index

2.9.9.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Refit the Cam shafts.
• Remove the Cam Shafts.

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 167
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.9.3 Removal

1. Remove the cam shafts. For additional

information refer to Cam shaft R&R section.

2. Carefully lift the hydraulic lash adjuster

from the cylinder head assembly and place
them safely in a oil filled container.

Keep the HLA in submerged condition

with engine oil, to ensure that the air
does not penetrate, which would result in
failure.

2.9.9.4 Inspection
• Check the HLA for any damage, and replace it if necessary.

Do not disassemble the HLA, as it is not a serviceable component. In case of a

failure of a HLA, replace the complete assembly.

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
168 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.9.5 Installation

1. Install the hydraulic lash adjuster into

the cylinder head assembly and properly
align them.

Hydraulic lash adjuster should be kept in

straight upward position in the cylinder
head.

2. Refit the cam shafts. For additional

information refer to Cam shaft R&R section.

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 169
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.10 Intake Manifold R&R

2.9.10.1 Component Location Index

2.9.10.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Ensure the proper functioning of engine.

Tools Required

Size Type Quantity

12 mm Socket spanner 1

— Hose clip pillar/Start Screw Each 1

Driver

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
170 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.10.3 Removal

1. Remove the inter cooler. For additional 5. Press the lock and pull out the electrical
information refer to intercooler R&R section. connector from the engine coolant
temperature sensor.
2. Remove the Fuel Line (High Pressure
Pump to Rail). For additional information
refer Fuel Line (High Pressure Pump to Rail)
R&R section

3. By Using 12 mm socket spanner remove

the EGR pipe ‘V’ clamp and remove the EGR
pipe form air Intake pipe.

6. Using a 12 mm socket spanner remove

the coolant outlet pipe assembly.

4. Using a hose clip plier unclip the spring

band clamp and detach the radiator inlet
hose.

Ensure that the coolant is not in hot

condition.
7. Grip the engine oil filter firmly using an oil
filter removal universal cup tool, rotate in anti-
clockwise direction and remove the oil filter
from engine assembly.

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 171
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Disconnect the HPP pump electrical 11. Rotate the HPP in anti-clock wise
connector. direction.

9. Disconnect the fuel lines from HPP. 12. Using a 12 mm socket spanner remove
the intake manifold mounting bolt & remove
the Intake Manifold assembly.

10. Using a 12 mm socket spanner remove

the HPP mounting bolts .
13. By Using 12 mm socket spanner
remove the air Intake pipe & Intercooler
bracket mounting bolts.

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
172 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14. By Using star screw driver remove the

air Intake pipe & Intercooler bracket
mounting bolts and remove the air intake
pipe.

2.9.10.4 Inspection
• Check for any external damage, if found replace.
• Check for oil seepage, if found clean before installation.
• Check the gasket condition, deformation found replace.

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 173
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.10.5 Installation

1. Install the air Intake pipe & Intercooler 3. Rotate the HPP in clock wise direction.
bracket mounting bolts on Intake Manifold.

4. Install the HPP mounting bolts and

Torque tighten the bolts to specified value.

2. Install the intake manifold and torque

tighten the bolts to specified value.
5. Connect the HPP fuel lines.

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
174 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Connect the HPP electrical connector. 9. Using hand rotate the oil filter in
clockwise direction till the O-ring makes
contact with the oil cooler surface.

7. Refit the Fuel Line (High Pressure Pump

to Rail). For additional information refer Fuel
Line (High Pressure Pump to Rail) R&R
section
• The oil filter should only be hand
8. Place the oil filter in its position. tightened. No special tool or spanner
to be used.
• Never use wrench or filter tool for
installation. If the oil filter is
overtightened then it cause O ring
distortion or damage, resulting in
engine seizure.

10. Install the coolant outlet pipe assembly,

along with the coolant temperature sensor
and Torque tighten the bolts to specified
value.

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 175
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Connect the electrical connector in the

engine coolant temperature sensor.

12. Install the coolant outlet hose and

fasten using spring band clamp.

13. Refit the EGR pipe by mounting the V

clamp.

14. Refit the inter cooler. For additional

information refer to intercooler R&R section.

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
176 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.11 Oil Sump R&R

2.9.11.1 Component Location Index

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 177
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.11.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Refill the oil & check for the oil leakage,
• Drain engine oil. Check for the oil level, which should be in
between the MAX & MIN level.

Removal Steps:
1. Oil sump mounting bolts.
2. Oil sump assembly.
Tools Required

Size Type Quantity

12 mm/ 17 mm Socket spanner 1

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
178 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.11.3 Removal

1. Drain the engine oil. For additional

information refer to Engine Oil Draining
Procedure Section.

2. Using a 17 mm open end spanner loosen

the guide bottom mounting nut. Detach and
remove the guide

3. Using a 12 mm socket spanner remove

the oil sump mounting bolts.

4. Remove the oil sump assembly.

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 179
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.11.4 Inspection
• Check for cracks and leaks, if found damage replace.

2.9.11.5 Installation

1. Clean the sump and sump seating area 5. Tighten the mounting bolts as suggested
on bed plate. and Torque tighten the bolts to specified
value and as per torque sequence.
2. Apply sealant as per recommendation
and position the sump on crankcase. Please
refer Sealant pattern session for sealant
apply pattern.

3. Install the oil sump assembly & the

mounting bolts.

6. Refill the engine oil. For additional

information refer to Engine Oil Filling
Procedure Section

4. Position the dip stick guide on sump and

Torque tighten the bottom nut to specified
value.

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
180 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.12 Oil Strainer R&R

2.9.12.1 Component Location Index

2.9.12.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit Oil sump.
• Remove Oil sump. • Refill the oil & check for the oil leakage,
Check for the oil level, which should be in
between the MAX & MIN level.

Tools Required

Size Type Quantity

12 mm Socket spanner 1

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 181
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.12.3 Removal

1. Drain the engine oil. For additional 5. Remove the strainer assembly.
information refer to Engine Oil Draining
Procedure Section.

2. Remove the oil sump. For additional

information refer to Oil sump R&R section.

3. Using a 12 mm socket spanner remove

the strainer mounting bolts and remove the
strainer.

4. Slide the strainer in the shown direction.

2.9.12.4 Inspection
• Check for any external damage, if found replace.

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
182 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.12.5 Installation

1. Install the oil strainer. 5. Refill engine oil. For additional

information refer to Engine Oil Filling
Procedure Section.

2. Slide the strainer in the shown direction.

3. Install the oil strainer mounting and

Torque tighten the bolts to specified value.

4. Install the oil sump. For additional

information refer to Oil sump R&R section.

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 183
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.13 Engine Mountings R&R

2.9.13.1 Component Location Index

2.9.13.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the Intercooler
• Open the bonnet. • Close the bonnet
• Remove the Intercooler

Tools Required

Size Type Quantity

19 mm Socket spanner 1

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
184 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.13.3 Removal

1. Remove the inter cooler. For additional 4. Using engine lifter lift the engine to
information refer to intercooler R&R section. desired position upwards.

2. Using a 19 mm socket spanner remove

the LH engine mounting nut from the bracket.

• Lift the engine with care, don’t over lift

3. Using a 19 mm socket spanner remove since chances of damaging parts are
the RH engine mounting nut from the high.
bracket. • Ensure none of the components are
effected or damaged during lifting.

5. Remove the RH & LH mounting bolts.

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 185
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Remove the engine mountings from the

vehicle.

2.9.13.4 Inspection
1. Check for cracks in the bedding. replace if found

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
186 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.13.5 Installation

1. Install the engine mountings on the 3. Release the engine from the engine lift.
vehicle.

4. Tighten the RH & LH mounting nuts. and

2. Install the RH & LH engine mounting Torque tighten the bolts to specified value.
bolts. and Torque tighten the bolts to
specified value.

5. Refit the inter cooler. For additional

information refer to intercooler R&R section.

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 187
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.14 Oil Cooler and Oil Filter Assembly R&R

2.9.14.1 Component Location Index

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
188 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.14.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refill the oil & check for the oil leakage,
Check for the oil level, which should be in
between the MAX & MIN level.

Removal Steps:
1. Remove Oil filter.
2. Remove Oil Cooler.
3. Remove Oil filter bracket mounting bolts.
4. Remove Oil filter bracket.
Tools Required

Size Type Quantity

12 mm / 34 mm Socket spanner 1

– Hose clip plier 1

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 189
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.14.3 Removal

1. Using a hose clip plier unclip the spring 4. Using 34 mm socket spanner remove
band clamp and detach the oil cooler inlet engine oil cooler mounting stud, then detach
hose from engine oil cooler. and remove the oil cooler.

2. Using a hose clip plier unclip the spring 5. Using a 12 mm socket spanner remove
band clamp and detach the oil cooler outlet the oil filter bracket mounting bolts.& remove
hose from engine oil cooler. oil bracket .

3. Grip the engine oil filter firmly using an oil

filter removal universal cup tool, rotate in
anti-clockwise direction and remove the oil
filter from engine assembly.

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
190 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.14.4 Inspection
• Check for any external damage, if found replace.

2.9.14.5 Installation

1. Install the oil filter bracket and the 3. Place the oil filter in its position.
mounting bolts. and Torque tighten the bolts
to specified value.

4. Using hand rotate the oil filter in

clockwise direction till the O-ring makes
2. Install the oil cooler and mounting bolt contact with the oil cooler surface.
and Torque tighten the bolts to specified
value.

• The oil filter should be only hand

tightened. No special tool or spanner
to be used.
• Never use wrench or filter tool for
installation. If the oil filter is
overtightened then it cause O ring
distortion or damage, resulting in
engine seizure.

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 191
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Install the oil cooler outlet hose on Oil

cooler.

6. Install the oil cooler inlet hose.

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
192 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.15 Glow Plug (Cylinder No. 1) - R&R

2.9.15.1 Component Location Index

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 193
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.15.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the NVH cover

• Open the bonnet. • Close the bonnet.
• Remove the NVH cover.

Removal Steps:
1. Disconnect the glow plug electrical connector.
2. Remove the glow plug.
Tools Required:

Size Type Quantity

8 mm / 10 mm Deep socket spanner 01

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
194 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.15.3 Removal

1. Remove the Intercooler assembly. For

additional information refer to intercooler
R&R section.

2. Gently pull-out glow plug electrical

connector.

3. Using a 8 mm deep socket spanner,

loosen and remove the glow plug.

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 195
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.15.4 Installation

1. Insert the glow plug, torque tighten the

glow plug to specified value.

2. Connect the glow plug electrical

connector.

3. Refit the Intercooler assembly. For

additional information refer to intercooler
R&R section.

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
196 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.16 Glow Plugs (Cylinder No. 2,3 & 4) - R&R

2.9.16.1 Component Location Index

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 197
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.16.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Install the Intake Manifold.

• Open the bonnet. • Close the bonnet.
• Remove the Intake Manifold.

Removal Steps:
1. Disconnect the glow plug electrical connectors.
2. Remove the glow plugs.
Tools Required:

Size Type Quantity

8 mm Deep socket spanner 01

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
198 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.16.3 Removal

1. Remove the Intake Manifold. For

additional information refer to Intake Manifold
R&R section.

2. Gently pull-out glow plugs electrical

connector.

3. Using a 8 mm deep socket spanner,

loosen and remove the glow plugs.

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 199
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.16.4 Installation

1. Insert the glow plugs, torque tighten the

glow plugs to specified value.

2. Connect the glow plug electrical

connectors.

3. Install the Intake Manifold. For additional

information refer to Intake Manifold R&R
section.

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
200 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.17 Vacuum Pump R&R

2.9.17.1 Component Location Index

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 201
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.17.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the Intercooler.
• Remove the Intercooler. • Check and ensure vacuum assistance.

Removal Steps:
1. Remove vacuum pump mounting bolts.
2. Remove the vacuum pump.
Tools Required

Size Type Quantity

— Hose clip plier 01

12 mm Socket spanner 01

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
202 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.17.3 Removal

1. Remove the Intercooler. For additional

information refer to intercooler R&R section.

2. Using a hose clip plier, unclip the spring

band clamp and disconnect the vacuum
hose.

3. Using a 12 mm socket spanner, remove

vacuum hose mounting bolts. Gently detach
and remove the vacuum pump.

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 203
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.17.4 Inspection
1. Inspect the vacuum pump for any damage. Replace if found.

2.9.17.5 Installation

1. Apply sealant as per recommended

pattern.

2. Refit the vacuum pump with the help of

mounting bolts. Torque tighten the bolts to
specified value.

3. Connect the vacuum hose and fasten

using spring band clamp.

4. Refit the Intercooler. For additional

information refer to intercooler R&R section.

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
204 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.18 Cam Phase Sensor R&R

2.9.18.1 Component Location Index

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 205
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.18.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a flat surface. • Refit the Intercooler.
• Remove the Intercooler. • Check and ensure proper functioning of
engine.

Removal Steps:
1. Remove sensor mounting bolt.
2. Remove the cam phase sensor.
Tools Required

Size Type Quantity

8 mm Socket spanner 01

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
206 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.18.3 Removal

1. Remove the Intercooler. For additional

information refer to intercooler R&R section.

2. Disconnect the cam phase sensor

electrical connector.

3. Using 8 mm socket spanner remove the

cam phase sensor mounting bolt, gently pull-
out and remove the cam phase sensor.

Take sufficient care not to damage the

sensor while removing.

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 207
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.18.4 Inspection
1. Inspect the sensor and connector for any physical damage. Replace if found.

2.9.18.5 Installation

1. Refit the cam phase sensor with the help

of mounting bolt. Torque tighten the bolt to
specified value.

Ensure correct torque value is given to

sensor mounting bolt. Else chances of
sensor malfunction is high.

2. Connect the sensor electrical connector.

3. Refit the Intercooler. For additional

information refer to intercooler R&R section.

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
208 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.19 Crank Shaft Sensor R&R

2.9.19.1 Component Location Index

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Erase if any DTC’s registered using i-
SMART diagnostic tester.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

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 209
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.19.2 Removal:

1. Disconnect the crank shaft sensor

electrical connector.

2. Using a 10 mm socket spanner loosen

and remove the mounting bolt first and then
carefully pull-out and remove the crank shaft
sensor.

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
210 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.19.3 Inspection:
1. Inspect the sensor for any damage. Replace if found.
2. Inspect the connector for any damage.
3. Inspect the connector for proper fitment.

2.9.19.4 Installation:

1. Refit the crank shaft sensor using

mounting bolt. Torque tighten the bolt to
specified value.

2. Connect the crank shaft sensor electrical

connector.

3. Check and erase if any DTC’s registered

using i-SMART diagnostic tester.

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 211
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.20 Dip Stick Guide R&R

2.9.20.1 Component Location Index

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
212 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.20.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Top-up the engine oil.
• Open the bonnet.

Removal Steps:
1. Remove dip stick guide bracket mounting nut.
2. Loosen dip stick guide lower mounting nut.
3. Remove the dip stick guide.
Tools Required

Size Type Quantity

12 mm Socket spanner 01

17 mm Open end spanner 01

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 213
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.20.3 Removal

1. Pull-out and remove the dip stick.

2. Remove dip stick guide bracket

mounting nut using 12 mm socket spanner.

3. Using a 17 mm open end spanner loosen

the guide bottom mounting nut. Detach and
remove the guide.

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
214 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.20.4 Inspection
1. Inspect the dip stick guide for any damage. Replace if found.
2. Inspect the dip stick for any damage or material deterioration. Replace if found.

2.9.20.5 Installation

1. Position the dip stick guide on sump.

2. Position the bracket on mounting stud,

fasten using mounting nut. Torque tighten the
nut to specified value.

3. Torque tighten the bottom nut to

specified value.

4. Insert the dip stick.

5. Check engine oil level and top up if

required.

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 215
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.21 Oil Pressure Switch R&R

2.9.21.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 lift. • Check for oil pressure warning lamp on
• Open the bonnet. cluster.

Tools Required

Size Type Quantity

24 mm Socket spanner 01

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
216 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.21.2 Removal

1. Disconnect the oil pressure switch

connector.

2. Using a 24 mm socket spanner loosen

and remove the oil pressure switch.

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 217
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.21.3 Installation

1. Refit the oil pressure switch, torque

tighten the switch to specified torque value.

2. Connect the electrical connector.

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
218 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.22 EMS ECU R&R

2.9.22.1 Component Location Index

Pre Removal Post Installation

• Place the vehicle on a flat surface. • Close Co-driver door.
• Open Co-driver door. • Check and ensure proper functioning of
engine.
• Reset date/time and FM channels.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

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 219
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.22.2 Removal

1. Open Co-driver door and access EMS

ECU located at Instrument panel bottom
side.

2. Open the lock and then gently pull-out

and remove the EMS ECU connector.

3. Using 10 mm socket spanner remove

EMS ECU mounting bolts.

4. Remove the EMS ECU.

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
220 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.9.22.3 Inspection
1. Inspect the EMS ECU for any damage. Replace if found.
2. Inspect the connector and lock for any damage.

2.9.22.4 Installation

1. Refit the EMS ECU on bracket. Torque

tighten the bolts to specified value.

2. Connect the EMS ECU electrical

connector and engage the lock.

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 221
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10 Disassembly and Assembly

2.10.1 Cylinder Head Assembly

2.10.1.1 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Refit the Cylinder Head assembly from
vehicle
• Remove the Cylinder Head assembly from
vehicle

Removal Steps:

1. Remove the cylinder head assembly. 5. Remove the valve stem seals.
2. Remove the valve spring locks. 6. Remove the valve spring lower retainers.
3. Remove the valve spring upper retainers. 7. Remove exhaust and intake valves.
4. Remove the valve springs. 8. Remove the valve guides.

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
222 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.1.2 Disassembly

1. Using a suitable valve compressor, 2. Remove the upper retainer and valve
compress and hold the valve spring and then springs.
remove the valve spring locks.

Incase of reusing the same valves spring,

make necessary marking according to
the respective cylinder.

3. Remove valve stem seals.

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 223
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Remove the valve spring lower retainers. 6. Using suitable tool remove the valve
guides.

Extreme care should be taken while

removing Valve stem. Failure to follow
may lead to cylinder head damage.

5. Remove the valves.

The valve should be identified , so that in

case the valves are being reused they
can be used. Failure to do so may
increase the probability of compression
leak through the valve after the engine is
rebuilt.

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
224 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.1.3 Inspection

1. Check the valve spring lock for any

internal and external damage.
2. Check the valve spring height.

1. Check the valve stem height.

2. Check the valve stem for any damages.

1. Check the valve for any damages.

2. Using a micrometer measures the
diameter of the valve stems.
3. If the measurements are not to
specification, install a new valve.
4. Check the valves for bend — especially
if the engine has suffered water entry
into combustion chamber

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 225
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Clean the cylinder head assembly

thoroughly, if any cracks or damages
are found replace the cylinder head.
2. Check the Cylinder Head for external
damages.
3. Remove carbon and varnish deposits
from inside of valve guides with a
reliable guide cleaner.
4. Check the valve seat area for leakages.

Check the cylinder head height and if not

meeting the specified value, replace the
cylinder head assembly.

Check the Cylinder Head bottom face for

distortion.

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
226 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Check the cylinder head flatness, if any

misalignment or bend found replace the
cylinder head assembly.

Check the cylinder head for warpage.

Check the length of the Cylinder Head bolts.

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 227
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Measure the valve seat width using the valve

seat width micrometer.
• Check for pitting.
• Check for valve seat insert looseness
(Engine overheat conditions).

1. Using a micrometer measure the

diameter at 90 degrees intervals to
determine if the journals are out-of-
round.
2. Measure at two different points on the
journal to determine if there is any
tapering.
3. If the measurements are out of the
specified range, install a new camshaft.
4. Check the inlet camshaft and the
exhaust camshaft for any damage and
replace it if necessary.

Inspect the rocker arm for wear or damage.

Replace as necessary.

Do not dis-assemble the HLLA, as it is

not a serviceable component. Incase of a
failure of a HLLA, replace the complete
assembly.

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
228 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.1.4 Assembly

1. Using the suitable tool, install the valve 2. Carefully insert the valve from bottom.
stems.

Incase of reusing the same valves again,

make sure the valves used is of
respective cylinder.

Extreme care should be taken while

installing Valve stem. Failure to follow
may lead to cylinder head damage.

3. Install the valve spring bottom retainers

to the cylinder head.

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 229
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Using suitable tool refit new valve stem

seals.

Never use old valve stem seal, always

use a new one.

5. Insert the respective valve spring and top

retainers.

6. Using a suitable tool, compress the valve

spring carefully insert the locking pins and
lock it properly.

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
230 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.2 Cylinder Block Disassembly & Assembly

2.10.2.1 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Install the oil sump.
• Remove the engine assembly. • Install the cylinder head assembly.
• Remove the cylinder head assembly. • Install the engine assembly.
• Remove the oil sump.

Tools Required:

Size Type Quantity

10 mm / 15 mm socket spanner 01

5 mm / 8 mm Allen Key 01

— Nose Plier / Mallet Each 01

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 231
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.2.2 Disassembly

1. Remove the engine assembly. For 7. By using 10 mm socket spanner remove

additional information refer to Engine connecting rod cap mounting bolts from the
assembly R&R section. crank shafts and remove connecting rod
caps.
2. Mount the engine on engine mounting
stand.

3. Remove the cylinder head assembly . Main bearing caps position /number
For additional information refer to Cylinder should be marked. They can not be
head R&R section. interchanged to a different position. The
bearing shell number and if top or bottom
4. Remove the oil sump assembly. For should be noted. The shells position
additional information refer to Oil sump should be same if they are being reused.
assembly R&R section. Also if marked correctly then it will be
useful to identify the type of wear. And
5. Remove the dual mass flywheel. For give useful information.
additional information refer to Dual Mass
Flywheel (DMF) R&R section.

6. Remove the flywheel pilot bearing. For

additional information refer to Flywheel pilot
bearing R&R section.

8. Remove the connecting rod lower

bearing.

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
232 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. By Using 15 mm socket spanner remove 12. Remove the bed plate & crank shaft
the crankshaft mounting bolts assembly.

10. By Using 8 mm allen key remove the 13. Mark the shell bearing, and remove the
bed plate mounting allen bolts. shell bearing from the cylinder block.

11. Mark the shell bearing, and remove the 14. By Using 10 mm socket spanner
shell bearing from the bed plate. remove the oil spray jets.

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 233
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15. Mark the thrust washer inner and outer, 18. Remove the connecting rod upper
and detach the thrust washers from the bearing.
crankcase.

19. Using a nose plier remove the gudgeon

16. Using 5 mm allen key, remove the three pin circlip.
crankshaft TDC sprocket mounting bolts and
detach the TDC sprocket.

20. Remove the gudgeon pin.

17. Using a mallet hammer, carefully tap
the connecting rod, and remove the
connecting rod with piston.

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
234 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21. Detach and remove piston from

connecting rod.

22. Using a piston ring removal tool,

expand and remove the piston compression
rings. Oil ring can be removed with hand.

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 235
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.2.1 Inspection

2.10.2.1.2 Cylinder Bore Taper Check

Measure the cylinder bore with an internal micrometer.

• Carry out the measurements in different directions and at different heights to determine if
there is any out-of-roundness or tapering.
• If the measurement is out of the specified range, install a new block or hone out the cylinder
block.

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
236 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.2.1.3 Piston Diameter

Using a micrometer measure the piston

diameter.

2.10.2.1.4 Piston Inspection

Do not use any aggressive cleaning fluid

or a wire brush to clean the piston.
1. Clean the piston skirt, pin bush, ring
grooves and crown and check for wear
or cracks.
2. If there are signs of wear on the piston
skirt, check whether the connecting rod
is twisted or bent.

2.10.2.1.5 Piston Ring-to-groove Clearance

The piston ring must protrude from the piston groove. To determine the piston ring
clearance, insert the feeler gauge right to the back of the groove, behind the wear
ridge.

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 237
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Using feeler gauge, measure the piston ring

clearance.

2.10.2.1.6 Piston Ring End Gap

1. Take the piston ring and use a piston

without Rings to push the piston ring
about xx mm into the cylinder bore.
2. Do not mix up the piston rings. Install
the piston rings in the same position
and location.

2.10.2.1.7 Bearing Inspection

Inspect Bearing for the following defects:

A. Cratering - fatigue failure
B. Spot polishing - incorrect seating
C. Imbedded dirt engine oil.
D. Scratching - dirty engine oil
E. Based exposed - poor lubrication
F. Both edges worn - journal damaged
G. One edge worn - journal tapered or
bearing not seated
H. Tin coating - bearing excessive wear

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
238 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.10.2.8 Assembly

1. Attach the crankcase to the engine 4. Position the piston assembly with
mounting stand. connecting rod.

2. Clean the mating faces of the cylinder

head and cylinder block with suitable metal
surface cleaner except cylinder bore and Arrow mark side on piston and notch on
piston. connecting rod should be aligned on
same side.
3. Install the piston rings on the piston
using piston ring compressor.

While fitting the piston rings ensure that

the rings end gap staggering is done at
an angle of 120 degrees. The top mark of
the first ring should face upwards. The
tapered face of the second ring should
be on the top. The third ring or oil ring
can be fitted in either way.

5. Align the connecting rod and piston

assembly and then Insert the gudgeon pin.

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 239
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Using a nose plier refit the gudgeon pin 9. Using a mallet hammer, carefully tap the
circlip. connecting rod and push the piston inside the
cylinder and observe the correct position,
marking and direction to the crankshaft.

7. Install the upper connecting rod bearing.

• Place the pistons to their respective

cylinders. To avoid crankshaft damage
do not interchange the connecting rod
shell bearing and connecting rod cap.
• While removing and installing the
connecting rod along with piston,
carry out necessary actions to avoid
the damage to the oil spray nozzle of
the cylinder block.

8. Using the piston ring compressor, tighten

piston rings to ensure easy entry of the Before assembling, adequately lubricate
piston into the cylinder block. the piston, cylinder walls and connecting
rod bearing shells with clean oil.

10. Install the piston cooling nozzles and

Torque tighten the bolts to specified value.

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
240 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Refit TDC sprocket on crankshaft using 13. Place the inner and outer thrust washer
mounting screws. Torque tighten the screws into the crankcase.
to specified value.

Carefully place the Crankshaft TDC

sprocket without any damage to the
sprocket teeth which may cause engine
starting problems.

14. Smear new oil on the main bearings

and journals and install crankshaft.

12. Install the crankshaft bearings shells

into the crankcase in correct order.

• Clean the engine block thoroughly

before assembling the bearing shells,
wipe the front and back ends of the
15. Install the crankshaft bearings shells
shells with a clean cloth. Ensure that
into the bed plate in correct order.
the bearing shells are located properly
in the notches
• Make certain oil holes in block line up
with oil holes in bearings. Bearing
tabs must seat in the block tab slots.

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 241
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16. Apply loctite 574 to the bed plate and 17. Position the connecting rod in the
install the bed plate on the engine block. crankshaft and install the connecting rod
Using a 8 mm allen key and 15 mm socket caps. Using a 10mm star socket and wrench,
and wrench set, tighten the bed plate tighten the connecting rod cap mounting
mounting bolts and crankshaft main bearing bolts to specified torque.
mounting bolts to the specified torque. For
additional information refer to Sealant
Application.

Use only the recommended sealant,

failure to follow the instruction may lead
to leakages. While tightening the bed
plate mounting bolts follow torque
sequence.

Lubricate the connecting rod caps before

tightening the caps.

18. Using the rear oil seal pressing dolly

(MST) install the rear end oil seal till the oil
seal is completely seated.

19. Install the flywheel pilot bearing. For

additional information refer to Flywheel pilot
bearing R&R section.

20. Install the dual mass flywheel. For

additional information refer to Dual Mass
Flywheel (DMF) R&R section.

21. Install the oil sump assembly. For

additional information refer to Oil sump
assembly R&R section.

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
242 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22. Install the cylinder head assembly. For

additional information refer to cylinder head
assembly chapter.

23. Install the engine assembly. For

additional information refer to Engine
assembly R&R section.

2.10.3 Testing:

1. Start the engine.

2. Run at idle for 5 minute. Observe for

leaks.

3. Drive the vehicle at 50% of the maximum

speed in each gear for about 10 to 30 Km
each (Approx.).

4. Hand over the vehicle to customer to

drive with speed limitation for 2000 Kms.

5. Change the engine oil at 5,000 kms.

• 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 components.

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 243
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.11 Specification and Wear Data

Sl No: Description Specification

1 Cylinder Bore Diameter (mm) 85

2 Circularity 0.004

3 Cylindricity (mm) 0.01

4 Stroke Length (mm) 96

5 Displacement (cc) 2179

6 Compression Ratio 16.5

7 Power Output @ RPM 103 kW (140 HP) @ 3750 rpm

8 Torque @ RPM 320 Nm@1500-2800 rpm

9 Idle Speed (RPM) 800±50

10 Maximum oil consumption ( L/ 1000 80 ml / 1000 kms (Upto 80,000 Km)

kms)
100 ml / 1000 kms ( Between 80,000
Km to 1,00,000 Km)

11 Engine oil Capacity (L) 6L

12 Engine Oil Specification MAXIMILE FEO

13 Cylinder block - Cylinder bore Diameter 85

(mm)

15 Cylinder block - Main Bearing parent 66

Bore Diameter (mm)

16 Cylinder block - Main Bearing Min. : 0.2925 , Max : 0.8 (Radial

clearance - Theoretical (mm) Interference)

17 Head gasket (Cylinder block surface 0.04 overall

flatness) (mm)
0.02 for 100 X100 area

18 Number of Cylinders 4

19 Firing Order 1-3-4-2

20 Piston ring end gaps - Upper 0.25 – 0.4

compression ring (mm)

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
244 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Sl No: Description Specification

21 Piston ring end gaps - Lower 0.4 – 0.6

compression ring (mm)

22 Piston ring end gaps - Oil control ring 0.25 – 0.5

(mm)

23 Piston ring width - Upper compression 2.5

ring (mm)

24 Piston ring width - Lower compression 2

ring (mm)

25 Piston ring width - Oil control ring (mm) 2.5

26 Piston skirt coating thickness 15±5µm

27 Crank Shaft - Main bearing journal end 0.1-0.3

float (mm)

28 Connecting rod - Big end bore diameter 54.006~54.018

(mm)

29 Connecting rod - Small end bore 31.025~31.041

diameter (mm) with press fit bush

30 Connecting rod - Bearing Clearance 0.1-0.3

(mm)

31 Connecting rod - Bearing Thickness 21. ±0.3

(mm)

32 Number of main bearing 4 sets

33 Piston pin length (mm) 70 ±0.3

34 Piston pin diameter (mm) 31 ±0.006

35 Crankshaft end float value (mm) 0.1-0.3

CAM SHAFT

1 Cam shaft end float (mm) 0.1 - 0.2

2 Intake Camshaft lobe lift (mm) 3.71003 (Max.)

3 Exhaust camshaft lobe lift (mm) 4.01777 (Max.)

VALVES

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 245
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Sl No: Description Specification

1 Head Diameter—Intake 29.3±0.1

2 Head Diameter—Exhaust 26.1±0.1

3 Valve Length (Overall)- Intake 96.62

4 Valve Length (Overall)- Exhaust 96.39

5 Valve Stem Diameter (Intake) 5.98±0.008

6 Valve Stem Diameter (Exhaust) 5.96±0.008

VALVE SPRINGS

1 Free Length (Approx.) 47.16

2 Nominal Force (Valve Closed) - stress Load = 204.0 ± 10.2 N Stress = 518.64
MPa

3 Nominal Force (Valve Open) - stress Load = 332.9 ± 16.6 N Stress= 846.36
MPa

4 Installed Height 34.5 mm

5 Number of Coils 8.57 (Total No. of Coils)

6.57 (Active No. of Coils)

6 Wire Diameter 2.8±0.03

CYLINDER HEAD

1 Material GK-AlSi7Mg

2 Gasket Thickness (Compressed) 1.3±0.04 mm

3 Cylinder Head - Maximum Distortion 0.1 overall

(Mating Face) (mm)
0.03/100 X 100

VALVE SEAT

1 Angle 60°±1° (Exhaust)

40°±1° (Intake)

2 Seat Diameter—Exhaust 27.090±0.008 mm

VALVE GUIDE

1 Guide Bore Diameter 11.0 +0.018/0

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
246 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Sl No: Description Specification

2 Guide Height (spring seat to guide tip) 40.43

OTHERS

1 Oil Pressure relief valve opening 0.8-1 kg/cm2

pressure @ rpm

2 Emission Level EII & EIV

FUEL SYSTEM

1 HPP Pump Type 3 Cyl. Radial plunger

2 Maximum Pressure 1600 Bar

3 Fuel Injector Type CRI 2.2

4 Injector IMA XXXXXX (Seven Digits)

5 Injector washer standard thickness 2.5±0.05

6 Fuel Rail Type Common rail - HFR (Hot Forged Rail)

7 Maximum Pressure 1600 Bar

8 Rail components RDS 4.2 -Common rail and Rail

Pressure sensor as assembly

9 Mounting Lugs 2

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 247
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12 Lubricants & Sealants

2.12.1 Lubricants

Performance Viscosity Grade SAE

Specification
Sl. Filling
N- System DIESEL DIESEL quantity
o. ENGINES ENGINES Upto -10° -10° C & Liters
(up to (up to C Below
Euro IV) Euro V)

API CH4, MB
228.3, VDS-
Engine 2, DHD-1
1 and / or ACEA C3 15W-40 5W-30 6 Liters
mHawk
ACEA A5/
B5; A3/B4

BASF MAKE "GLYSANTIN" G 30 #

Note: # Mix non-conductive (de mineralized) water with
Engine coolant externally & fill upto the max level.
2 7.5 Liters
coolant
Ratio : 30% Coolant + 70% water for temperatures up to
-10°C, Below -10°C use 50% Coolant + 50% water

2.12.2 Sealants

Sl. Place of Sealant Pattern

No. Application

1 Cam cover and Head Loctite 5188 Only at T-joint as per sealant
pattern

2 Front Cover Loctite 5900 Apply as per mentioned in

sealant pattern

3 Cam Cover and Oil Loctite 5900 Apply as per mentioned in

Separator sealant pattern

4 Bed plate Loctite 5900 Apply as per mentioned in

sealant pattern

5 Oil sump Loctite 5900 Apply as per mentioned in

sealant pattern

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
248 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.3 Accessory Drive Belts Tension Values

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 249
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.4 Honing Specifications

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
250 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.5 Oil Cooler Position with respect to Oil Filter Module Mounting Face

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 251
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6 Sealant Application Pattern

2.12.6.1 Bed plate

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
252 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.2 Timing cover assembly

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 253
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.3 Cylinder head and cam cover

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
254 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.4 Cam cover and Oil Separator

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 255
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.5 Oil sump

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
256 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.6 Water pump

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 257
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.7 Vacuum pump

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
258 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.8 Cylinder block to Bed plate

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 259
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.12.6.9 Cylinder head and cylinder block

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
260 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13 Tightening Specifications & Sequence

2.13.1 Tightening Specifications

Place of Application Torque in

Specification Quantity
Bolt Nm
CYLINDER HEAD

CYLINDER HEAD M13x 1.5x 138 65±3 N-m + 2X90°

10
MOUNTING BOLTS ±1°

TAPER PLUG M10 M10x1 5 13±2

GLOW PLUG M8x1 — 6H 4 9±1

PLUG HLA OIL GALLERY M10x1

1 16.5±1.5
REAR M10

PIPE OIL COOLER M6X1X12X8.8

OUTLET FLANGE SCREW 2 11±1
M6

PIPE EGR COOLER INLET M6X1X12X8.8

2 11±1
FLANGE SCREW M6

BRKT TRANSMISSION M8x1.25x15

BREATHER FLANGE 1 25±3
SCREW M8

ENGINE LIFTING HOOK M8x1.25x20

2 25±3
REAR SCREW

ENGINE LIFTING HOOK M8x1.25x30

1 25±3
REAR – INTAKE STUD

ENGINE LIFTING HOOK M8x1.25

REAR – INTAKE FLANGED 1 25±3
NUT

ENGINE LIFTING HOOK M8x1.25x20

1 25±3
REAR – INTAKE SCREW

CAMSHAFT AND CAM COVER

CAM COVER MOUNTING M6x1x35

31 11±1
FLANGE BOLT

ELBOW OIL FILLER M6x1x20

2 11±1
SCREW M6

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 261
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
PHASE SENSOR M6x1x20
1 11±1
MOUNTING SCREW

SPROCKET CAMSHAFT M12x1.75x45

2 90±5
MOUNTING BOLT

BREATHER SYSTEM

CCV MOUNTING BOLT M6 M6X1X20 6 11±1

EXHAUST & EGR SYSTEM

STUD EXHAUST M8x I.25x30

8 25±3
MANIFOLD

EXHAUST MANIFOLD M8x 1.25

8 25±3
MOUNTING NUT

STUD TURBOCHARGER M8x 1.25x25 2 25±3

TURBOCHARGER M8X1.25X25X8.8XP-
1 25±3
MOUNTING SCREW M8 L

CLINTCH NUT FOR M8x 1.25

2 25±3
TURBOCHARGER

T3-TEMPERATURE M14X1.5
1 42.5±2.5
SENSOR

BOLT TURBOCHARGER M8x 1.25x25 1 25±3

ELBOW T/C M6x 1x20

3 11±1
COMPRESSOR

STUD EGR PIPE SHORT M8x 1.25x25

2 25±3
TO MANIFOLD

CLINCH NUT FOR SHORT M8x 1.25

2 25±3
PIPE

ASSY EGR COOLER M8X1.25X45X8.8XP-

MOUNTING ON EGR H 1 18.5±1.5
MIXER UPPER

ASSY EGR COOLER M8X1.25X63X8.8

MOUNTING ON EGR 1 18.5±1.5
MIXER LOWER

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
262 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
ASSY EGR COOLER M8X1.25X63X8.8
MOUNTING ON INTAKE 2 25±3
MANIFOLD

EGR TEMPERATURE M14X1.5

1 37.5±2.5
SENSOR

BRKT W/H MOUNTING ON M6X1X12X8.8

1 11±1
EGR COOLER

EGR LONG PIPE

MOUNTING ON EGR
M8X20 2 25±3
COOLER- M9 ALLEN
SCREW

EGR SHORT PIPE TO EGR M8x 1.25x25 ALLEN

2 25±3
VALVE

EGR SHORT PIPE TO M8X1.25X2526-A193

2 25±3
EXHAUST MANIFOLD

EGR LONG PIPE M8 x 20

MOUNTING ON EXHAUST
2 25±3
MANIFOLD- M8 ALLEN
BOLTS

EGR LONG PIPE M8 x 1.25

MOUNTING ON FRONT 1 25±3
COVER

EGR SHORT PIPE M8 x 20

MOUNTING ON EGR
2 25±3
COOLER- M8 ALLEN
SCREW

EGR SHORT PIPE M8 x 20

MOUNTING ON EGR
2 25±3
MIXER COVER PLATE- MB
ALLEN SCREW

EGR COOLER TO EGR M8X1.25X43X8.8XZ-

2 25±3
VALVE N

EGR COOLER TO LONG M8X1.25X25X10.9X-

2 25±3
PIPE ZN

BANJO BOLT TURBO M10X1

2 17.5±3
INLET

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 263
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
OIL LINE TURBO INLET M6x1x12X8.8
MOUNTING ON HSG. 1 11±1
WATER PUMP INLET

ASSY. OIL RETURN T/C M6x1x20X8.8

MOUNTING ON TURBO 2 11±1
CHARGER

TURBO SUPPORT M8x1.25x20

BRACKET TO 2 25±3
CRANKCASE

INTAKE SYSTEM

INTAKE MANIFOLD MTG. M8x1.25x25X8.8

4 25±3
BOLTS

BOLTS FOR MTG INTAKE M8x1.25x117

4 25±3
MANIFOLD

PIPE CYLINDER HEAD M8x1.25x25

WATER OUTLET
2 17.5±2.5
MOUNTING ALLEN
SCREW

WATER TEMPERATURE M12x 1.5

1 22.5±2.5
SENSOR

BOOST PRESSURE M6x1x16

1 11±1
SENSOR MTG.

GUIDE DIPSTICK OIL M8x1.25x43

1 25±3
LEVEL MOUNTING BOLT

GUIDE DIPSTICK OIL M8X1.25

1 25±3
LEVEL MOUNTING NUT

FUEL SYSTEM

COMMON RAIL M8x1.25x20

MOUNTING ON CYLINDER 2 25±3
HEAD

HIGH PRESSURE PIPES

1 27±2
NUT ON PUMP

ASSY. FUEL INJECTION M8x1.25x43

PUMP MOUNTING ON 3 25±3
CRANKCASE

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
264 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
PIPE HIGH PRESSURE M14x1.5
5 35±2
NUT ON COMMON RAIL

PIPE HIGH PRESSURE M14x1.5

4 27±2
NUT ON INJECTOR

INJECTOR CLAMP STUD M8x1.25x40 4 22.5±2.5

INJECTOR CLAMP NUT M8x1.25 4 25±3

ASSY FUEL INJECTION M14x1.5X11x8xZN

1 72±3
PUMP SPROCKET NUT

PIPE HIGH PRESSURE M6x1x12

PUMP TO RAIL MTG. ON 1 11±1
INTAKE MANIFOLD

CYLINDER BLOCK

MAIN BEARING BOLTS M12x 1.5X103 10 65±3 N-m +2X60°

BED PLATE BOLTS M1Ox1.5x70 10 50±3

BOLT OIL JET (PISTON M6x1x12

COOLING) 4 11±1

BED PLATE PLUG M18 MC18x1.5 4 22.5±2.5

WATER DRAIN PLUG M14 M14x1.5 2 37.5±2.5

PRE COATED PLUG M10 M1Ox1 1 14±1

SPEED SENSOR MTG. M6x1x12 1 11±1

OIL FILTER BODY FLANGE M8x1.25x50

2 25±3
BOLT M8

OIL FILTER BODY FLANGE M8x1.25x25

1 25±3
SCREW M8

HSG. WATER PUMP INLET M8x1.25x25

2 25±3
MTG. BOLT

ENGINE MTG. BRACKET M10x1.5x25 8 48±3

PIPE HEATER OUTLET M6x1x12

1 11±1
SCREW

OIL FILTER SOGEFI M20x1.5 1 14±2

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 265
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
BED PLATE PRE-COATED M16x1.5
1 25±3
TAPER PLUG M16

FRONT COVER

M8x 1.25x50 7 25±3

M8x 1.25x63 - 25±3

BOLT FRONT COVER M8x 1.25x70 16 25±3

M8x 1.25x75 2 25±3

M8x 1. 25x55 - 25±3

TIMING SYSTEM

SHOULDER BOLT- M6x1

2 11±1
PRIMARY GUIDE

MI0X1 2 25±3
SHOULDER BOLT-GUIDE
SECONDARY
M6x1 2 11±1

SHOULDER BOLT ARM MI0X1.5 1 35±3

HYDRAULIC TENSIONER M6x1x25

(PRIMARY) 2 11±1

HYDRAULIC TENSIONER M8X 1.25X30

2 35±3
(SECONDARY HOUSING)

CHAIN COOLING JET — M6X 1X20

SECONDARY MTG. 1 11±1
SCREW

POWER TRAIN

BOLT FLYWHEEL M12x 1.5x47 6 50±3 Nm+60°

BOLT CONNECTING ROD M9x 1.0x51 8 35±3NM +60°

SCREW TRIGGER WHEEL M8x 1.25x22 3 17.5±2.5

FEAD SYSTEM

M8X 1.25X50 2 25±3

A/C COMPRESSOR
BRACKET
M8X 1.25X43 2 25±3

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
266 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
A/C COMPRESSOR ON M8X 1.25X 105
4 25±3
BRACKET

WATER PUMP MTG. M8x 1.25x30 5 25±3

POWER STEERING PUMP M8x 1.25x90

2 25±3
MTG. BOLT

POWER STEERING PUMP M8x 1.25

2 17.5±2.5
MTG. NUT

VISCOUS FAN NUT M30x 1.5 1 55±5

TENSIONER ASSY. MTG. M8x 1.25x30 1 25±3

ON AC COMPRESSOR
BRKT. M30x 1.5x30 1 32.5±2.5

BOLT DAMPER PULLEY M16x 1.5x95 1 150±3NM+ 65°±1°

AUTO TENSIONER MTG. M8x 1.25x43

3 25±3
ON FRONT COVER

BRACE ALTERNATOR M8x1.25x30 1 25±3

M8x1.25x70 1 25±3

BRKT. ALTERNATOR M10x1.5x50 - 32.5±2.5

M10x1.5x60 4 32.5±2.5

ALTERNATOR MTG. BOLT M8x1.25x125 1 25±3

ALTERNATOR MTG. NUT M8x1.25 1 25±3

DUMMY PULLEY MTG. M12x1.25X45

1 65±5
BOLT

DUMMY PULLEY BRKT. TO M8x1.25X50

4 25±3
CRANKCASE

OIL SUMP

M8x 1.25x25 13 25±3

OIL SUMP MTG. BOLTS M8x 1. 25x135 2 25±3

M8x 1.25x90 2 25±3

OIL DRAIN PLUG M16x1.5 1 27.5±2.5

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 267
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in

Specification Quantity
Bolt Nm
GUIDE DIPSTICK OIL M14x1.5
1 22.5±2.5
LEVEL CONNECTOR

GUIDE DIPSTICK OIL M14x1

1 25±3
LEVEL MTG. NUT

INTERCOOLER

BRKT. INTERCOOLER M8 X 1.25X20

2 27.5±2.5
INTAKE FLANGE SCREW

BRKT. INTERCOOLER M8 X 1.25X20

EXHAUST FLANGE 3+3 27.5±2.5
SCREW

HEAT SHIELD CCV MTG. M6x 1x12

ON BRKT. INTERCOOLER 2 11±1
EXHAUST

VACUUM PUMP FLANGE M8x 1.25x20

3 27.5±2.5
SCREW

NVH DAMPER EAGLE 4 10±2

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
268 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2 Tightening Sequence

2.13.2.1 Cam Cover

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 269
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.2 Timing Cover Assembly

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
270 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.3 Head Assembly

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 271
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.4 Bed Plate and Main bearing

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
272 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.5 Oil Separator

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 273
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.6 Oil Sump

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
274 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.7 Intake Manifold

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 275
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.8 Exhaust Manifold

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
276 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.9 Flywheel

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 277
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.10 AC Compressor

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
278 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.11 Dummy pulley AC bracket

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 279
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.12 EGR Long pipe — Euro II

2.13.2.13 EGR Short pipe

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
280 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.14 EGR cooler

2.13.2.15 Engine mounting bracket

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 281
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.16 Intake pipe

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
282 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.13.2.17 Intercooler brackets

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 283
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2.14 Mahindra Special Tools (MST)

Sketch Description /Part No.

Flywheel Lock MST

0301BM0008ST

Lock Pin for Chain Tensioner MST

273

Drift Flywheel Bearing MST – 544

HPP removal tool

0305BAM0007ST

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
284 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Sketch Description /Part No.

Injector removal tool

TDC Locking Pin

0301BM0004ST

Camshaft locator/ Camshaft linear

alignment tool
0301BM0002ST

0301BM0001ST
Front end timing tool for camshaft

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 285
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
286 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3 AIR INTAKE SYSTEM

3.1 Description & Operation

3.1.1 Air intake System

Air is sucked through the intake hose by the suction created by the engine. The unfiltered air
enters the air cleaner housing at the bottom and leaves through the top after passing through a
filter element. The filter element has multiple filtering media layers which have different
porosities and cleaning efficiencies. Dust and other fine particles are sucked inside along with
air which gets trapped in the air cleaner while passing through the filter element. A Hot Film air
Mass Flow rate (HFM) sensor is attached to outlet of the air cleaner. Clean air coming out of
the air cleaner passes through the sensor mounted after the air cleaner housing. The HFM
sensor measures the air mass flow rate and temperature of air coming out of the system.
The filtered air enters the turbocharger (VGT type) the air is compressed. The heated
compressed air then passes through the intercooler where the heat gets dissipated. From here
it is drawn into the intake manifold and further into the engine.
The Variable Geometry Turbocharger (VGT) controls the boost pressure. The boost
temperature sensor fitted on the outlet hose of the intercooler unit measures the boost
pressure. The boost signal is given to the ECU. Based on the load, engine speed and
temperature, the ECU controls the boost pressure by manipulating the VGT.

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 287
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.1.2 Crank case ventilation system

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

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
288 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.1.3 Air filter element

The air cleaner element is Paper + Foam

type (Dry Type). Filtration happens in two
stages. Coarser particles are filtered in first
stage by foam media and fine particles are
filtered by Paper media in second stage.
The dust and other fine particles which are
sucked inside along with air gets trapped in
the air cleaner while passing through the
filter element.

If the air cleaner is completely chocked

then due to monitoring the vehicle will
not emit smoke. However there will be a
limitation of smoke. The active smoke
limitation while driving for the complete
range can be noticed through the
diagnostic tester – live parameters.

3.1.4 Oil Separator

The oil separator separates oil from the blow

by gas of the engine and sends it back to
engine oil sump. The remaining air and other
gases are sent to the inlet manifold. There is
also a spring loaded diaphragm valve
provided on the oil separator outlet to the
inlet manifold.
This prevent the flow of excessive of blow by
from the oil separator to the inlet manifold in
case the air filter is chocked and high suction
starts acting on outlet port of oil separator.
No leakage past diaphragm or top cover of
oil separator is permitted. Replace the
assembly if there is any leakage are found.

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 289
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.1.5 Intercooler

The intercooler typically an air-to-air heat

exchanger. Intercooler cools the air
compressed by the turbocharger by reducing
its temperature and increasing the density of
the air supplied to the engine and thus
improving the volumetric efficiency by
increasing intake air charge density through
nearly isobaric (constant pressure) cooling.
As the air is compressed by a turbocharger it
gets very hot, very quickly. As its temperature
climbs, its oxygen content (density) drops, so
by cooling the air, an intercooler provides a
denser, more oxygen rich air to the engine
thus improving the combustion by allowing
more fuel to be burned. It also increases
reliability as it provides a more consistent
temperature of intake air to the engine which
allows the air fuel ratio of the engine to
remain at a safe level.
An Air-to-Air intercooler extracts heat from
the compressed air by passing it through its
network of tubes with cooling fins. As the
compressed air is pushed through the
intercooler it transfers the heat to the tubes
and, in turn to the cooling fins. The cool air
from outside, traveling at speed, absorbs the
heat from the cooling fins reducing the
temperature of the compressed air. This
system’s advantages are simplicity, lower
cost and light weight.

3.1.6 Turbo Charger

The VGT has a set of movable vanes in the

turbine housing, and they control the boost.
At low engine speeds when exhaust flow is
low, the vanes are partially closed. This
increases the pressure of the exhaust gases
pushing against the turbine blades, making
the turbine spin faster and generating more
boost. As engine speed increases, so does
the exhaust flow, so the vanes are opened to
reduce turbine pressure and hold boost
steady or reduce it as needed. By reading
the boost pressure sensor, the ECU can
adjust turbine inlet pressure (by varying the
Geometry of Vanes) instantaneously to
control the boost at any speed/ load and to
limit boost at full load.

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
290 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.1.7 HFM Sensor

HFM Sensor is mounted between air filter

and turbocharger. This sensor gives
Information about the amount of air quantity
and temperature of the air entering in the
engine. This input is used by the ECU for
corrections of fuel quantity based on amount
of air availability for optimization of exhaust
gas circulation & the turbocharger control.

3.1.8 Boost Pressure Sensor

Boost Pressure Sensor is fitted on intercooler

outlet near the hose connecting intercooler to
engine intake. The measured boost pressure
is used for the actuation of VGT type
turbocharger.

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 291
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.2 Component Location Index

3.2.1 Air intake System View

A. Intercooler outlet hose G. Breather hose from oil separator

B. Boost pressure sensor H. Turbo charger inlet.

C. Intercooler I. HFM Sensor

D. Oil Separator J. Dirty side duct mesh & hose

E. Intercooler inlet hose K. Air cleaner housing

F. Turbo charger assembly

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
292 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.3 Trouble Shooting

3.3.1 Symptom based Trouble Shooting

Symptom Possible Causes Remedy

Engine does not give full 1. Air intake restricted due to • Replace the air filter
power clogged air filter. element.

2. Air leaks in system after • Plug the leaks, replace

turbocharger. hose or clip if required.

3. Boost pressure sensor • Correct the sensor and find

stuck in open condition. the cause.

4. Turbocharger damaged. • Replace the turbocharger.

Black smoke 1. Air leaks between the • Check for leaks between
turbocharger and inlet the turbocharger and the
manifold. intercooler and between the
intercooler and the inlet
manifold. Remove the
restriction or replace the
respective hose or part if
necessary.

2. Air intake restricted due to • Replace the air filter

clogged air filter. element.

Excess oil consumption 1. Clogged air filter. • Replace the air filter
element.

2. Obstruction in the • Locate and remove the

crankcase ventilation. restriction.

3. Leaks in the inlet manifold • Change the manifold gasket

mounting face which allows or replace the manifold.
the entry of dust particles.

4. Air leakage between the • Locate the leaks, change

turbocharger and intake the hose /clamp/ O-rings if
manifold. required.

5. Thick oil/sludge or coke in • Change oil, filter, service

the turbo chargers central the turbo charger and use
housing. recommended oils and drain
intervals. Follow the
recommended procedure
while shutting down.

6. Turbo charger damaged. • Replace the turbo charger.

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 293
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

Whining noise clearly Indication of air leakage • Tighten the clamps at the
audible after 2000 RPM between the turbocharger to intercooler and the
inlet manifold. turbocharger inlet and outlet.

• Check the hoses for

leakage and replace the
hoses if necessary.

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
294 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.3.2 Component Inspection and Action Table

Component Inspection Action

Air filter 1. Inspect the air filter element 1. Replace the element.
for possible damage.

2. Inspect the air filter element 2. Clean the element and

for clogging. replace if required.

Air intake manifold and 1. Inspect air intake manifold 1. Replace if cracks or
hoses for cracks or distortion. damages are found.

2. Check for air leakage 2. Check surface for

between block and intake distortion.
manifold.

Intercooler 1. Check for fins distortion, 1. Replace the intercooler.

damage.

2. Check for blockage. 2. Replace the intercooler.

Turbo Charger 1. Inspect turbine wheel for 1. Replace turbo assembly.

damage.

2. Inspect compressor wheel 2. Replace turbo assembly.

blades damage.

3. Inspect turbo lubrication 3. Replace the washer or the

pipe line for damage or gasket, if damage in pipe line,
leakage. replace the assembly.

4. Check for excessive carbon 4. Clean.

deposit on the turbine wheel.

Intake Manifold 1. Check for oil sledge. 1. Clean.

2. Check for O ring joints, 2. Replace the ‘O’ ring &

EGR joints & gaskets for never reuse the gasket.
swelling or damage.

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 295
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.4 Care of the system

3.4.1 Service Tips and Precautions
Observe the following precautions when disassembling and servicing the air intake system
and its elements.
• Always wear hand gloves before starting any servicing.
• Stay clear of rotating vehicle parts.
• Stay clear of hot vehicle parts.
• Avoid repeated contact with fluids.
• Do not let fuel, coolant and other fluids to spill over electrical and hot vehicle parts.
• Before removing and servicing, clean the outer surface of the parts.
• Care must be taken when handling the air intake system components. Components should
not be lifted by using their hoses or pipes.
• Hoses and lines must not be subjected to any twists or stress.
• Ensure that hoses are positioned in their correct position before tightening the couplings,
and ensure that all clips and supports are used.
• Do not place any tool or parts over the intercooler as it will damage the fins which will lead
reduced performance of intercooler.

3.4.2 Do’s & Don’ts For Turbocharger Assembly

Do’s

• Always use recommended grade of engine oil & oil filter and periodic change as per
maintenance schedule.
• Do cleaning or replacement of air filter elements as per maintenance schedule and
always use recommended genuine air filter element.
• Idle the engine for few minutes after starting the engine to ensure oil supply to
turbocharger.
• Idle the engine for few minutes before switching off the engine to reduce operating
temperature.
• Do the periodic cleaning of crankcase breather to allow free flow of oil from
turbocharger outlet.
• Inspect exhaust pipe mountings for damages, leaks & blockages.
• Check fuel injections system for its proper functioning.
• Close all the turbocharger opening with protective plugs when not in use.

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
296 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Don’ts

• Do not run the engine with low oil pressure, as the proper lubrication of
turbocharger bearing will be restricted, further it will lead to bearing damage.
• Do not put the engine under full load immediately after starting, to ensure the oil
supply for lubricating the turbo bearings.
• Do not switch off the engine under full load.
• Do not run the engine with leaky, restricted oil feed and drain pipes.
• Do not run the engine with blocked, punctured, aged deformed hose / pipe
connections to the turbocharger turbine inlet and turbine outlet.
• Do not tamper the fuel injection system.
• Do not tamper the actuator setting. Do not use actuator control for lifting
turbocharger.
• Do not dismantle the turbocharger.

3.4.3 HFM Sensor Cleaning

Possible customer complaints / symptoms
1. Poor pickup.
2. Black smoke.

Root cause:
Wrong indication of the air flow to the ECU from the HFM sensor. This is due to the deposition
of oil & dust particles on sensor element.
Logic:
Under normal driving conditions, if required boost pressure is not generated by the
turbocharger, the smoke limitation map limits the fueling to avoid smoke due to lack of air.
If oil / other soot particles are deposited on the HFM sensor element, the HFM sensor will not
read the actual airflow and may report a lesser value to the ECU, thereby limiting the fuelling.
This brings down the vehicle performance below acceptable limits. In such cases, the HFM
sensor performance can be restored by cleaning the sensor with Petrol thoroughly as per the
procedure given below.

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 297
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Take Petrol in a container such that HFM 6. Blow pressurized air jet ( Pressure
sensor unit can be immersed completely. between 3 to 5 bars) from a distance of 10
cm to 15 cm from one end of the sensor so
as to remove any Petrol content present in
the mesh.
Ensure that the electrical connector is
not immersed in the petrol bath.

7. Clean the electrical connector using

pressurized air to remove any liquid content
2. Allow the HFM sensor unit to immerse in on it.
Petrol for about 5-10 min.

Petrol once used should not be re-used

for cleaning the HFM sensor.

3. Shake the HFM Sensor thoroughly

keeping it inside the Petrol bath, such that
any oil content stuck to the sensor can be
flushed out.

4. Remove the sensor assembly from the

Petrol bath and remove the Petrol completely
from the sensor.

5. Allow the sensor to get dry.

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
298 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.4.4 Air Filter Element — Replace

3.4.4.1 Component Location Index

Tools Required

Size Type Quantity

5 mm Allen key / Allen key socket 1

7 mm Socket spanner 1

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 299
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.4.4.2 Removal

1. Disconnect the HFM sensor electrical 4. Detach and remove grate upstream from
connector. top cover.

2. Using a 7 mm socket spanner loosen the 5. Gently pullout and remove the air filter
clean end hose mounting clamp & element.
disconnect the hose.

3. Using 5 mm allen key, remove air filter

top cover mounting bolts first and then
remove the top cover.

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
300 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.4.4.3 Inspection
1. Inspect the foam for cut, torn or foam layer separation. If found replace.

3.4.4.4 Installation

1. Refit the new air filter element. 4. Refit the clean side hose, fasten the hose
with the mounting clamp torque tighten the
clamp to specified value.

2. Position the grate upstream on top of

filter element.

3. Position and refit the air cleaner housing

top cover, torque tighten the mounting bolts
to specified value.

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 301
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Connect HFM sensor electrical

connector.

• Always use recommended genuine air

filter element.
• Do not tap or hit the new filter element.
• Replace air filter element at 30,000
kms or 18 Months and then at every
30,000 kms or 18 Months (Distance
Covered in km / Months in service
whichever is earlier). Under Extremely
Dusty Conditions Interval to be
reduced at every 10,000 kms.
• Do not clean & reuse the air filter
element.
• For Non– ABS vehicles, 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
the correct LSPV setting height.

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
302 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5 In Car Repairs

3.5.1 Air Cleaner Duct Dirty Side R&R

3.5.1.1 Component Location Index

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 303
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Close the bonnet.
• Open the bonnet. • Check and ensure the proper working of
engine.

Removal Steps:
1. Remove the duct mesh bracket mounting bolt.
2. Remove the duct mesh mounting clamp.
3. Remove duct mesh dirty side.
Tools Required

Size Type Quantity

7 mm Socket Spanner 1

10 mm Socket Spanner 1

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
304 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.1.3 Removal

1. Using a 10 mm socket spanner remove

the air duct mesh bracket mounting bolt.

2. Using a 7 mm socket spanner remove

the air duct mesh dirty side mounting clamp .

3. Remove the air duct mesh assembly.

3.5.1.4 Inspection
• Check for the external damage of air intake mesh. If any damage found replace.

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 305
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.1.5 Installation

1. Refit the air duct mesh dirty side, torque

tighten the mounting clamp to specified
value.

2. Refit the air duct mesh dirty side bracket

mounting bolt, torque tighten the bolt to
specified value.

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
306 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.2 Air Cleaner housing assembly R&R

3.5.2.1 Component Location Index

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 307
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Connect the HFM sensor electrical
• Open the bonnet. connection.
• Check and ensure proper working of
• Disconnect the HFM sensor electrical
engine.
connection.

Removal Steps:
1. Remove the turbo side hose mounting clamp.
2. Disconnect the turbocharger side hose.
3. Remove the dirty side hose clamp.
4. Disconnect the dirty side hose from air cleaner assembly.
5. Remove the air cleaner housing mounting bolts.
6. Remove the air cleaner housing.
Tools Required

Size Type Quantity

13 mm / 10 mm/ 7 mm Socket Spanner 1

- Star screw driver 1

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
308 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.2.3 Removal

1. Using a 7 mm socket spanner loosen the 3. Using a 13 mm socket spanner with an

clean end hose mounting clamp & extension rod remove the air cleaner housing
disconnect the hose. mounting bolts.

2. Using a 7 mm socket spanner loosen the

dirty side inlet hose mounting clamp &
disconnect the hose.

4. Disconnect the HFM sensor electrical

connector.

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 309
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Using 10 mm socket spanner, remove

HFM sensor mounting bolts and then gently
detach and remove the HFM sensor.

Ensure the sensor is stored in a dust free

area.

6. Remove the air cleaner housing

assembly.

3.5.2.4 Inspection
1. Inspect HFM sensor for any physical damage, if found replace.
2. Inspect HFM sensor connector for any damage, if found do appropriate action.
3. Inspect air filter assembly for any damage, crack etc. Replace if found any.

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
310 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.2.5 Installation

1. Refit the HFM sensor on air cleaner 3. Refit the dirty side inlet hose on air
housing, torque tighten the mounting bolts to cleaner housing, torque tighten the mounting
specified value. clamp to specified value.

2. Refit the air cleaner housing mounting 4. Refit the turbo side air cleaner outlet
bolts, torque tighten the bolts to specified hose, torque tighten the mounting clamp to
value. specified value.

5. Reconnect the HFM sensor electrical

connector.

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 311
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.3 Air cleaner Clean hose turbo side R&R

3.5.3.1 Component Location Index

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
312 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Refit Engine NVH top cover.
• Open the bonnet. • Check and ensure proper working of
engine.
• Remove Engine NVH top cover.

Removal Steps:
1. Remove the HFM sensor side mounting clamp.
2. Remove the turbocharger side mounting clamp.
3. Remove the crank case ventilation hose.
4. Remove the air cleaner clean hose turbo side.
Tools Required

Size Type Quantity

- Hose clip plier 1

7 mm / 8 mm / 10 mm Socket spanner 1

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 313
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.3.3 Removal

1. Using a 10 mm deep socket spanner 4. Using 8 mm socket spanner loosen and

remove the NVH cover mounting bolts . remove the turbocharger inlet mounted
clamp.

2. Using a hose clip plier disconnect the

blow by breather hose from turbocharger 5. Remove the hose turbocharger side.
side hose.

3. Using a 7 mm socket spanner loosen

and remove the HFM sensor mounted clamp.

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
314 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.3.4 Inspection
• Check for the external damage. If any damage found please replace.

3.5.3.5 Installation

1. Refit the turbocharger side hose, torque 3. Connect the blow by hose and fasten it
tighten the HFM sensor mounted clamp to with the help of mounting clamp.
specified value.

4. Refit the NVH cover, torque tighten the

2. Refit the turbocharger side hose, torque mounting bolts to specified value.
tighten the turbo inlet mounted clamp to
specified value.

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 315
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.4 Intercooler assembly R&R

3.5.4.1 Component Location Index

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
316 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the engine top NVH cover.
• Remove the engine top NVH cover. • Check and ensure that there is no leakage
from the hose joints.

Removal Steps:
1. Disconnect boost sensor electrical connector.
2. Remove the boost pressure sensor.
3. Remove the intercooler inlet hose.
4. Remove the intercooler outlet hose.
5. Remove the intercooler mounting bolts.
6. Remove the intercooler assembly.
Tools Required

Size Type Quantity

7 mm Socket spanner / T spanner 1

10 mm / 13 mm Socket spanner 1

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 317
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.4.3 Removal

1. Using a 10 mm deep socket spanner 4. Using a 7 mm socket spanner remove

remove the NVH cover mounting bolts . the intercooler outlet hose mounted clamp
and disconnect the hose.

2. Press the lock and disconnect the boost

pressure sensor electrical connector. 5. Using a 7 mm socket spanner remove
the intercooler inlet hose mounted clamps
and disconnect the hose.

3. Using a 10 mm socket spanner remove

the boost pressure sensor mounting bolt and
remove the sensor. 6. Using a 13 mm socket spanner remove
the intercooler assembly mounting bolts and
remove the intercooler assembly.

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
318 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.4.4 Inspection
1. Inspect intercooler assembly for any physical damage, replace if found any.
2. Inspect intercooler hoses for any damage. Replace if found any.
3. Inspect intercooler rubber Isolators for any damage. Replace if found any.

3.5.4.5 Installation

1. Refit the intercooler assembly, torque 3. Refit the intercooler outlet hose mounted
tighten the mounting bolts to specified value. clamp, torque tighten the clamp to specified
value.

2. Refit the intercooler inlet hose mounted

clamp, torque tighten the clamp to specified 4. Refit the boost pressure sensor mounted
value. bolt, torque tighten the bolt to specified value.

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 319
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Connect the boost pressure sensor

electrical connector.

6. Refit the NVH cover, torque tighten the

mounting bolts to specified value.

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
320 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.5 Intercooler Inlet Hose R&R

3.5.5.1 Component Location Index

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 321
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.5.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Engine NVH top cover.
• Remove the engine top NVH cover. • Check and ensure that there is no air
leakage at hose joints.

Removal Steps:
1. Remove the intercooler inlet hose clamp.
2. Remove the hose clamp at turbocharger side.
3. Remove the Intercooler Inlet hose.
Tools Required

Size Type Quantity

7 mm / 10 mm Socket spanner 1

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
322 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.5.3 Removal

1. Using a 10 mm deep socket spanner

remove the NVH cover mounting bolts .

2. Using a 7 mm socket spanner loosen

and remove the intercooler intake hose
clamps .

3. Remove the intercooler intake hose.

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 323
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.5.4 Inspection
1. Inspect hose for any damage, crack or degradation. Replace if found any.

3.5.5.5 Installation

1. Insert the hose on intercooler side first

and then on turbocharger, fasten the hose
using mounting clamps torque tighten the
clamps to specified value.

2. Refit the NVH cover, torque tighten the

mounting bolts to specified value.

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
324 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.6 Intercooler Outlet Hose R&R

3.5.6.1 Component Location Index

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 325
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.6.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Engine NVH top cover assembly.
• Remove Engine NVH top cover assembly. • Check and ensure that there is no air
leakage from the intercooler hose joints.

Removal Steps:
1. Remove the intercooler outlet hose clamp.
2. Remove the Intercooler outlet hose clamp from intake pipe.
3. Remove the intercooler outlet hose.
Tools Required

Size Type Quantity

7 mm / 10 mm Socket spanner 1

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
326 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.6.3 Removal

1. Using a 10 mm deep socket spanner

remove the NVH cover mounting bolts .

2. Using a 7 mm socket spanner loosen

intercooler outlet hose mounted clamps and
disconnect the hose.

3. Remove the intercooler outlet hose.

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 327
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.6.4 Inspection
1. Inspect hose for any damage, crack or degradation. Replace if found any.

3.5.6.5 Installation

1. Insert the intercooler outlet hose on

intercooler side first and then on pipe intake
manifold, torque tighten the mounting clamp
to specified value..

2. Refit the NVH cover, torque tighten the

mounting bolts to specified value.

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
328 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.7 Oil Separator assembly R&R

3.5.7.1 Component Location Index

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 329
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.7.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Engine NVH top cover assembly.
• Remove Engine NVH top cover assembly. • Check and ensure proper working of
engine.

Removal Steps:
1. Remove the oil separator mounting bolts.
2. Oil separator assembly.
Tools Required

Size Type Quantity

7 mm Combination spanner 1

10 mm Deep socket spanner 1

13 mm Socket spanner 1

- Hose clip plier 1

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
330 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.7.3 Removal

1. Remove the Intercooler assembly. For

additional information refer to intercooler
R&R section.

2. Remove the breather hose from oil

separator.

3. Remove the oil separator assembly

using 10 mm socket spanner.

3.5.7.4 Inspection
• Inspect the oil separator for any external damage, if found replace

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 331
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.7.5 Installation

1. Position and refit the oil separator

assembly, torque tighten the mounting bolts
as per the sequence shown and to the
specified value.

2. Connect the oil separator breather hose,

fasten the hose using the mounting clamps.

3. Refit the Intercooler assembly. For

additional information refer to intercooler
R&R section.

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
332 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.8 Oil Separator Breather Hose R&R

3.5.8.1 Component Location Index

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 333
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.8.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Engine NVH top cover assembly.
• Remove Engine NVH top cover assembly. • Check and ensure proper working of
engine.

Removal Steps:
1. Remove the breather hose clamp from hose turbocharger side.
2. Remove the breather hose clamp from oil separator assembly.
3. Remove the breather hose.
Tools Required

Size Type Quantity

- Hose clip plier 1

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
334 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.8.3 Removal

1. Using a 10 mm deep socket spanner

remove the NVH cover mounting bolts .

2. Remove the clamps using a hose clip

plier & remove the breather hose.

3.5.8.4 Inspection
1. Check for any external damage, if found replace.
2. Check for oil seepage, if found check the oil separator and replace.

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 335
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.8.5 Installation

1. Connect the breather hose fasten the

hose using the mounting clamps.

2. Refit the NVH cover, torque tighten the

mounting bolts to specified value.

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
336 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.9 NVH Engine Top Cover R&R

3.5.9.1 Component Location Index

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 337
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.9.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Close the bonnet.
• Open the bonnet.

Removal Steps:
1. Remove the NVH cover mounting bolts.
2. Remove the NVH cover.
Tools Required

Size Type Quantity

10 mm Deep socket spanner 1

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
338 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.9.3 Removal

1. Open the bonnet.

2. Using a 10 mm deep socket spanner

remove the NVH cover mounting bolts .

3.5.9.4 Inspection
1. Inspect for any external damage, if found replace.

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 339
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.9.5 Installation

1. Refit the NVH cover, torque tighten the

mounting bolts to specified value.

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
340 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.10 Turbo Charger Assembly R&R

3.5.10.1 Component Location Index

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 341
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.10.2 Removal and Installation Summary

Pre Removal Post Installation

• Open the bonnet. • Refit Engine NVH top cover assembly.
• Remove the NVH cover. • Check and ensure proper working of
engine.

Removal Steps:
1. Remove the intercooler inlet hose mounting clamp.
2. Remove the turbocharger oil line banjo bolt.
3. Remove the cat - con flange mounting nut and bolts.
4. Remove the turbocharger bracket mounting bolts.
5. Remove the turbocharger oil drain hose mounting clamp.
6. Remove the turbocharger flange top mounting bolt.
7. Remove the turbocharger flange bottom mounting nuts
Tools Required

Size Type Quantity

10 mm / 14 mm Socket spanner 1

13 mm Combination spanner 1

- Hose clip plier 1

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
342 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.10.3 Removal

1. Using 8 mm socket spanner loosen the 3. Using a 12 mm combination spanner

mounted clamp and disconnect the remove the pre - cat con assembly flange
turbocharger intake hose. mounting bolts 2 nos further using 13 mm
combination spanner remove the remaining
flange mounting nut and disconnect the pre -
cat con assembly.

2. Using a 7 mm combination spanner

loosen the mounted clamp and disconnect
the intercooler intake hose .
4. Using a 13 mm combination spanner
remove the pre - cat con assembly bottom
flange mounting bolts and remove the pre -
cat con assembly.

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 343
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Using a hose clip plier loosen the oil 8. Using a 13 mm combination spanner
drain hose mounting clamp and disconnect remove the turbocharger top mounted bolt.
the hose.

9. Using 13 mm combination spanner

6. Using 14 mm deep socket spanner remove the turbo mounted bottom flange
remove the inlet oil pipe line mounting banjo nuts.
bolt.

10. Using a 12 mm socket spanner remove

7. Using 12 mm socket spanner remove the the bracket mounting bolt and remove the
turbocharger bracket mounting bolts. bracket.

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
344 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Using a 10 mm deep socket spanner

remove the oil return line mounting bolts.

12. Remove the turbo charger assembly.

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 345
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.10.4 Inspection

1. Inspect the Compressor/Turbine wheel 2. Inspect the Compressor/Turbine wheel

for damage. for rubbing.

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
346 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Inspect the Rotor for free rotation. 4. Inspect the rotor play by pressing the
shaft outward & rotate, It should be rotate
freely.

3.5.10.5 Installation

1. Refit the oil return line mounting bolts, 2. Refit the bracket mounting bolt, torque
torque tighten the bolts to specified value. tighten the bolts to specified value.

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 347
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Refit the turbocharger flange bottom 6. Refit the turbocharger oil inlet line, torque
mounting nuts, torque tighten the nuts to tighten the banjo mounting bolt to specified
specified value. value.

4. Refit the turbocharger flange top 7. Connect the oil drain hose, fasten the
mounting bolt, torque tighten the bolt to hose using mounting clamp.
specified value.

8. Refit the pre - cat con bottom flange

5. Refit the turbocharger bracket mounting mounted bolts, torque tighten to specified
bolts, torque tighten the bolts to specified value.
value.

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
348 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Refit the pre - cat con flange mounted

bolts and nut on turbo, torque tighten to
specified value.

10. Refit the intercooler inlet hose, torque

tighten the mounting clamp to specified
value.

11. Refit the turbocharger inlet hose, torque

tighten the mounting clamp to specified
value.

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 349
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.11 Boost Pressure Sensor R&R

3.5.11.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the engine top NVH cover.
• Remove the engine top NVH cover. • Erase if any DTC’s registered using i-
SMART diagnostic tester.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

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
350 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.11.2 Removal:

1. Using a 10 mm deep socket spanner

remove the NVH cover mounting bolts.

2. Press the lock and disconnect the boost

pressure sensor electrical connector.

3. Using a 10 mm socket spanner remove

the boost pressure sensor mounting bolt and
remove the sensor.

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 351
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.11.3 Inspection:
1. Inspect the sensor for any damage. Replace if found.
2. Inspect the connector for any damage.
3. Inspect the connector for proper fitment.

3.5.11.4 Installation:

1. Refit the boost pressure sensor mounted 3. Refit the NVH cover, torque tighten the
bolt, torque tighten the bolt to specified value. mounting bolts to specified value.

2. Connect the boost pressure sensor 4. Check and erase if any DTC’s registered
electrical connector. using i-SMART diagnostic tester.

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
352 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.12 HFM Sensor R&R

3.5.12.1 Component Location Index

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 353
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.12.2 Removal and Installation Summary

Pre Removal Post Installation

• Open the bonnet. • Connect the battery terminal.
• Disconnect the battery negative terminal. • Erase if any DTC’s registered using i-
SMART diagnostic tester.
• Close the bonnet.

Removal Steps:
1. Remove the clean side hose mounting clamp.
2. Disconnect the clean side hose.
3. Remove the HFM sensor mounting bolts.
4. Remove the HFM sensor.
Tools Required

Size Type Quantity

10 mm Socket spanner 1

- Star screw driver 1

- Flat screw driver 1

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
354 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.12.3 Removal

1. Disconnect the negative terminal from 4. Using a 10 mm socket spanner remove

the battery. the HFM sensor mounting bolts & gently take
out the sensor.

2. Press the lock disconnect the HFM

sensor electrical connector.

3. Using a 7 mm socket spanner or a star

screw driver loosen the mounted clamp &
disconnect the clean side hose.

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 355
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.5.12.4 Inspection
1. Check for any external damage, if found replace.

3.5.12.5 Installation

1. Position and refit the HFM sensor, torque 3. Connect the HFM sensor electrical
tighten the mounting bolts to specified value. connector.

2. Refit the turbocharger side hose 4. Connect the negative terminal on battery.
mounted clamp, torque tighten the clamp to
specified value.

5. Check and erase if any DTC’s registered

using i-SMART diagnostic tester.

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
356 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.6 Technical Specification

3.6.1 Specification

Description Specification

Air Filter

Air Filter Type Paper+Foam

Air Filter Volume 11 L Approximately

Service Interval Replace air filter element at 30,000

kms or 18 Months whichever is earlier
and then at every service. Under
extreme operating conditions replace
air filter at every 10,000 kms.

HFM Sensor

Rate of air flow 540 kg/hr

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 357
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3.7 Torque Specification

3.7.1 Tightening Specification

Fastners Specification Torque in Nm

INTAKE MANIFOLD SCREW 25±3

INTAKE AIR THROTTLE MOUNTING SCREW 11±1

PIPE CYL. HEAD WATER OUTLET MOUNTING 17.5±2.5

ALLEN SCREW

WATER TEMPERATURE SENSOR 22.5±2.5

BOOST PRESSURE SENSOR MOUNTING 11±1

SCREW

GUIDE DIPSTICK OIL LEVEL MOUNTING BOLTS 25±3

GUIDE DIPSTICK OIL LEVEL MOUNTING NUTS 25±3

INTAKE MANIFOLD BOLTS 25 ± 3

STUD TURBOCHARGER 25±3

CLINTCH NUT FOR TURBOCHARGER 25±3

BOLT TURBOCHARGER 25±3

ELBOW T/C COMPRESSOR 11±1

ASSYL. OIL RETURN T/C 11±1

BANJO BOLT TURBO INLET 17.5±3

TURBO SUPPORT BRKT TO CRANKCASE 25±3

INTERCOOLER HOSE MOUNTING 5±1

AIR CLEANER MTG. 25 ± 5

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
358 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4 EXHAUST & EMISSION CONTROL SYSTEM

4.1 Description & Operation

4.1.1 Exhaust System

The normal operating temperature of the exhaust system is very high. therefore, never
work around or attempt to service any part of the exhaust system until it is cooled.
special care should be taken when working near the catalytic converter. The
temperature of the converter rises to a high level after a short period of engine
operation time.
The basic exhaust system consists:
1. Exhaust manifold.
2. Pre Catalytic converter.
3. Post Catalytic converter.
4. Muffler with tail pipe.
5. Exhaust Pipes.
6. Turbo charger.
7. EGR Cooler.
8. EGR valve.
9. Vacuum modulator.

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 359
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10. Hanger insulators.

The catalytic converter is provided to reduce the exhaust emission, whereas the muffler is
provided to dampen the sound of the exhaust gases coming out of the engine.
The exhaust system consists of a closed coupled catalytic converter and muffler connected by
exhaust pipes. The exhaust pipes are supported using rubber hangers.

4.1.2 Major pollutants in diesel engine:

4.1.2.1 CO [Carbon Monoxide]:

Colorless, odorless, Poisonous -Hemoglobin of blood has more affinity for CO than Oxygen,
leading to slow poising and death ,if exposed for very long times.

4.1.2.2 HC [Hydrocarbons] :
Partially burned or Unburned components of the fuel. Combines with NOx , in the presence of
sunlight to form photochemical smog.

4.1.2.3 NOx [Oxides of Nitrogen] :

Brownish gas, poisonous -Once inhaled by humans mixes with moisture in the lungs and
forms Dilute Nitric acid which corrodes lung cells.

4.1.2.4 Particulates:
Components of Sulfur and unburned carbon. Sulfur is used in diesel to improve lubricity.

4.1.2.5 CO2 [Carbon DI Oxide] :

Not considered as a pollutant as of now. However, it is termed as a Green house gas leading
to the phenomena of Global warming.

4.1.3 Emission Control System

During acceleration and in higher loads the engine generates high combustion temperatures.
The high combustion temperatures increases the NOx generation. The higher percentage of
NOx generated in the combustion chamber comes out through the tail pipe in the atmosphere
thereby increasing air pollution.
To reduce the amount of NOx coming through the tail pipe, the EGR (Exhaust gas re-
circulation) system are being used. EGR recirculates a part of the engine’s exhaust back into
the engine at a lower temperature. The cooled gases have a higher heat capacity and contain
less oxygen than air, lowering combustion temperatures, thus reducing the formation of NOx.
To control the amount/percentage of exhaust gases to be circulated back to the combustion
chamber, engine ECU is used.
The ECU monitors the air flow, coolant temperature, engine speed, and accelerator pedal
position. Based on the above parameters the EMS ECU operates EGR modulator that in turn

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
360 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

controls the amount of vacuum going to the EGR valve. The amount of vacuum applied
controls the lift of the EGR valve.
During cold starts, till the glow plug remains "ON", the EGR system does not function thus
avoiding any hunting or vibration during initial start conditions.

4.1.4 EGR System Layout

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 361
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.5 EGR System Layout — Euro II

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
362 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.6 Crankcase ventilation

A. Crankcase Ventilation Outlet.

B. Breather Assembly.

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 363
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

The crank case ventilation is not let out to atmosphere. The crankcases blow by gas goes to
through a integrated oil separator which separates the oil from the blow by gas and allows the
air to pass to the intake manifold; the separated oil particles/ droplets drain back into the
engine. Blow by gases are drawn from crankcase and cylinder head cover.
Certain amount of oil will be carried from the oil separator to the Air inlet hose, which is normal.
However if it is excessive please look for all the causes mentioned in the high blow-by.

4.1.7 Exhaust Manifold

The exhaust manifold is attached to the

cylinder head which combines the exhaust
gas flow from each cylinder into one
direction.

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
364 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.8 Catalytic Converter (Pre & Post)

The pre & post catalytic converter is mounted

between the turbo charger and the muffler. It
converts harmful carbon monoxide and
hydrocarbons into water vapour and carbon
dioxide. It also reduces harmful nitrogen
oxides.

4.1.9 Muffler

The main function of the muffler is to reduce

the amount of noise emitted by the engine
exhaust gases flow. It typically makes use of
the change in the cross sectional area which
can be made as a chamber to filter or reduce
the sound waves which the engine produces.
The muffler is typically installed along the
exhaust pipe as part of the exhaust system of
the engine. It has a resonating chamber,
which is specifically designed such that
opposite sound waves collide to cancel each
other out.

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 365
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.10 EGR Valve

The EGR valve is a vacuum controlled valve

which recirculates a specific amount of
exhaust gas back into the intake manifold, to
prevent the formation of nitrogen gases.
The EGR valve is a diaphragm valve that is
actuated by vacuum from the vacuum pump
through Pressure modulator. The valve is
fitted to exhaust manifold. It has three
connections, one for the vacuum, and one for
the exhaust gas inlet from the exhaust
manifold and one for the exhaust gas outlet
to the inlet manifold. The valve opens to
allow the Exhaust gas to re-circulate to the
intake manifold.

4.1.11 EGR Cooler

The EGR cooler is an air-to-liquid heat

exchanger which reduces the temperature of
the exhaust gases before circulating to the
combustion chamber. The EGR cooler has
metal tubes that are surrounded by coolant
for cooling the exhaust gases passing
through the metal tubes.

4.1.12 Vacuum Modulator

EGR & VGT modulator is an electro

pneumatic solenoid switch, which is
controlled more precisely by the EMS ECU
based on the Engine speed, Coolant
Temperature and Accelerator pedal position
etc.

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
366 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.13 Turbocharger Oil Outlet (Drain) Pipe

Turbocharger oil drain pipe collects the oil

from turbine housings to oil sump.

4.1.14 Turbocharger Oil inlet Pipe

Turbocharger oil inlet pipe takes oil from

main oil gallery to turbine housing for turbine
shaft lubrication.

4.1.15 EGR Pipe

The EGR pipe is connected between EGR

cooler to Intake Manifold pipe. Through this
pipe the desired quantity of the inert exhaust
gas is mixed with intake air.

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 367
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.1.16 EGR Pipe — Euro II

The EGR pipe is connected between EGR

valve to Intake Manifold pipe. Through this
pipe the desired quantity of the inert exhaust
gas is mixed with intake air.

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
368 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.2 Component Index

4.2.1 Exhaust System View

A. Tail Pipe G. EGR pipe (Head outlet to EGR

cooler)

B. Muffler assembly H. Pre- Catalytic converter

C. Post-Catalytic converter I. EGR valve

D. Flexible bellow J. Exhaust manifold assembly

E. EGR pipe (EGR cooler to Intake manifold) K. Turbocharger assembly

F. EGR Cooler

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 369
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.2.2 Emission Control System View

A. Vacuum Pump F. EGR Modulator

B. EGR Cooler G. Vacuum Hose Assembly.

C. EGR valve H. EGR pipe (EGR Cooler to Intake

Manifold)

D. Vacuum Hose Kit I. EGR pipe (Exhaust manifold to EGR

Valve )

E. VGT Modulator

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
370 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.3 Trouble Shooting

4.3.1 Symptom Possible Causes

Symptom Possible Causes Remedy

Engine is 1. Inter cooler Inlet / Outlet ● Check the hose condition and
underpowered hose is damaged. replace it if necessary.

2. Turbocharger or vacuum ● Replace the Turbocharger or

modulator is damaged. vacuum modulator if required.

Blue smoke 1. Air restriction between ● Locate the restriction and rectify.
the air filter outlet to
turbocharger inlet.

2. Turbocharger oil return ● Locate the blockage or damage in

tube is blocked or the oil return tube, and replace the
damaged. tube if necessary.

Excess oil 1. Restrictions in the ● Remove the restriction from the drain
consumption turbocharger oil drain pipe. pipe.

2. Turbocharger is ● Replace the Turbocharger.

damaged.

3. Air leakage in the intake ● Locate the leaks, change the hose,
system. gasket or clamp if necessary.

4. Usage of not ● Change the oil and filter and use

recommended oil. recommended oil and filter only.

Noisy exhaust and 1. Leaks at pipe joints. ● Tighten the nuts to specific torque.
leaking exhaust
gases 2. Rusted or blown out ● Replace the muffler.
muffler.

3. Broken or rusted exhaust ● Replace the exhaust pipe.

pipe.

4. The exhaust pipe leaking ● Tighten/replace the flange mounting

at the manifold flange. nuts.

5. Leakage between the ● Replace the gasket. Tighten the nuts

exhaust manifold and between the exhaust manifold and
cylinder head. cylinder head.

6. The silencer mounting ● Replace the isolators.

isolators are damaged.

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 371
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

Engine growling 1. EGR pipe Leakages. ● Replace the gasket. Tighten the
noise mounting bolts to specified torque.

Engine power loss 1. Gas leakage between ● Change the gasket or the Pipe.
EGR pipe joints.

2. Improper functioning of ● Check and replace the EGR valve.

the EGR valve.

3. Vacuum hose crack, ● Ensure proper connection of vacuum

loose, fallen off. hose at the vacuum modulator & EGR
Valve. Check for cracks and replace
the vacuum hoses if necessary.

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
372 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.3.2 Component Inspection and Action Table

Symptom Possible Causes Remedy

Turbocharger 1. Check for physical ● Replace the turbocharger.

damage.

2. Check for carbon ● Clean and check operation

deposition and dirt on vehicle.
accumulation in all the
openings.

3. Check the pneumatic ● Replace the turbocharger.

linkages for damages and/or
bend.

4. Check all vacuum lines for ● Replace the lines if

blockage, deterioration, required.
damages.

5. Check the impeller and ● Replace the turbocharger.

turbine blades for damages.

Vacuum Modulator 1. Check for physical ● Replace the modulator.

damage.

2. Check for operation. ● Perform the vacuum test

and replace if required.

Exhaust Intermediate Pipe 1. Check for physical ● Replace the Exhaust

and muffler damage. intermediate pipe and
muffler.

EGR Valve 1. Check for physical ● Replace the EGR Valve.

damage.

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 373
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.4 Care of the System

4.4.1 Service Tips & Precautions

To avoid the injuries due to extreme heat, do not touch exhaust system when the
system is hot. Any service on the exhaust system should be performed when the
system is cool.
At every interval of periodic maintenance service and when vehicle is raised for other
service, check exhaust system as follows:
• Check rubber mountings for damage, deterioration or out of position.
• Keep sufficient clearance between exhaust system component and underbody.
• Check exhausts system for leakage, loose connection, dent & damage. If bolts or
nuts are loosened, tighten them to the specified torque.
• Check nearby body areas for damage, missing or mis-positioned part, open seam,
hole, loose connection or any other defect which could permit exhaust fumes to
seep into vehicle.
Precautions for Catalytic Converter
• In the event of following symptoms, drive the vehicle at slow speed without rapid
acceleration.
• Engine misfires or runs irregularly, following a cold start.
• A significant loss of power is noticed.

Parking Warning: Avoid parking of vehicle over inflammable materials, such as dry
leaves; grass etc. as exhaust system is hot enough to initiate fire.

• Ensure exhaust system and catalytic converter is not blocked and is free from
obstruction.
• Blockages in the exhaust can create back pressure, low top speed, poor pick up,
black smoke, carbon build up and low mileage.
• Check and ensure EGR Valve & control system is clean and functioning properly.

The Catalytic converter should not be dropped from a height. If dropped, Please
replace.

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
374 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.5 Exhaust pipe mountings and damage/leakage - Inspect

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 375
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Position the vehicle on a 2 post / 4 post 4. Check the Exhaust lower & upper pipe
lift. insulators for elongation, replace if found
elongated. Also check the flange joint
2. Check the insulators of the tail pipe and between lower pipe and post catlytic
muffler, replace if found elongated or convertor for any leakage, if found replace
damaged. the gasket and toque tighten the bolts to
specified value.

5. Check the joint between Exhaust upper

pipe and pre & post catalytic convertor for
leakage, if found leakage then replace the
gasket and torque tighten the nuts to
specified value.

3. Check the Muffler front insulator for

elongation, replace if found elongated. Also
check the U Clamp joint between muffler and
exhaust lower pipe for any leakage, if found
replace the U clamp and toque tighten the
nuts to specified value.

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
376 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Check the joint between Turbocharger

and catalytic convertor for leakage, if found
leakage then replace the gasket and torque
tighten the nut and bolts to specified value.

• Do not work when the exhaust system is hot. Failure to follow this instruction will
result in personal injury.
• Check all the exhaust joints for leakage and correct fittings. If leakage is found,
check the exhaust pipe gasket. Replace if required.
• It is recommended to inspect exhaust pipe mountings for damages & leaks first at
,5000 kms or 3 Months and then every regular service.
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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 377
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6 In Car Repairs

4.6.1 Exhaust Manifold R&R

4.6.1.1 Component Location Index

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
378 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift and • Refit the Turbocharger assembly
open the bonnet. • Check and ensure the correct fitment and
• Remove the Turbocharger assembly further check for any leakage.

Removal Steps:
1. Remove the EGR valve bottom flange mounting bolts.
2. Remove the exhaust manifold mounting nuts.
3. Remove the exhaust manifold metal gaskets.
4. Remove the EGR valve short pipe mounting nuts.
5. Remove the EGR valve short pipe.
6. Remove the exhaust manifold.

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 379
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

13 mm Socket spanner 1

6 mm Allen key 1

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
380 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.1.1 Removal

1. Remove the Turbocharger assembly. For 4. Using 13 mm socket spanner remove the
additional information refer to the EGR valve short pipe mounting nuts.
Turbocharger assembly R&R section.

2. Using a 12 mm socket spanner remove

the EGR valve short pipe bottom flange
mounting bolts.

5. Remove the exhaust manifold.

3. Using 13 mm socket spanner remove the

exhaust manifold mounting nuts and also
remove the metal gaskets..

4.6.1.1.2 Inspection
• Check for any external cracks, if found replace the exhaust manifold.

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 381
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.1.1.3 Installation

1. Refit the EGR valve short pipe on the 4. Refit the Turbocharger assembly. For
exhaust manifold, torque tighten the additional information refer to the
mounting nuts to specified value. Turbocharger assembly R&R section.

2. Refit the metal gasket and further refit

the exhaust manifold, torque tighten the
mounting nuts to specified value.

3. Refit the EGR valve short pipe bottom

flange mounting bolts, torque tighten the
bolts to specified value.

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
382 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.2 Pre Catalytic Converter R&R

4.6.2.1 Component Location Index

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 383
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Check and ensure the proper fitment of
pre catalytic converter further check for
any leakage.

Removal Steps:
1. Remove the pre catalytic converter mounting bolts on turbocharger.
2. Remove the pre catalytic converter top mounting nut on turbocharger.
3. Remove the pre catalytic converter flange mounting bolts from exhaust upper pipe.
4. Remove the pre catalytic converter.
Tools Required

Size Type Quantity

13 mm Ring spanner 1

13 mm Socket spanner 1

- Flat screw driver 1

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
384 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.2.3 Removal

1. Using a 13 mm socket spanner remove

the pre catalytic converter flange mounting
bolts from the exhaust upper pipe.

2. Using a 13 mm socket spanner remove

the pre catalytic converter mounting bolts
and nut on the turbo charger.

3. Remove the pre catalytic converter.

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 385
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.2.4 Inspection
• Check for any external damage, if found please replace.
• Check for the obstruction of the air flow, if found please replace.

4.6.2.5 Installation

1. Refit the metal gasket and pre catalytic

converter on turbocharger outlet, torque
tighten the mounting bolts and nut to
specified value.

2. Refit the metal gasket and pre catalytic

converter, torque tighten the flange mounting
bolts to specified value.

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
386 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.3 Post Catalytic Converter R&R

4.6.3.1 Component Location Index

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 387
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Check and ensure the proper fitment of
post catalytic converter further check for
any leakage.

Removal Steps:
1. Remove the post catalytic converter mountings from exhaust upper pipe flange.
2. Remove the post catalytic converter mountings on exhaust lower pipe flange.
3. Remove the insulators.
4. Remove the post catalytic converter.
Tools Required

Size Type Quantity

13 mm Ring spanner 1

13 mm Socket spanner 1

- Flat screw driver 1

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
388 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.3.3 Removal

1. Using a 13 mm socket spanner remove

the post catalytic converter mounting bolts
from exhaust upper pipe flange.

2. Using a 13 mm socket spanner remove

the post catalytic converter mounting bolts
from exhaust lower pipe flange.

3. Remove the post catalytic converter.

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 389
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.3.4 Inspection
• Check for any external damage, if found please replace.
• Check for the obstruction of the air flow, if found please replace.

4.6.3.5 Installation

1. Refit the metal gasket and exhaust lower

pipe on post catalytic converter, torque
tighten the flange mounting bolts to specified
value.

2. Refit the metal gasket and exhaust upper

pipe on post catalytic converter, torque
tighten the flange mounting bolts to specified
value.

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
390 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.4 Exhaust Upper Pipe R&R

4.6.4.1 Component Location Index

4.6.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Check for leaks.

Tools Required

Size Type Quantity

13 mm Socket spanner 1

13 mm Combination spanner 1

12 mm Socket spanner 1

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 391
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.4.3 Removal

1. Using a 13 mm socket spanner remove 4. Detach the rubber insulator.

the exhaust upper pipe flange mounting bolts
from the catalytic converter.

5. Remove the exhaust upper pipe

assembly and then the gasket.
2. Using a 13 mm socket spanner remove
the exhaust upper pipe flange mounting bolts
from post catalytic converter

3. Using 12 mm socket spanner loosen and

remove upper pipe bracket mounting bolt on
transmission.

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
392 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.4.4 Inspection
1. Inspect the exhaust upper pipe assembly for any damage, crack or bend. Replace if
found.

4.6.4.5 Installation

1. Insert the new gasket. 5. Insert the upper pipe bracket mounting
bolt, torque tighten the bolt to specified value.

Never use old gasket.

2. Position the exhaust upper pipe.

3. Refit the metal gasket and exhaust upper

pipe on catalytic converter, torque tighten the
flange mounting bolts to specified value.

6. Refit the rubber insulator.

4. Refit the metal gasket and exhaust upper

pipe on post catalytic converter, torque
tighten the flange mounting bolts to specified
value.

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 393
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.5 Exhaust Lower Pipe R&R

4.6.5.1 Component Location Index

4.6.5.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Check and ensure the proper fitment
further check for any leakage.

Tools Required

Size Type Quantity

- Flat screw driver 1

13 mm Combination spanner 1

13 mm Socket spanner 1

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
394 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.5.3 Removal

1. Using a 13 mm socket spanner remove

the exhaust lower pipe flange mounting bolts
from the post catalytic converter.

2. Using 13 mm socket spanner remove the

muffler mounted ‘U’ clamp mounting nuts.

3. Detach the rubber insulator.

4. Remove the exhaust lower pipe

assembly and then the gasket.

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 395
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.5.4 Inspection
1. Inspect the Exhaust lower pipe assembly for any damage, crack or bend. Replace if
found.

4.6.5.5 Installation

1. Insert the new gasket. 5. Refit the rubber insulator.

Never use old gasket.

2. Position the exhaust lower pipe.

3. Refit the metal gasket and exhaust lower

pipe on post catalytic converter, torque
tighten the flange mounting bolts to specified
value.

4. Refit the muffler mounted ‘U’ clamp

mounting nuts, torque tighten the flange
mounting nuts to specified value.

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
396 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.6 Muffler Assembly R&R

4.6.6.1 Component Location Index

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 397
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.6.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Check and ensure the proper fitment
further check for any leakage.

Removal Steps:
1. Remove the muffler mounted ‘U’ clamp nuts.
2. Remove the tail pipe rubber hanger.
3. Remove the rear mounted muffler rubber hanger.
4. Remove the front mounted muffler rubber hanger.
5. Remove the muffler assembly (with tail pipe).
Tools Required

Size Type Quantity

- Flat screw driver 1

13 mm Socket spanner 1

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
398 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.6.3 Removal

1. Using 13 mm socket spanner remove the 4. Detach the front end mounted rubber
muffler mounted ‘U’ clamp mounting nuts . hanger from muffler.

2. Detach the tail pipe rubber hanger. 5. Remove the muffler assembly with Tail
pipe.

3. Detach the muffler mounted rubber

hangers from rear end.

4.6.6.4 Inspection
• Check for any external damage, if found please replace.

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 399
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.6.5 Installation

1. Position the muffler assembly. 5. Refit the muffler mounted ‘U’ clamp
mounting nuts, torque tighten the flange
2. Refit the front end mounted rubber mounting nuts to specified value.
hanger on muffler assembly.

3. Refit the rubber hangers on rear end of

the muffler assembly.

4. Refit the tail pipe mounted rubber

hanger.

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
400 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.7 EGR Valve R&R

4.6.7.1 Component Location Index

4.6.7.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Engine NVH top cover.
• Remove Engine NVH top cover. • Check and ensure the proper fitment of
EGR valve further check for any leakage.

Tools Required

Size Type Quantity

6 mm Allen key 1

10 mm Deep socket spanner 1

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 401
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.7.3 Removal

1. Using a 10 mm deep socket remove the

NVH mounting bolt & take out the cover.

2. Gently pullout and remove the Vacuum

inlet hose.

3. Using a 6 mm allen key and 10 mm

socket spanner loosen and remove the EGR
valve flange mounting bolts.

4. Remove the EGR valve.

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
402 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.7.4 Inspection
• Check for any external damage, if found please replace.

4.6.7.5 Installation

1. Position the EGR valve. 4. Refit the NVH cover.

2. Refit the EGR valve mountings, torque

tighten them to specified value.

3. Connect the vacuum inlet hose.

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 403
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.8 EGR Cooler R&R

4.6.8.1 Component Location Index

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
404 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.8.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the cooler inlet and outlet hose.
• Remove the NVH cover • Top up the coolant.
• Remove cooler inlet and outlet hose. • Refit the NVH cover
• Check and ensure for the proper fitment
further check for any leakage.

Removal Steps:
1. Remove the EGR valve mounted bolts.
2. Remove the EGR long pipe mounted bolts.
3. Remove the EGR cooler bracket mounting bolts.
4. Remove the EGR cooler assembly.

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 405
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

— Hose clip plier 1

10 mm Deep socket 1

6 mm Allen key 1

12 mm Ring Spanner 1

12 mm Socket spanner 1

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
406 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.8.3 Removal

1. Using a 10 mm deep socket remove the 4. Using a hose clip plier remove the EGR
NVH mounting bolt & take out the cover. cooler outlet hose .

2. Using 7 mm socket spanner remove the 5. Using a hose clip plier remove the EGR
intercooler inlet hose . cooler inlet hose.

3. Using 6 mm allen key remove the EGR 6. Using 6 mm allen key remove the EGR
valve mounted allen bolts . long pipe mounted bolts .

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 407
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using 12 mm socket spanner remove the

EGR cooler bracket mounting bolt .

8. Remove the EGR cooler assembly.

4.6.8.4 Inspection
• Inspect the pipe for any physical damage. Replace if found.
• Inspect for any leakages. Replace if found.

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
408 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.8.5 Installation

1. Align the EGR cooler assembly. 4. Connect the EGR cooler inlet hose,
fasten the hose using mounting clamp.

2. Refit the EGR cooler assembly bracket

mounting bolt, torque tighten the bolt to 5. Connect the EGR cooler outlet hose,
specified value. fasten the hose using mounting clamp.

3. Refit the EGR long pipe mounted bolts, 6. Refit the EGR valve mounted allen bolts,
torque tighten the bolts to specified value. torque tighten the bolts to specified value.

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 409
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit the intercooler inlet hose, torque

tighten the mounting clamp to specified
value.

8. Refit the NVH cover.

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
410 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.9 EGR Cooler Long Pipe (Cooler to Intake Manifold) R&R

4.6.9.1 Component Location Index

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 411
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.9.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Refit the intercooler assembly.
• Remove the intercooler assembly. • Check and ensure the proper fitment and
any leakages in the EGR long pipe.

Removal Steps:
1. Remove the EGR long pipe flange mounted bolts and nuts on EGR cooler.
2. Remove the air intake pipe mounted ‘V’ clamp.
3. Remove the EGR long pipe bracket mounting bolts.
4. Remove the EGR long pipe.

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
412 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

12 mm Combination spanner 1

12 mm Socket spanner 1

6 mm Allen key 1

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 413
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.9.3 Removal

1. Remove the intercooler assembly. For 4. Using 12 mm combination spanner

additional information refer to intercooler remove the EGR cooler long pipe bracket
R&R section. mounting bolt.

2. Using 6 mm allen key remove the EGR

cooler mounted allen bolts .

3. Using 12 mm ring spanner remove the

air intake pipe mounted ‘V’ clamp .

4.6.9.4 Inspection
1. Check for any external damage, if found please replace.

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
414 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.9.5 Installation

1. Refit the EGR cooler long pipe bracket 4. Refit the intercooler assembly. For
mounting bolt, torque tighten the bolt to additional information refer to intercooler
specified value. R&R section.

2. Refit the air intake pipe mounted ‘V’

clamp, torque tighten the clamp to specified
value.

3. Refit the EGR cooler mounted bolts,

torque tighten the bolts to specified value.

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 415
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.10 EGR Long Pipe (EGR Valve to Intake Manifold) R&R — Euro II

4.6.10.1 Component Location Index

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
416 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.10.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Refit the intercooler assembly.
• Remove the intercooler assembly. • Check and ensure the proper fitment and
any leakages in the EGR long pipe.

Removal Steps:
1. Remove the EGR long pipe flange mounted bolts and nuts on EGR valve.
2. Remove the air intake pipe mounted ‘V’ clamp.
3. Remove the EGR long pipe bracket mounting bolts.
4. Remove the EGR long pipe.

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 417
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

12 mm Combination spanner 1

12 mm Socket spanner 1

6 mm Allen key 1

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
418 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.10.3 Removal

1. Remove the intercooler assembly. For 4. Using 12 mm combination spanner

additional information refer to intercooler remove the EGR long pipe bracket mounting
R&R section. bolts.

2. Using 12 mm socket spanner remove the

EGR long pipe mounted bolts on EGR valve.

3. Using 12 mm ring spanner remove the

air intake pipe mounted ‘V’ clamp .

4.6.10.4 Inspection
1. Check for any external damage, if found please replace.

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 419
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.10.5 Installation

1. Refit the EGR long pipe bracket 3. Refit the EGR long pipe mounting bolts,
mounting bolts, torque tighten the bolt to torque tighten the bolts to specified value.
specified value.

4. Refit the intercooler assembly. For

additional information refer to intercooler
R&R section.

2. Refit the air intake pipe mounted ‘V’

clamp, torque tighten the clamp to specified
value.

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
420 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.11 Cylinder Head Outlet to EGR Cooler Pipe R&R

4.6.11.1 Component Location Index

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 421
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.11.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2/4 post lift. • Top up coolant.
• Check for proper fitment and ensure for
any leakage.

Removal Steps:
1. Remove the EGR cooler inlet hose mounted clamp.
2. Remove the cylinder head mounted flange mounting bolt.
3. Remove the EGR short pipe bracket mounting bolt.
4. Remove the EGR short pipe assembly.
Tools Required

Size Type Quantity

- Hose clamp plier 1

10 mm Deep socket spanner 1

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
422 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Size Type Quantity

13 mm Socket spanner 1

10 mm Socket spanner 1

10 mm Combination Spanner 1

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 423
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.11.3 Removal

1. Using a hose clip plier remove the EGR

cooler inlet hose mounted clamp .

2. Using 12 mm combination spanner

remove the cylinder head mounted flange
mounting bolts .

3. Using 10 mm socket spanner remove the

EGR short pipe bracket mounting nut .

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
424 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.11.4 Inspection
• Check for any external damage, if found please replace.

4.6.11.5 Installation

1. Refit the EGR short pipe bracket 2. Refit the cylinder head mounted flange
mounting nut, torque tighten the nut to mounting bolts, torque tighten the bolts to
specified value. specified value.

3. Connect EGR cooler inlet hose, fasten

the hose using mounting clamp.

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 425
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.12 EGR Short Pipe (Exhaust Manifold to EGR Valve) R&R

4.6.12.1 Component Location Index

4.6.12.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2/4 post lift. • Refit Engine NVH top cover.
• Remove Engine NVH top cover. • Check for proper fitment and ensure for
any leakage.

Tools Required

Size Type Quantity

6 mm Allen key 1

10 mm Deep socket spanner 1

13 mm Socket Spanner 1

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
426 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.12.3 Removal

1. Using a 10 mm deep socket spanner

remove the NVH cover mounting bolts .

2. Using a 6 mm allen key loosen and

remove the EGR short pipe flange mounting
bolts.

3. Using 13 mm socket spanner remove the

EGR valve short pipe mounting nuts on
exhaust manifold.

4. Remove the EGR short pipe.

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 427
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.12.4 Inspection
1. Check for any external damage, if found please replace.

4.6.12.5 Installation

1. Position the EGR short pipe. 4. Using a 10 mm deep socket install the
mounting bolts & the NVH cover.
2. Refit the EGR short pipe on the exhaust
manifold, torque tighten the mounting nuts to
specified value.

3. Refit the EGR short pipe bottom flange

mounting bolts, torque tighten the bolts to
specified value.

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
428 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.13 EGR Short Pipe (Exhaust Manifold to EGR Valve) R&R — Euro II

4.6.13.1 Component Location Index

4.6.13.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2/4 post lift. • Refit Engine NVH top cover.
• Remove Engine NVH top cover. • Check for proper fitment and ensure for
any leakage.

Tools Required

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 429
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Size Type Quantity

6 mm Allen key 1

10 mm Deep socket spanner 1

13 mm Socket Spanner 1

4.6.13.3 Removal

1. Using a 10 mm deep socket spanner 3. Using 13 mm socket spanner remove the

remove the NVH cover mounting bolts . EGR valve short pipe mounting nuts on
exhaust manifold.

2. Using a 6 mm allen key loosen and

remove the EGR short pipe flange mounting 4. Remove the EGR short pipe.
bolts.

4.6.13.4 Inspection
1. Check for any external damage, if found please replace.

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
430 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.13.5 Installation

1. Position the EGR short pipe.

2. Refit the EGR short pipe on the exhaust

manifold, torque tighten the mounting nuts to
specified value.

3. Refit the EGR short pipe bottom flange

mounting bolts, torque tighten the bolts to
specified value.

4. Using a 10 mm deep socket install the

mounting bolts & the NVH cover.

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 431
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.14 Vacuum Modulators R&R

4.6.14.1 Component Location Index

4.6.14.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Check for any leakages.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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
432 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.14.3 Removal

1. Remove the Vacuum hoses from EGR 5. Repeat the procedure steps 1 — 4 for
Vacuum Modulator. removing the Turbo Vacuum Modulator .

2. Remove the Electrical connector from

EGR Vacuum Modulator.

3. Using 10 mm socket spanner, remove

the EGR Vacuum Modulator mounting nuts
on bracket.

4. Remove the EGR Vacuum Modulator .

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 433
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.6.14.4 Inspection
1. Check for any external damage, if found please replace.
2. Check the hoses for any damage and proper fitment.

4.6.14.5 Installation

1. Position the EGR Vacuum Modulator. 4. Connect the Vacuum hoses on EGR
Vacuum Modulator.
2. Install the EGR Vacuum Modulator
mounting nuts on bracket.

5. Repeat procedure steps 1 — 4 for

refitting the Turbo Vacuum Modulator .
3. Install the Electrical connector on EGR
Vacuum Modulator.

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
434 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4.7 Torque Specification

4.7.1 Tightening Specification

Place of Application Torque in Nm

FITMENT OF MIDDLE PIPE ON TO MUFFLER (U

CLAMP) 20±4

POST CATALYTIC CONVERTOR MTG 50±10

PRE CATALYTIC CONVERTOR MTG 50±10

PRESSURE MODULATOR 4.5±0.5

EXHAUST (BRKT ON TRANSMISSION & CATCON

FLANGE) 20±4

STUD EXHAUST MANIFOLD 25±3

EXHAUST MANIFOLD MOUNTING NUT 25±3

STUD TURBOCHARGER 25±3

CLINTCH NUT FOR TURBOCHARGER 25±3

BOLT TURBOCHARGER 25±3

ELBOW T/C COMPRESSOR 11±1

STUD EGR PIPE SHORT TO MANIFOLD 25±3

EGR SHORT PIPE TO EGR VALVE 25±3

EGR LONG PIPE MOUNTING ON EXHAUST

25±3
MANIFOLD- M8 ALLEN BOLTS

EGR LONG PIPE MOUNTING ON FRONT COVER 25±3

BANJO BOLT TURBO INLET 17.5±3

OIL LINE TURBO INLET MOUNTING ON HSG. WATER

11±1
PUMP INLET

ASSY. OIL RETURN T/C MOUNTING ON TURBO

11±1
CHARGER

EGR COOLER (EGR VALVE END) 25±3

EGR COOLER (INTAKE PIPE END) 25±3

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 435
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in Nm

ASSY BRKT EGR COOLER 25±3

TURBO SUPPORT BRACKET TO CRANKCASE 25±3

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
436 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5 FUEL SYSTEM

5.1 Description & Operations

5.1.1 Fuel Supply 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 & injectors 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.
While filling the tank, the air entrapped inside is vented by the vent tube, which is connected at
the fuel filling neck. The venting is done from the highest point in the fuel tank.
During operation, the fuel is sucked through the filter using the high pressure pump. The high
pressure pump, pressurizes, & supplies the fuel to the common rail. The fuel leak back from
injectors and return from HPP comes through return line.

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 437
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.1.2 Fuel supply layout

5.1.3 Injectors

The injector uses electronically controlled

solenoid actuation for precise control of
injection.
The solenoid injectors can inject very small
quantities of fuel. The injection can be split
into pilot and main injection. Or without pilot
and only main injection.
Each fuel injector is mounted directly above
the piston within the cylinder head and is
connected to the fuel rail by rigid steel lines
that can withstand the high fuel pressure.
The actuation of injectors is done by EMS
ECU.

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
438 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.1.4 Common rail

The common fuel rail is a high pressure

accumulator in which the fuel from HPP is
accumulated and is maintained at required
pressure.

5.1.5 High pressure pump

The fuel pump unit has a feed pump and a

HPP. The feed pump is a gear type pump
which sucks the fuel from the tank and feeds
the HPP i. e. radial piston pump. High
pressure is generated by the radial piston
pump having three pistons located at 120
degree intervals. The three cylinders are
arranged radially in which the plungers
reciprocate and increase the fuel pressure to
the required level.
The high pressure pump maximum pressure
is 1600 bar and the maximum pump speed is
3000 rpm. The flow into the pump is
controlled by an electrical solenoid valve
called metering unit. This valve is located at
the inlet of the pump. This meters and
controls the amount of fuel that is sucked into
the pump in accordance with desired
pressure to be maintained at the rail. The
metering unit is an integral part of the HPP
and is not serviceable.

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 439
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.1.6 Fuel filter

The fuel filter filters the fuel of small

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

5.1.7 Fuel Rail Pressure Sensor

This pressure sensor is fitted on the fuel rail

and gives a close loop control of the rail
pressure. Fuel is maintained at a high
pressure in the fuel rail depending on
requirement of the engine.

5.1.8 Fuel Tank and Strainer

The fuel tank is a reservoir for the fuel and

incorporates the strainer for primary filtration.
The strainer acts as a primary filter and helps
in filtering the larger impurities which
otherwise can get into the high pressure side
of the fuel system. The fuel gauge sensor is
mounted in the fuel tank, it provides the level
of fuel in the tank. The tank is ventilated to
the atmosphere so as to avoid collapse due
to the engine vacuum

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
440 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.1.9 High Pressure Fuel Lines (CR to Injectors)

This high pressure fuel lines connects

common rail with injectors and thus supplies
high pressure fluid from rail to injectors.

5.1.10 High Pressure Fuel Line ( PF Pump to CR)

This high pressure fuel line connects High

pressure pump with common rail and
supplies compressed high pressure fluid to
common rail.

5.1.11 Fuel Filler Pipe

Fuel filler pipe guides the fuel from filling

neck to fuel tank.

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 441
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.2 Component Location Index

5.2.1 Fuel System View 1

A. Injector leak off pipe D. Rail pressure sensor

B. Injector E. High pressure fuel line (Common rail to

Injectors)

C. Common rail

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
442 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.2.2 Fuel System View 2

A. High pressure fuel line (Common rail to G. Fuel strainer unit.

HPP).

B. Fuel filter. H. Fuel float unit.

C. High pressure pump. I. Fuel tank.

D. Fuel main line tank to filter. J. Fuel filler pipe.

E. Fuel return line Tee connector to tank. K. Fuel filler cap.

F. Fuel tank stone guard. L. Fuel tank ventilator pipe.

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 443
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.3 Standard Checking Procedure

Possible customer complaints / symptoms
1. Engine not starting.
2. Engine vibrations / Engine Noise.
3. Engine knocking.
4. Cylinder misfiring.

5.3.1 Injector Leak off Test

Other observations
1. No error codes registered.
2. In the live data the status of torque limitation, synchronization status and the state of
staring system are correct.
3. If H.P pipe is removed at the rail end then fuel can be observed.
Parts Required
1. Test tube with graduations, capacity 30 to 75 ml (Quantity : 03 Nos).
2. Engine tube connection injection, Part Number : 9350042680, Length 310 mm (Quantity
: 03 Nos.).

The ID of the tube is important hence use only the part number specified.

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
444 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.3.1.1 Injector Checking Procedure:

1. Remove the Intercooler assembly. For 4. Insert the hose firmly in each Injector and
additional information refer to intercooler insert the other end in test tubes as shown in
R&R section. illustration below. (Use Rubber Band to hold
the test tubes in stand).
2. Blow air around the injectors to remove
the dust.

3. Remove injector leak — off hose clips Images are only for representation.
and then gently pullout and remove leak-off Actual image for this vehicle may vary.
hose from injectors.

Keep the removed leak —off pipe behind

injectors.

Do not remove overflow tube connection

from the fuel return line.

5. Start engine and keep it in idle.

6. Collect fuel in test tube for one minute.

7. Stop the engine, ignore first reading.

Empty the test tubes & reconnect.

8. If any test tube gets filled during the test,

“STOP” the test and replace that cylinder
injector.

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 445
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Start engine & repeat test for exactly one

minute.

• Observe the quantity of leakage fuel

corresponding to each injector.
• If the leakage quantity of any injector
is higher than 3 times the minimum of
any three injector, then that injector is
faulty. Replace the injector.

5.3.1.2 For engine not starting complaint

1. Crank the engine for 30 seconds, the

faulty injector's will show leakage quantity
more than 3 times the minimum of any three
injector.

2. Replace the defective injector's.

3. Repeat the test with new replaced

injector (s) & confirm the resolution for
starting problem.

Images shown is just for representation.

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
446 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.4 Trouble Shooting

5.4.1 Symptom Possible Causes

Symptom Possible Causes Remedy

Engine will not start and 1. Clogged fuel filter or fuel • Change fuel filter element
emit black smoke lines. and check fuel supply lines.

2. Defective injectors. • Replace the injectors.

3. Improper engine timing. • Check & correct the engine

timing

4. Defective HP Pump • Replace HP Pump,

Noisy engine & black 1. Faulty injectors. • Replace injectors.

smoke.
2. CR system. • Refer diagnostic manual.

3. Chocked air filter. • Replace air filter element.

4. Chocked fuel filter. • Replace the fuel filter

element.

Engine speed falls off. 1. Clogged fuel filter/fuel • Change fuel filter element
lines. and check fuel supply lines.

2. Common rail system • Refer diagnostic manual.

Engine does not give full 1. Clogged fuel filters/ fuel • Change fuel filter element.
power. lines.
• Check fuel supply line.

2. Defective injectors • Replace injectors.

3. Return pipe blocked. • Locate the kink/block in

return pipe and rectify.

4. Defective HP Pump • Replace the HP Pump.

Black smoke 1. Defective injectors. • Check and replace the

injectors.

2. Common rail system. • Refer diagnostic manual.

Irregular idling 1. Defective injectors. • Check and replace the

injectors.

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 447
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

2. Leaking HP unions. • Tighten the unions or

replace the High-pressure
pipes.

3. Air entering fuel system. • Check for cracks in fuel line

particularly from Tank to PF
Pump.

4. Defective HP Pump • Replace HP Pump.

5. Wrong High pressure • Replace with original pipes.

pipes

Engine stalls when Water contamination causing • Find the cause of water
accelerator pedal is partial seizure of HP Pump contamination & take
released corrective action

5.4.2 Component Inspection and Action Table

Component Inspection Action

High Pressure Pump 1. Check for Physical damage 1. Replace the High pressure
especially on the sprocket and pump if any part found
union connectors. damaged.

2. Check high pressure pump 2. Replace high pressure pump

for any signs of fuel leakage. if any signs of leakage is found.

Fuel Rail 1. Check for fuel rail physical 1. Replace the fuel rail
damage. assembly.

2. Check for malfunction of rail 2. Replace the defective part.

Pressure sensor using iSmart.

Fuel Lines (High 1. Check for fuel rail physical 1. Replace the fuel lines if
pressure) damage. damage is found.

2. Check for leakage from the 2. Replace the lines if leakage

lines. is found.

Fuel lines (Low pressure 1. Check lines for physical 1. Replace the line if damage is
side) damage especially crimping. Found.

2. Check for signs of leakage 2. Replace the line if required.

especially at joints.

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
448 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Component Inspection Action

Fuel Injectors 1. Check for physical damage. 1. Replace injector if damage is

found.

2. Check for signs of leakage. 2. Replace the injector if

leakage is found.

3. Check for carbon deposition 3. Clean the tip and refit.

at the nozzle tip.

Fuel Filter 1. Check fuel filter for clogging. 1. Replace the fuel filter
element.

2. Check for physical damage 2. Replace the fuel filter

on the filter body or connectors. assembly.

Fuel Tank 1. Check for physical damage. 1. Replace the fuel tank.

2. Check for dirt accumulation 2. Clean the tank and replace

in Tank. the fuel.

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 449
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5 Care of the system

5.5.1 Service Tips and Precautions
Before attempting any service on fuel system, following precautions should be always followed
for personal safety and to avoid system damages.
• Do not smoke, and place 'NO SMOKING" sign near work area make sure to have fire
extinguisher handy.
• Make sure to perform work in well-ventilated area and away from any open fire/flames.
• Wear Safety glasses
• Small amount of fuel may drip after the fuel lines are disconnected. In order to reduce the
risk of personal injury, cover the pipe/ hose ends with suitable plugs with no rust or
contamination.
• After servicing, make sure that the fuel hoses and clamps are properly connected.
• After servicing, check for fuel leakages at fuel hose joints.

• Keep open flames and sparks away from the work area. Failure to follow these
instructions will result in personal injury.
• Before working on the fuel system, switch off the engine, wait for two minutes. This
will allow the static current in the injector to discharge. Failure to follow this
instruction may lead to serious personal injury.
• Avoid repairing the fuel injection system while the engine is running. The fuel
pressure within the system is very high. Failure to follow this instruction will result
in personal injury.
• Eye protection and a mask must be worn at all times while working near any fuel
related components. Failure to follow this instruction will result in personal injury.

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
450 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.2 Do’s and Don’ts

Do’s Don’ts

• Drain water from sedimentary / filter at • Do not leave open inlets and outlets of
regular intervals. common rail components- Cap them
immediately.
• EMS wiring harness to be properly routed
as specified using clamps / clips and • Flushing of common rail components
brackets. should be avoided.
• Do check for any faults /malfunctioning in • Do not remove battery, sensor & actuator
the system using i-SMART before connections when ignition key is ON.
cranking the engine (after any repair). • Do not spray water on the EMS ECU.
• When Injectors are replaced/Changed.
• Sensor connections should not be
Injector IQA values must be loaded
removed unnecessarily.
correctly as per cylinder order. For
additional information refer to EMS • High pressure pipe lines should not be
diagnostic manual. bent and force should not be applied.
• Plug the port of Common rail system • Failed or broken common rail components
components whenever any pipe should not be used, leakage may cause
connections are removed. malfunction.
• Tighten the mounting nuts / cap nuts etc. • Don't let EMS ECU body touch any
only to the specified torque values. metallic part while the EMS ECU is
powered ON (Ignition key switched "ON").
• Carefully install the removed parts in the
correct order. If work is interrupted, the • Don't keep any sensor branch hanging
removed parts must be covered with a /loose while assembly. Fix them properly
nylon or paper cloth. using clips provided in wiring harness.
• Fuel lines should not be twisted or • Don't remove any sensor /injector
stressed and the bending radii of fuel lines connector once fitted and locked properly.
and high pressure lines should not be • Do not run the vehicle with 'OBD' lamp
altered at any circumstances. ON.
• Replace high pressure lines if they are • Do not bleed the air by removing or
loose. This may lead to leaks at fuel line loosening the HP pipes.
union connectors.
• Do not start the vehicle if battery voltage is
low.
• The ECU gets tripped if the battery
voltage is below 6 volts. Replace /
Recharge the battery and then start the
engine.
• Do not clean the Injectors with
pressurized water. The injector is not
designed to be washed with pressurized
water.
• Do not clean the HP pipes with
compressed air, oil or water. Cleaning
may dirt HP pipes and common rail
system.

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 451
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Do not use any failed/ broken water

sedimentary/ fuel filters, even if there's no
external sign of damage.

5.5.3 IQA Management

Precautions to be followed:
1. Never interchange injectors between engines / ECU's.
2. Never change ECU's between vehicles.
3. Never interchange injectors between cylinders in same engine.
4. When Injectors are replaced/Changed Injector IQA values must be loaded correctly as
per cylinder order. For additional information refer to EMS diagnostic manual.
Whenever an injector or ECU need to be replaced, the new injector’s IQA code need to be
written in to the ECU, using i-FLASH/ i-SMART.
IQA code is engrave on the top of the injector. It is a 6 character alphanumeric code.

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
452 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.4 Fuel Filter Element — Replace

5.5.4.1 Component Location Index

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 453
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Check and ensure proper functioning of
engine.

Removal Steps:
1. Remove the fuel filter assembly.
2. Remove the bottom cover.
3. Remove the O - ring.
4. Remove the fuel filter element.
Tools Required

Size Type Quantity

32 / 12 mm Socket spanner 1

2–3 inch M 12 Bolts & nuts 2

— Bench vice 1

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
454 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.4.3 Fuel filter element removal procedure:

• Ensure that the fuel is drained from filter assembly before the fuel filter element is
removed.
• Do not hold fuel filter body part and avoid damage to the fuel filter body.

1. Remove the fuel filter assembly. For 4. Remove the bottom cover of fuel filter
additional information refer to Fuel filter R&R assembly.
section.

2. Use two approx. 2–3 inches long size M

12 bolts and nuts to hold fuel filter assembly
in a bench vice as shown in illustration.

5. Remove the O-ring from the fuel filter

housing.

3. Using 36 mm ring/socket spanner, rotate

the fuel filter bottom cover in anti-clockwise
direction.

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 455
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Take out the filter element from the fuel

filter housing.

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
456 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.4.4 Fuel Filter Element Installation Procedure:

1. Insert the filter element correctly into 3. Tighten the filter body using 36 mm size
housing as shown in illustration. socket spanner to specified torque value.

2. Assemble the new O-ring back on to filter

housing, which is supplied along with new
filter element. Ensure little oil is smeared on
• Do not over tighten beyond 25 ±5 Nm.
to the surface of O-ring before assembly on
This may cause damage to the bowl
to head.
and head.
• It is recommended to tight the fuel
filter using torque wrench.
• Assemble filter element on to head in
the direction shown. Ensure open end
of filter element goes inside first.
• Press the filter element by gentle push
into the head.

4. Refit the fuel filter assembly. For

additional information refer to Fuel filter R&R
section.

It is recommended to do air bleeding

after installation of Fuel Filter Element.
Follow the procedure prescribed below.

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 457
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.4.5 SOGEFI FUEL FILTER AIR BLEEDING PROCEDURE:

• Fuel system air bleeding is to be done whenever the fuel filter is replaced.
• Before doing air bleeding procedure, take one transparent tube and connect its one
end to air vent and put the other end to a bottle in order to prevent spilling of fuel in
to engine compartment.

1. Loosen the air went screw, 3. Fuel starts flowing through air vent via
transparent tube to the bottle, once there is
no air bubble seen in transparent tube tighten
the air vent.

2. For priming the fuel system, press the

primer on top of the filter assembly.
4. Start the engine and check for any leaks.

• Always use recommended filter

element only.
• Before removing the fuel filter, open
the fuel tank cap to release the
pressure from the tank and fuel lines.
• Fuel filter to be replaced first at 20,000
kms or 12 months and then every
20,000 kms or 12 months (Distance
Covered in km / Months in service
whichever is earlier).
• Fuel Filter cartridge needs to be
replaced earlier in case of repeat
warning in cluster even after the water
is drained from the system.

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
458 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.5 Water Sediment Drain– Fuel Filter

5.5.5.1 Component Location Index

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 459
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.5.5.2 WATER SEDIMENT DRAINING PROCEDURE:

1. Connect the transparent pipe to the drain 4. Start the engine and check for any leaks.
plug outlet of the fuel filter assembly.

• Drain plug requires hand tight only; do

not use any tool and avoid over
tightening.
• Water sediments to be drain from fuel
filter at every service or when the
water in fuel tell-tale lamp up in cluster
• Do not over tight the drain plug.

2. Rotate drain plug anti clockwise till the

water starts flowing from the tube.

3. Rotate drain plug in clockwise direction

to stop the flow as soon as water gets over
and fuel flow starts.

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
460 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6 In Car Repairs

5.6.1 Fuel Filter assembly R&R

5.6.1.1 Component Location Index

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 461
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Check and ensure proper functioning of
engine.

Removal Steps:
1. Disconnect the electrical connector.
2. Disconnect the fuel filter fuel inlet line.
3. Disconnect the fuel filter fuel outlet line.
4. Remove the fuel filter mounting bolts.
5. Remove the fuel filter.
Tools Required:

Size Type Quantity

12 mm Socket spanner 01

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
462 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.1.3 Removal:

• Ensure that the fuel is drained from filter assembly before the fuel filter element is
removed.
• Do not hold fuel filter body part and avoid damage to the fuel filter body.

1. Press the lock and disconnect the fuel 3. Using 12 mm socket spanner remove
filter electrical connector. fuel filter assembly mounting bolts and then
gently pullout and remove the fuel filter
assembly.

2. Press the lock and disconnect fuel filter

inlet and outlet fuel lines.

All are quick fix connectors, press gently

and remove it carefully; avoid seal
damages.

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 463
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.1.4 Inspection:
1. Inspect the fuel filter assembly for any physical damage, replace if found.
2. Inspect the fuel filter assembly for any leakage, rectify if found.
3. Inspect the fuel lines and connectors for any damage. Replace if damaged.

5.6.1.5 Installation:

1. Refit the fuel filter assembly, torque 3. Connect the fuel filter electrical
tighten the mounting bolts to specified value. connector.

2. Connect fuel filter assembly inlet and 4. Carry-out Fuel air bleeding procedure.
outlet fuel lines. For additional information refer to Fuel
system air bleeding procedure.

Check and ensure proper fitment of fuel

lines, any leakage can lead to fire.

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
464 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.2 Injector R&R

5.6.2.1 Component Location Index

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 465
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a flat surface. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Check and ensure proper functioning of
• Remove the engine NVH cover.
engine.

Removal Steps:
1. Disconnect the electrical connector.
2. Disconnect the fuel leak-off pipe.
3. Remove the high pressure fuel line from injector and loosen from common rail.
4. Remove injector hold down clamp.
5. Remove the injector.
Tools Required

Size Type Quantity

17 mm / 14 mm Open end spanner 1 each

0305BAM0001ST Injector removal tool 1

12 mm Socket spanner 1

— Flat end screw driver 1

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
466 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.2.3 Removal

1. Remove the Intercooler assembly. For 4. Using a 14 mm open end spanner loosen
additional information refer to intercooler the high pressure pipe mounting nut on
R&R section. injector, also slightly loosen the high pressure
pipe mounting nut on common rail using 17
2. Press the lock and disconnect the mm open end spanner.
electrical connectors.

5. Remove the injector holding clamp

3. Using a flat end screw driver, pull the mounting nut using 12 mm deep socket
lock upwards and then gently pullout and spanner, then gently pullout and remove the
detach the leak-off pipe from injector. injector hold down clamp.

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 467
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Install injector removal tool (MST

0305BAM0001ST), using that pull — out and
remove the injector.

• Plug the fuel inlet and wiring harness

connector slot using protective cover
as soon an injector is removed.
• Store the injector in a neat tray.
• Never drop the injectors.
• Never clean the injector using
pressurized water.

5.6.2.4 Inspection
1. Check for the carbon deposit & check for any external damage, if found please replace.

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
468 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.2.5 Installation

1. Replace the injector lower copper 3. Mount the injector with the help of hold
washer and O-ring with new ones whenever down clamp and nut. Torque tighten the nut
injector is removed. to specified value.

4. Refit the high pressure fuel pipe on

Injector & common rail. Torque tighten the
mounting nuts to specified torque values.

2. Insert the injector in its position.

5. Refit the injector leak-off pipe.

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 469
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit the injector electrical connectors.

7. Refit the intercooler assembly. For

additional information refer to intercooler
R&R section.

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
470 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.3 Common Rail (CR) R&R

5.6.3.1 Component Location Index

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 471
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Refit the Intake Manifold
• Remove the Intake Manifold.
• Check and ensure proper functioning of
engine.

Removal Steps:
1. Remove the rail pressure sensor electrical connector.
2. Remove the fuel lines.
3. Remove common rail mounting bolts.
4. Remove the common rail.
Tools Required:

Size Type Quantity

12 mm Ring spanner 01

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
472 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.3.3 Removal:

1. Remove the Intake Manifold. For

additional information refer to Intake Manifold
R&R section.

2. Press the lock and disconnect the rail

pressure sensor electrical connector.

3. Remove fuel line (High pressure pump to

Common rail). For additional information
refer Fuel Line (High Pressure Pump to Rail)
R&R section

4. Remove high pressure lines (Common

rail to Injectors). For additional information
refer to high pressure pipes (Common rail to
Injectors) R&R section.

5. Using 12 mm ring spanner, loosen and

remove common rail mounting bolts.

6. Remove the common rail.

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 473
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.3.4 Inspection:
1. Inspect the common rail for any damage. Replace if found.
2. Inspect the connector for any damage.
3. Inspect the rail pressure sensor for any damage.

5.6.3.5 Installation:

1. Refit the common rail, torque tighten the 5. Refit the Intake Manifold. For additional
mounting bolts to specified value. information refer to Intake Manifold R&R
section.

6. Carry-out fuel system air bleeding. For

additional information refer to Fuel circuit air
bleeding section.

2. Refit high pressure fuel line (High

pressure pump to Common rail). For
additional information refer Fuel Line (High
Pressure Pump to Rail) R&R section

3. Refit high pressure fuel lines (Common

rail to Injectors). For additional information
refer to high pressure pipes (Common rail to
Injectors) R&R section.

4. Connect rail pressure sensor connector.

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
474 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.4 High Pressure Pump R&R

5.6.4.1 Component Location Index

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 475
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Install the timing chain & case assembly.
• Open the bonnet. • Install the fuel filter.
• Remove the Fuel filter assembly. • Close the bonnet.
• Remove the Timing Chain & Sprocket • Bleed the fuel system.
assembly.

Tools Required

Size Type Quantity

12 mm Deep socket spanner 1

12 mm / 13 mm Socket spanner 1

14 mm Open end spanner 1

Flat screw driver (Big &

- 1
small)

12 mm Combination Spanner 1

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
476 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.4.3 Removal

1. Remove the timing chain & sprocket. For 4. Using 12 mm socket spanner remove
additional information refer to Timing chain & fuel filter assembly mounting bolts and then
sprocket R&R section. gently pullout and remove the fuel filter
assembly.
2. Press the lock and disconnect the fuel
filter electrical connector.

5. Using a 13 mm socket spanner remove

the mounting nut & remove the alternator
3. Press the lock and disconnect fuel filter positive cable.
inlet and outlet fuel lines.

6. Remove the electrical coupler from the

alternator.
All are quick fix connectors, press gently
and remove it carefully; avoid seal
damages.

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 477
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Remove the engine oil filter. For 11. Disconnect the fuel lines from the HPP.
additional information refer to engine Oil filter
removal procedure.

8. Using 12 mm combination spanner

loosen the alternator bottom mounting bolt &
slide the alternator clock wise.

12. By using 12 mm socket spanner,

remove the HPP mounting bolts.

9. Disconnect the fuel metering valve

electrical connector.

13. Remove the HPP assembly.

10. Using a 14 mm open end spanner

disconnect the high pressure line from HPP.

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
478 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.4.4 Inspection
• Check for fuel leakage in the fuel lines.
• Check for rust or corrosion due to increased water content in the fuel.
• Check for any external damage, if found replace.

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 479
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.4.5 Installation

1. Install the HPP mounting bolts, torque 4. Install the HPP metering valve electrical
tighten the bolts to specified value. connector.

2. Install the fuel lines on HPP. 5. Slide the alternator in anti-clock wise
direction.

3. Install the high pressure fuel line on the

HPP, torque tighten to specified value 6. Refit the engine oil filter. For additional
information refer to engine oil filter installation
procedure.

7. Install the alternator electrical connector.

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
480 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Install the alternator positive cable. 11. Connect fuel filter assembly inlet and
outlet fuel lines.

9. Refit the timing chain & the sprocket. For

additional information refer to Timing chain &
sprocket R&R section
Check and ensure proper fitment of fuel
10. Refit the fuel filter assembly, torque lines, any leakage can lead to fire.
tighten the mounting bolts to specified value.
12. Connect the fuel filter electrical
connector.

13. Carry-out Fuel air bleeding procedure.

For additional information refer to Fuel
system air bleeding procedure.

14. Check engine oil level and top up if

required.

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 481
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.5 Injector Leak-off Pipe R&R

5.6.5.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Carry-out fuel system air bleeding
procedure.
• Open the bonnet.
• Remove the Intercooler. • Refit the Intercooler.
• Check and ensure proper functioning of
engine.

Tools Required

Size Type Quantity

- Small flat end screw driver 01

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
482 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.5.2 Removal:

1. Remove the Intercooler Assembly. For

additional information refer to intercooler
R&R section.

2. Using a flat end screw driver, lift the

locks first and then gently pullout and detach
the leak-off pipe from all the injectors.

3. Gently pullout and disconnect the leak-

off pipe from T-joint and remove the leak-off
pipe.

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 483
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.5.3 Inspection:
1. Inspect the leak-off pipe for any damage. Replace if found any.
2. Inspect the leak-off for any leakages. Replace if found any.

5.6.5.4 Installation:

1. Connect the leak-off pipe on T-Joint.

2. Refit the leak-off pipe on injectors by

positioning gently pressing to seat and then
push the locks downwards for locking.

3. Refit the Intercooler Assembly. For

additional information refer to intercooler
R&R section.

4. Carry-out Fuel air bleeding procedure.

For additional information refer to Fuel circuit
air bleeding section.

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
484 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.6 High Pressure Pipes (Common Rail to Injector) R&R

5.6.6.1 Component Location Index

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 485
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.6.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on flat surface. • Refit the Intercooler assembly
• Open the bonnet. • Carry-out fuel system air bleeding
procedure.
• Remove the Intercooler assembly.
• Close the bonnet.
• Check and ensure proper functioning of
engine.

Tools Required

Size Type Quantity

14 mm Open end spanner 1

17 mm Open end spanner 1

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
486 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.6.3 Removal

1. Remove the Intercooler assembly. For

additional information refer to intercooler
R&R section.

2. Loosen high pressure fuel line mounting

nuts on either sides (17 mm open end
spanner on common rail side and 14 mm
open end spanner on Injector side).

3. Remove the high pressure fuel lines.

5.6.6.4 Inspection
1. Inspect the high pressure fuel pipes for any damage. Replace if found any.
2. Inspect the high pressure fuel pipes for leakage, rectify if found.

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 487
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.6.5 Installation

1. Position the high pressure fuel lines,

torque tighten the mounting nuts to specified
values.

2. Refit the Intercooler assembly. For

additional information refer to intercooler
R&R section.

3. Carry-out fuel system air bleeding. For

additional information refer to Fuel circuit air
bleeding section.

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
488 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.7 Fuel Pipe (High Pressure Pump to Common Rail) R&R

5.6.7.1 Component Location Index

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 489
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.7.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on flat surface. • Refit the Intercooler assembly
• Open the bonnet. • Carry-out fuel system air bleeding
procedure.
• Remove the Intercooler assembly.
• Close the bonnet.
• Check and ensure proper functioning of
engine.

Removal Steps:
1. Remove the HPP pump electrical connector.
2. Remove the high pressure fuel line mounting nut on common rail.
3. Remove the high pressure fuel line mounting nut on high pressure pump.
4. Remove the high pressure fuel line bracket mounting bolt.
5. Remove the high pressure fuel line (HPP to CR) assembly.
Tools Required

Size Type Quantity

14 & 17 mm Open end spanner 1

12 mm Ring spanner 1

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
490 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.7.3 Removal

1. Remove the intercooler assembly. For 5. Using a 17 mm open end spanner

additional information refer to intercooler remove the high pressure fuel line mounted
R&R section. nut on common rail side.

2. Remove the alternator/power steering

belt. For additional information refer to Auto
tensioner & belt (Alternator/Power Steering) -
Replace).

Make sure not to remove the auto

tensioner assembly.

3. Remove the alternator supporting brace

mounting bolts using a 12 mm ring spanner
further slide the alternator clock wise by
loosening the bottom mounted bolt. 6. Using a 14 mm open end spanner
remove the high pressure line mounting nut
on HPP and also the fuel line bracket
mounting bolt.

4. Press the lock and disconnect the

metering unit electrical connector.

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 491
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.7.4 Inspection
1. Inspect the fuel pipe for any damage. Replace if found any.
2. Inspect the joints for fuel leakage. Rectify if found.

5.6.7.5 Installation

1. Refit the high pressure fuel line on HPP 3. Connect the fuel metering valve electrical
side, torque tighten the mounting nut and the connector.
fuel line bracket mounting bolt to specified
value.

4. Refit the alternator by rotating it anti-

clockwise further refit the supporting brace,
2. Position the high pressure fuel line on torque tighten the supporting brace mounting
common rail side, torque tighten the bolts and alternator bottom mounting bolt to
mounting nut to specified value. specified value.

5. Refit the alternator/power steering belt.

For additional information refer to Auto
tensioner & belt (Alternator/Power Steering) -
Replace)

6. Refit the intercooler assembly. For

additional information refer to intercooler
R&R section.

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
492 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.8 Fuel Line (Fuel filter to High Pressure Pump) R&R

5.6.8.1 Component Location Index

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 493
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.8.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Check and ensure proper functioning of
engine.
• Close the bonnet.

Removal Steps:
1. Remove the fuel line on fuel filter end.
2. Remove the fuel line on HPP end.
3. Remove the fuel pipe line.

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
494 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.8.3 Removal

1. Disconnect the fuel filter electrical 3. Press the lock and disconnect the fuel
connector. line connector on the HPP end.

2. Disconnect and remove the fuel pipe by 4. Remove the fuel line (Fuel filter to HPP)
pressing the lock and gently pulling the pipe assembly.
from clip & remove outwards from fuel filter.

All are quick fix connectors, press gently

and remove it carefully; avoid seal
damages.

5.6.8.4 Inspection
1. Inspect the fuel pipe for any damage. Replace if found any.
2. Inspect the joints for fuel leakage. Rectify if found.

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 495
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.8.5 Installation

1. Refit the fuel pipe by positioning and 4. Carry-out Fuel air bleeding procedure.
gently pushing inwards to get it locked on For additional information refer to Fuel
either sides and refit on the clip. system air bleeding procedure.

2. Connect the fuel line connector on HPP

end.

3. Connect the fuel filter electrical

connector.

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
496 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.9 Fuel Pipe Main (Tank to Fuel Filter) R&R

5.6.9.1 Component Location Index

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 497
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.9.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Check and ensure proper functioning of
engine.
• Close the bonnet.

Removal Steps:
1. Disconnect the fuel line from fuel filter end.
2. Remove the fuel line from the routing clamps.
3. Disconnect the fuel line from fuel tank end.
4. Remove the fuel line (Fuel tank to Fuel filter) assembly.
Tools Required

Size Type Quantity

- Flat screw driver 1

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
498 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.9.3 Removal

1. Disconnect and remove the fuel pipe by 3. Press the lock and remove the fuel line
pressing the lock and gently pulling the pipe from fuel tank end.
from clip & remove outwards from fuel filter.

2. Remove the fuel lines from the routing

clamps.

5.6.9.4 Inspection
1. Inspect the fuel pipe for any damage. Replace if found any.
2. Inspect the joints for fuel leakage. Rectify if found.

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 499
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.9.5 Installation

1. Refit the fuel line over the routing 3. Connect the fuel line connector on the
clamps. fuel filter end.

2. Refit the fuel pipe by positioning and

gently pushing inwards to get it locked on
either sides and refit on the clip.

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
500 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.10 Fuel Return Line (High Pressure pump to Fuel Tank) R&R

5.6.10.1 Component Location Index

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 501
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.10.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Carry-out fuel system air bleeding
• Open the bonnet. procedure.
• Check and ensure proper functioning of
engine.
• Close the bonnet.

Removal Steps:
1. Disconnect the fuel line from HPP end.
2. Remove the fuel line from the routing clamps.
3. Disconnect the fuel line from fuel tank end.
4. Remove the fuel line (HPP to Fuel tank) assembly.
Tools Required

Size Type Quantity

- Flat screw driver 1

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
502 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.10.3 Removal

1. Disconnect the fuel line from HPP end. 3. Press & remove the clip from the fuel
tank end & remove the fuel line assembly.

2. Remove the fuel line from the holding

clamps.

5.6.10.4 Inspection
1. Inspect the fuel pipe for any damage. Replace if found any.
2. Inspect the joints for fuel leakage. Rectify if found.

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 503
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.10.5 Installation

1. Refit the fuel line on the routing clamps. 3. Press & refit the fuel line coupler on HPP
end.

2. Press & refit the fuel line near fuel tank.

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
504 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.11 Fuel Filler Pipe/ Hose & Breather Hose Assembly R&R

5.6.11.1 Component Location Index

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 505
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.11.2 Removal and Installation Summary

Pre Removal Post Installation

• Disconnect and isolate a negative cable of • Carry-out fuel system air bleeding
the battery. procedure.
• Place the vehicle on a 2/4 post lift. • Check and ensure proper functioning of
engine.
• Connect the negative cable of the battery.

Tools Required

Size Type Quantity

7 mm / 13 mm / 18 mm Socket spanner 1

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
506 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.11.3 Removal

1. Using a 7 mm socket spanner loosen 4. Using a 18 mm socket spanner loosen

and remove the spring band clamp from fuel and remove the stabilizer link rod mounted
filler hose at fuel tank end. bracket mounting nut.

2. Remove the Vent hose on fuel tank. 5. Using a 7 mm socket spanner loosen
and remove the spring band clamp from fuel
filler hose at fuel filler neck end and further
disconnect the breather hose also.

3. Using a 13 mm socket remove the fuel

filler bracket mounting bolts on chassis.

6. Remove the Fuel filler pipe/hose

assembly along with breather hose.

5.6.11.4 Inspection
1. Check the pipe/hoses for any damage or deterioration and replace if necessary.

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 507
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.11.5 Installation

1. Position the Fuel filler pipe/hose 4. Refit the fuel filler hose and breather
assembly along with breather hose. hose on the filler neck, torque tighten the
fastening clamp to specified value.
2. Refit the stabilizer link rod mounted
bracket nut, torque tighten the mounting nut
to specified value.

5. Refit the fuel filler hose and breather

hose on the fuel tank, torque tighten the
fastening clamp to specified value.
3. Refit the chassis mounted fuel filler
bracket mountings, torque tighten the
mounting bolts to specified value.

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
508 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.12 Fuel Filler Neck Assembly R&R

5.6.12.1 Component Location Index

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 509
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.12.2 Removal and Installation Summary

Pre Removal Post Installation

• Disconnect and isolate a negative cable of • Close the fuel lid.
the battery. • Carry-out fuel system air bleeding
• Place the vehicle on a 2/4 post lift. procedure.
• Open the fuel lid. • Check and ensure proper functioning of
engine.
• Connect the negative cable of the battery.

Tools Required

Size Type Quantity

- Flat screw driver 1

7 mm Socket spanner 1

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
510 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.12.3 Removal

1. Open the fuel lid & remove the fuel filler

neck mounting screws using a star screw
driver.

2. Using a 7 mm socket spanner loosen

and remove the spring band clamp and
breather hose from fuel filler neck.

3. Remove the Fuel filler neck assembly.

5.6.12.4 Inspection
1. Inspect the pipe assembly for any damage.
2. Inspect the mounting clips for any damage.
3. Inspect the pipe assembly for any leakages.

5.6.12.5 Installation

1. Position the Fuel Filler Neck Assembly.

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 511
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2. Refit the fuel filler hose and breather

hose on the fuel filler neck, torque tighten the
fastening clamp to specified value.

3. Refit the fuel filler neck mounting screws,

torque tighten the screws to specified value.

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
512 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.13 Fuel Tank & Strainer Assembly R&R

5.6.13.1 Component Location Index

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 513
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.13.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Carry-out fuel system air bleeding
procedure.
• Check and ensure proper functioning of
engine.

Removal Steps:
1. Remove the float sensor electrical connector.
2. Remove the breather hose from fuel tank.
3. Remove the fuel filler hose from fuel tank.
4. Disconnect the fuel main line and return line.
5. Remove the fuel tank front side mounting bolts.
6. Remove the fuel tank rear side mounting bolts.
7. Remove the fuel tank and strainer assembly.
Tools Required

Size Type Quantity

13 mm Ring spanner 1

7 mm / 8 mm Small Socket spanner 1

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
514 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.13.3 Removal

1. Press the coupler clip over the fuel tank 3. Press and release the quick release
and disconnect the float sensor connector. coupling of the fuel supply line and the return
line. Detach the fuel lines from the tank.

2. Using a 7 mm socket spanner, loosen

and remove the securing clip which connects 4. Using a 13 mm socket spanner, loosen
the filler hose on top of the fuel tank, further and remove the front mounting bolts of the
disconnect the breather hose. fuel tank.

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 515
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Using a 13 mm socket spanner loosen 7. Using a 8 mm socket spanner loosen

and remove the fuel tank rear side mounting and remove the strainer mounting bolts from
bolts and remove the Fuel Tank assembly the top of fuel tank.
from the vehicle.

Support the fuel tank using a suitable

jack support.

6. Using a 7 mm socket spanner, loosen

and remove the mounting bolts of Fuel tank
float unit.

5.6.13.4 Inspection
1. Check the fuel tank for any damage and replace it if necessary.
2. Check the tank ventilation hose for clog/debris.
3. Check for free movement of float assembly without any restriction.

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
516 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.13.5 Installation

1. Refit the new gasket lock ring on the 3. Refit the fuel tank front and rear side
strainer & install the assembly on fuel tank, mounting bolts, torque tighten the bolts to
torque tighten the mounting bolts to specified specified value.
value.

2. Refit the new rubber gasket and Fuel

tank float unit on fuel tank, torque tighten the
mounting bolts to specified value.

4. Connect the fuel main line and return

line.

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 517
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the fuel filler hose on the fuel tank,

torque tighten the mounting clamp to
specified value.

6. Refit the breather hose on the fuel tank.

7. Connect the fuel float sensor electrical

connector.

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
518 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.14 Fuel Tank Gauge Unit R&R

5.6.14.1 Component Location Index

5.6.14.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit Fuel Tank Assembly.
• Remove Fuel Tank Assembly. • Carry-out fuel system air bleeding
procedure.
• Check and ensure proper functioning of
engine.

Tools Required

Size Type Quantity

7 mm Socket spanner 1

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 519
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.14.3 Removal

1. Remove Fuel Tank Assembly. For

additional information refer to Fuel Tank
Assembly R&R section.

2. Press the coupler clip over the fuel tank

and disconnect the float sensor connector.

3. Using a 7 mm socket spanner, loosen

and remove the mounting bolts of Fuel tank
gauge Unit.

4. Remove the Fuel Tank Gauge Unit.

5.6.14.4 Inspection
1. Check the fuel tank gauge unit for any damage and replace it if necessary.
2. Check the fuel tank gauge unit function and replace it if necessary.

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
520 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.6.14.5 Installation

1. Refit the New rubber gasket & fuel tank

gauge unit assembly on fuel tank, torque
tighten the mounting bolts to specified value.

2. Connect the fuel float sensor electrical

connector.

3. Refit Fuel Tank Assembly. For additional

information refer to Fuel Tank Assembly R&R
section.

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 521
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.7 Technical Specification

5.7.1 Specification

Component Description Specification

Type 3 Cyl. Radial plunger

HPP Pump Maximum Pressure 1600 Bar

Maximum Pump Speed 3000 RPM

Type CRI 2.2

Fuel Injector Maximum Pressure 1600 Bar

IMA 7 digit

Common rail — HFR (Hot

Type
Forged Rail)

Maximum Pressure 1600 Bar

Fuel Rail RDS 4.2 - Common rail and
Rail components Rail Pressure sensor as
assembly

Mounting Lugs 2

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
522 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5.8 Torque Specification

5.8.1 Tightening Specification

Place of Application Torque in Nm

COMMON RAIL MOUNTING BOLT 25 ± 3 Nm

HIGH PRESSURE PIPE NUT ON PUMP 27 ± 2 Nm

HIGH PRESSURE PIPE NUT ON COMMON RAIL 35 ± 2 Nm

HIGH PRESSURE PIPE NUT ON INJECTORS 27 ± 2 Nm

INJECTOR CLAMP STUD 22.5 ± 2.5 Nm

INJECTOR CLAMP NUT 25 ± 3 Nm

FIP SPROCKET NUT 72 ± 3 Nm

CLAMP HPP TO RAIL FOR PLASTIC MANIFOLD 10 ± 2 Nm

FUEL TANK MOUNTING 25 ± 5 Nm

FUEL LID ACTUATOR MOUNTING 3.5 ± 0.5 Nm

FUEL NECK MOUNTING 7 ± 1Nm

FUEL TANK CONNECTING HOSE REGULAR 5.5 ± 1 Nm

FUEL LINE WORM CLIP MTG 3.5 ± 0.5 Nm

FLOAT MOUNTING ON FUEL TANK 1.7 ± 0.5 Nm

FUEL FILTER MTG ON BODY BRKT. 45 ± 7 Nm

FUEL FILTER MTG ON BODY 25 ± 5 Nm

FUEL NECK WORM CLAMP 7 ± 1 Nm

FUEL TANK MTG. ON CHASSIS 25 ± 5

ASSY MAIN FUEL LINE A ND FUEL LINE FIP TO CONN 25 ± 5

FUEL NECK MTG. 7±1

STRAINER MTG. ON FUEL TANK 3.5 ± 0.5

FUEL LINK WORM CLIP MTG. 3.5 ± 0.5

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 523
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Place of Application Torque in Nm

FUEL TANK HOSE CLIP CONNECTING PIPE 4.5 ± 0.5

FITMENT OF FUEL LINE 4.5 ± 0.5

5.9 Mahindra Special Tools (MST)

Tool
MST NO Illustration
Name

Injector
0305BAM0001ST Removal
Tool

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
524 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6 COOLING SYSTEM

6.1 Description and Operation

Above schematic gives the coolant flow circuit with the components. The coolant flow is
controlled by the thermostat. In addition to the cylinder head and block, the coolant also
circulates through oil cooler, HVAC heater core. Cooling system is designed to dissipate the
excess heat energy liberated from engine combustion. It maintains the engine temperature in
specified range to achieve the maximum combustion efficiency at all engine speeds, in
different operating conditions.
The cooling system is designed for the following functions:
• Remove & dissipate excess heat from the combustion process.
• To maintain the optimum temperature for complete and uniform combustion.
• To provide heating for the heater system. (In the models where the heater is provided).
The cooling system has following components:
1. Radiator.
2. Viscous fan.
3. Thermostat.
4. Water pump.

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 525
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Degassing tank.
6. Coolant hoses & Coolant.
7. Pressure cap.

6.1.1 Radiator

The radiator is a heat exchanger that

dissipates the heat from the coolant passing
through it.

The coolant flows inside the radiator from LH

to RH. The cool ambient air flows thru the
fins of the radiator . The heat exchange
happens between the coolant to air.

6.1.2 Degassing tank

Function of the degassing tank is to remove

air bubbles or vapour from the cooling
system. Proper filling of the coolant inside
the cooling system is must in order to
pressurize the system.

6.1.3 Coolant Temperature Sensor

Coolant temperature sensor is a negative

temperature coefficient sensor in which
resistance increases with decrease in
temperature and vice versa.

This sensor is fitted on the cylinder head

coolant outlet pipe to radiator and senses the
coolant temperature

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
526 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.1.4 Viscous Fan

A viscous fan is connected to a drive pulley

by viscous coupling. The drive for the pulley
is taken from the water pump end (drive ratio
is 1:31 with crank shaft). The fan cools the
radiator which in turn cools the engine
coolant.
The viscous fan is placed behind the radiator
core. The fan drive engages or disengages
depending upon the temperature of air
passing through radiator core and reaching
the bimetallic coil on the fan. The fan will
engage high speed at the temperature of 77°
C (170.6 ° F) and will disengage to normal
speed at 45° C (113 °F).
The viscous coupling works according to the
following principle. When the air surrounding
the coupling crosses the designed limit, the
coupling engages the fan with the pulley by
transferring the positive drive to the pulley
and provides more cooling to the radiator.
When the air surrounding the coupling flows
down, the fan gets disconnected from the
pulley and rotates freely.

6.1.5 Thermostat

Thermostat valve is a coolant flow control

device which is operated by virtue of heat
received from the engine coolant flowing
across it. Thermostat valve helps in
regulating the operating temperature of
engine by controlling the amount of coolant
flowing through the radiator.
When engine and coolant are relatively
colder, the thermostat valve remains closed
thereby preventing the coolant from flowing
through the radiator, coolant flows directly to
the water pump inlet through bypass hose,
because of this, coolant and the engine
progressively get warmer.
Once engine and coolant are warm enough,
the valve start opening up, thereby allowing
coolant to flow through the radiator, thus
thermostat keeps the coolant temperature
within the range to improve the combustion
efficiency of the engine.

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 527
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.1.6 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.
The water pump impeller is pressed onto 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.
The water pump is not serviceable and has
to be changed as an assembly.

6.1.7 Viscous Fan Logic

• The Viscous fan drive engages or disengages depending upon the temperature of air
passing through radiator core and reaching the bimetallic coil on the fan. The fan will
engage high speed at the temperature of 77° C (170.6 ° F) and will disengage to normal
speed at 45° C (113 °F).

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
528 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.2 Component Location Index

A. Thermostat. G. Degassing tank.

B. Radiator Inlet hose. H. Pressure cap.

C. Bypass Radiator hose. I. Viscous fan.

D. Hose radiator to degassing tank (Vent

J. Water pump.
hose).

E. EGR Cooler. K. Radiator.

F. EGR Cooler inlet hose. L. Radiator outlet hose.

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 529
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.3 Component Location Index — Euro II

A. Radiator inlet hose. G. Hose radiator to tank.

B. Thermostat bypass hose. H. Water pump.

C. Cylinder head outlet pipe. I. Viscous fan.

D. Thermostat. J. Radiator.

E. Degassing tank. K. Radiator outlet hose.

F. Pressure cap.

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
530 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.4 Trouble Shooting

Refer below chart for various symptoms, causes and there remedial actions -

Symptom Causes Remedial action

Engine does not Thermostat valve stuck at ● Check and replace the thermostat
reach normal partial/fully open condition. if require.
operating
temperature. Check the accessory drive ● Replace the drive belt if any
belt for abrasion, cracking, abnormalities found.
improper installation, uneven
rib wear, misalignment,
chunk-out, gravel penetration
and piling.

Cooling system 1. Mechanical damage in ● Tighten the bolts on shroud, and

component noisy. shrouds. replace the shrouds if required.

2. Loose water pump impeller ● Replace the water pump.

or bearing failure.

3. Drive belt damaged. ● Replace the belt.

4. Rough surface on the drive ● Replace the drive pulley.

pulley.

5. Improper belt alignment. ● Check the belt alignment and

rectify.

6. Cooling fan blade damage. ● Replace the cooling fan.

Engine getting over 1. Coolant level is too low . ● Maintain the coolant level between
heated (excessively MIN and MAX marking on the
high engine coolant degassing tank when coolant is at
temperature) normal room temperature and the
vehicle is parked on flat-horizontal
surface.

2. Leakages in the cooling ● Check and repair if any coolant

system. leakages from radiator, hose, joints,
thermostat housing, and water
pump, cylinder head, crank case,
cabin heater etc.

3. External blockages in heat ● Check and clean/clear external

exchangers restricting the air blockages from core/fins of the
flow. radiator, condenser.

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 531
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

4. Contaminated or aged ● Drain and refill fresh recommended

coolant mixture inside coolant mixture.
system.

5. Thermostat valve stuck at ● Replace the thermostat valve.

closed condition.

6. Faulty pressure cap. ● Check and replace the pressure

cap if necessary.

7. Faulty or damaged drive ● Replace the drive belt.

belt.

8. cooling fan not working ● Diagnose and identify the root

cause

Noisy cooling fan. 1. Fan blades striking with ● Locate the fan blade contact and
surrounding object. repair it if necessary.

2. External blockages in the ● Check and clean/clear external

heat exchangers restricting blockages from core/fins of radiator,
the air flow. condenser.

Coolant entry into 1. Low cylinder head torque. ● Replace the cylinder head gasket,
crankcase or and adjust the torque as per
cylinder block. procedure.

2. Faulty cylinder head ● Replace the cylinder head gasket

gasket. with a new one.

Coolant spill over 1. Coolant level is too high. ● Park the vehicle on flat horizontal
from degassing surface and allow the coolant to cool
tank. down to ambient temperature. Check
and correct coolant level.

2. Coolant level is too high ● Check whether the degassing tank

and insufficient sealing cap is tightened sufficiently.
between the degassing tank
neck and pressure cap. ● Check sealing of pressure cap. If
required replace the degassing tank
assembly.

3. Engine getting over ● Check and clean/clear external

heated. blockages from core/fins of radiator,
condenser.

Observed water in 1. Coolant mixes with oil. ● Check and rectify.

oil cooler

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
532 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

2. Oil cooler punctured/ ● Carry out the pressure test and

damaged between coolant replace the oil cooler if required.
and oil passage.

3. Blow holes causing the ● Check and rectify.

coolant and oil to mix with
each other in crankcase
galleries.

No coolant flow 1. Restricted return inlet in ● Remove restriction.

through heater core water pump.

2. Heater hoses collapsed or ● Pressure test to isolate & repair.

restricted.

3. Restricted heater core. ● Remove restriction or replace.

4. Restricted outlet in the ● Remove restriction.

thermostat housing.

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 533
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.4.1 Component Inspection Table

Component Inspection Action

Water Pump 1. Check for leakages. ● Replace the water pump if leakage
found.

2. Check for bearing noise. ● Replace the water pump if any

bearing noise noticed.

Viscous Fan 1. Check for physical ● Replace the fan if any damage
damage. found.

2. Check for fan noise. ● Check for any foreign particles on

the fan blades. Replace the fan if
required.

3. Check for both high speed ● Rectify if any abnormalities noticed.

and normal speed
functionality

Degassing Tank Check for physical damage ● Replace the degassing tank.
like cracks, wear and tear.

Thermostat 1. Check for physical ● Replace the thermostat assembly.

damage.

2. Check thermostat normal ● Perform thermostat valve test and

operation. replace if required.

Radiator 1. Check for physical ● Replace radiator if required.

damage, fin distortion etc.

2. Check for radiator ● Flush the radiator, replace only if

blockage. required.

Pressure cap 1. Check the cap for physical ● Replace if required.

damage.

2. Check pressure cap for ● Perform pressure cap test and

leakage. replace if required.

Coolant Hoses Check hoses for cracks, ● Replace the concerned hose and
distortion or flaring. perform coolant pressure test.

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
534 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.5 Standard Checking Procedures

6.5.1 Water Pump Leakage Test
Typical sign of failed water pump is leakage through the seal and bearings. Water pump has a
small hole below where the coolant will seep out if the seal or bearing is failed. If the water
pump is leaking replace the pump as soon as possible. Water pump failure can be confirmed
by below steps:
1. Remove the Viscous fan.
2. Rotate the water pump pulley and check for free rotation.
3. Check for water leakage through the leakage hole.
4. Replace the water pump, if necessary.

6.5.2 Thermostat Valve Test

1. Remove the thermostat valve from the 4. Keep track of water temperature and
thermostat housing, by removing the respective valve opening/travel.
respective mounting bolts. For additional
information refer to Thermostat R&R section.

• Thermostat and thermometer bulb

should be suspended in water. If they
touch bottom or the sides then
temperature in which thermostat /
thermometer operate will not be
correct and wrong diagnosis will take
place.

2. Insert the thermostat valve in to a

container filled with water. 5. Thermostat should start opening at 92+2
° C (0.1 mm travel). Once temperature
3. Heat the container and measure the reaches 98+2 °C valve should be fully open,
temperature of water by using a digital at this moment, valve travel will be
thermometer. approximately 8 mm.

6. In case thermostat valve behavior does

not confirm to above specifications, it should
be replaced.

• Use extreme caution while the engine

is running. Do not stand in a direct line
with the fan. Do not put your hands
near the pulleys, belt or fan. This will
lead to personal injury

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 535
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.5.3 Cooling System Leakage Test

1. Force low air pressure into the system

which cause the coolant to pour or drip from
any leak in the system.

• Should not over pressurize the

system, since this may lead to
leakages and bursting of the coolant
hoses. Refer to the pressure ratings
prior to the test.

2. Using the pressure tester which is

essentially a hand- operated air pump,
pressurize the system for leak detection.

• Refer to the pressure ratings of the

system/cap before pressuring an
external tester/device; else it will
damage the hose leading to leakage.

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
536 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.6 Care of the System

Observe the following precautions when disassembling or servicing the cooling system and its
components.
• Ensure that the work place is a dust free environment.
• Do not remove the degassing tank cap or the engine coolant plate drain with the engine in
hot condition.
• If the coolant is not contaminated then collect the coolant in a clean container so that it can
be reused. Replace coolant as per recommendation.
• Always ensure that spring band clamp position is with respect to hose as per paint marking.

White Marking Engine End Yellow Marking Radiator End

• Before installing or servicing the cooling system, clean the outer surface of the parts.
• Prevent entry of foreign objects during servicing the cooling system parts.
• Use cloth to clean the parts, common shop rags can leave lint that might interfere with the
operation of the cooling system parts.
• Avoid twisting or stressing of the engine cooling hoses.
• Always maintain coolant level to the recommended level.

• Do not commence repair operations of the cooling system until the engine is
switched OFF and cooled down considerably. The pressure within the system is
extremely high which will cause personal injury.
• Never open the degassing tank pressure cap when coolant is hot. The pressure
within the system is extremely high, failure to follow this instruction will cause
personal injury.

• Eye protection must be worn while working near the cooling system, failure to
follow this may cause personal injury.

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 537
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Precautions with Degassing Tank

1. Do not open pressure cap when coolant in heated condition (Immediately after turning
OFF the engine).
2. Coolant level shall be between Max line to Min line.
3. Ensure proper tightening of the pressure cap.
4. Ensure recommended coolant is filled.

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
538 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.6.1 Coolant Level & Leak - Inspect

Coolant – BASF MAKE "GLYSANTIN" G 30 #

Note: # Mix non-conductive (de mineralized) water with coolant externally & fill upto the max
level.
Ratio : 30% Coolant + 70% water for temperatures up to -10°C, Below -10°C use 50% Coolant
+ 50% water.
Capacity – ~ 7.5 Litres.

1. Inspect the degassing tank pressure cap

for any damage or coolant leakage. Rectify
the leakage if found.

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 539
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2. Check the coolant level in the degassing 5. Inspect the coolant leakages at radiator
tank, it should be between MAX and MIN outlet hose, T connector and water pump inlet
marks. pipe connection. Also inspect the mounting
spring band clamp for any damage, replace if
found loose or damage.
Check the coolant level when the engine
is cold.

3. If found below MIN mark then top it up

with BASF MAKE "GLYSANTIN" G 30 #"
(ready to use coolant. no need to mix water).

4. Inspect the coolant leakages at the

degassing tank outlet hose and vent hose to
degassing tank. Also inspect the mounting
spring band clamp for any damage, replace if
found loose or damage.

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
540 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Check for evidence of coolant leakages 8. Inspect for coolant leakage at EGR
at degassing tank outlet hose both ends for cooler Inlet hose, outlet & heater inlet hose.
any leakage, rectify if any leakage found. Also check the mounting spring band clamp
Also inspect the mounting spring band clamp for any damage, replace the spring band
for any damage, replace if found loose or clamp if found damaged or loose.
damage.

9. Inspect for coolant leakage at water

pump housing inlet from Oil cooler, heater
outlet joint. Also check the mounting spring
band clamp for any damage, replace the
spring band clamp if found damaged or
loose.

7. Inspect the coolant leakages at

thermostat hoses, engine coolant outlet pipe
and thermostat housing. Also inspect the
mounting spring band clamp for any damage,
replace if found loose or damage.

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 541
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10. Inspect oil cooler inlet & outlet hoses for

coolant leakage, rectify the leakage if found.
Also inspect the mounting spring band clamp
for any damage, replace the mounting spring
band clamp if found damaged or loose.

11. Inspect the heater inlet & heater outlet

hoses for any coolant leakage, rectify if found
any leakage. Also inspect the mounting
spring band clamp for any damage, replace if
found damaged or loose.

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
542 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Never remove the degassing cap when the engine is hot.

• Use BASF MAKE "GLYSANTIN" G 30 # coolant.
Note: # Mix non-conductive (de mineralized) water with coolant externally & fill upto
the max level.
Ratio : 30% Coolant + 70% water for temperatures up to -10°C, Below -10°C use 50%
Coolant + 50% water.
• Coolant level and leaks to be checked at every regular service.
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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 543
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.6.2 Coolant - Replace

Coolant – BASF MAKE "GLYSANTIN" G 30 #

Note: # Mix non-conductive (de mineralized) water with coolant externally & fill upto the max
level.
Ratio : 30% Coolant + 70% water for temperatures up to -10°C, Below -10°C use 50% Coolant
+ 50% water.
Capacity – ~ 7.5 Litres.

6.6.2.1 Engine Coolant Drain Procedure:

1. Position the vehicle on a 2 post lift / 4 3. Open the degassing tank cap by rotating
post lift. it in anti-clockwise direction.

2. Open the bonnet.

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
544 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Remove the drain plug with the help of a

flat end screw driver and allow the entire
coolant to get drained.

5. Allow the entire fluid to get drained.

• Place a tray beneath the drain plug to

collect coolant drained.

6. Refit the radiator drain plug back and

tight it properly.

6.6.2.2 Engine Coolant Filling & De-aeration Procedure:

1. Fill the recommended coolant in 4. Check coolant level in degassing tank

degassing tank up to MAX mark on and add coolant to MAX level.
degassing tank.

2. Check all the hoses & clamps for

leakage and correct fitment.

3. Start the engine and run at approx. 3000

rpm for about 7 minutes, So that the
thermostat valve will open.

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 545
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the degassing cap.

• Never remove the degassing cap when the engine is hot.

• Use BASF MAKE "GLYSANTIN" G 30 # coolant.
Note: # Mix non-conductive (de mineralized) water with coolant externally & fill upto
the max level.
Ratio : 30% Coolant + 70% water for temperatures up to -10°C, Below -10°C use 50%
Coolant + 50% water.
• Coolant to be replaced first at 40,000 kms/24 Months & 80,000 kms / 48 Months
(Distance Covered in km / Months in service whichever is earlier).
• Do not overfill the system; allow free space in the degassing tank for expansion of
the fluid.
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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
546 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7 In Car Repairs

6.7.1 Degassing Tank R&R

6.7.1.1 Component Location Index

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 547
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Carry-out coolant filling and de-aeration
• Open the bonnet. procedure.
• Check for traces of leakage from
degassing hose joints.

Removal steps:
1. Remove the degassing tank mounting bolts.
2. Disconnect the radiator outlet to degassing tank hose.
3. Disconnect the degassing tank outlet hose.
4. Remove the degassing tank.
Tools Required

Size Type Quantity

- Hose clip plier 01

10 mm Socket spanner 01

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
548 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.1.3 Removal:

1. Open the degassing tank cap. 4. Lift the degassing tank, using hose clip
plier unclip the hose clip and then detach
outlet hose from degassing tank.

2. Using 10 mm socket spanner, remove

the degassing tank mounting bolts.
5. Remove the degassing tank.

3. Using a hose clip plier, unclip the spring

band clamp of vent hose first and then
detach the vent hose from degassing tank.

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 549
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.1.4 Inspection:
1. Check degassing tank for any damages, replace if found.
2. Check hoses for any damages, cracks or kinks, if found replace the hose assembly.
3. Check degassing hose clamps for proper fitment, if found loose then replace the clips.

6.7.1.5 Installation:

1. Refit the degassing tank outlet hose. 3. Refit the degassing tank, torque tighten
Fasten the hose using mounting clamp. the mounting bolts to specified value.

2. Refit the degassing tank vent hose. 4. Carry-out coolant filling and de-aeration
Fasten the hose using mounting clamp. process. For additional information refer to
Coolant filling and de-aeration section.

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
550 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.2 Viscous Fan R&R

6.7.2.1 Component Location Index

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 551
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check the viscous fan operation.
• Open the bonnet.

Removal steps:
1. Remove the radiator shroud mounting bolts.
2. Detach the shroud from radiator.
3. Remove the Viscous fan along with shroud.
Tools Required

Size Type Quantity

- Hose clip plier 01

10 mm Socket spanner 01

36 mm Open end spanner 01

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
552 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.2.3 Removal:

1. Remove the degassing tank mounting 3. Remove the viscous fan mounting nut
bolts. using 36 mm open end spanner.

2. Remove the tank mounted vent hose

using the hose clip plier, and slightly lift the
tank to gain access to radiator shroud and
• Note that the threads are anti-
fan assembly.
clockwise threads. Hence to loosen
then the direction of rotation has to be
clockwise when viewed from front.
• Do not tamper or service the center
portion of the fan.

4. Carefully take out the thermostat bypass

hose from the shroud clamps.

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 553
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Remove the radiator shroud mounting

bolts using 10 mm socket spanner.

6. Carefully take out both the radiator

shroud and viscous fan assembly from the
vehicle.

6.7.2.4 Inspection:
1. Check Viscous fan blades for any damages.
2. Check for dust accumulation, clean with pressurised air.

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
554 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.2.5 Installation:

1. Position the radiator shroud and viscous 2. Refit the shroud side mounting bolts,
fan assembly. torque tighten the bolts to specified value.

• Ensure the shroud bottom mountings Refit the thermostat bypass hose on the
are snap fitted properly on radiator. shroud clamps.

3. Refit the viscous fan on water pump

pulley, torque tighten the mounting nut to
specified value.

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 555
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Refit the radiator vent hose on degassing

tank, fasten it using the mounting clamp.

5. Refit the degassing tank mounting bolts,

torque tighten the bolts to specified value.

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
556 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.3 Thermostat R&R

6.7.3.1 Component Location Index

6.7.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Park the vehicle on a flat surface. • Top up recommended coolant if found
below MIN mark on degassing tank,
always maintain the coolant level between
MAX and MIN mark on degassing tank.
• Check for coolant leakage or seepage
from thermostat housing.

Tools Required

Size Type Quantity

10 mm Ring spanner 1

10 mm Socket spanner 1

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 557
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.3.3 Removal:

1. Drain the coolant. For additional

information refer to Coolant draining section.

2. Using 10 mm socket spanner, loosen

and remove the thermostat housing
mounting bolts.

While loosening the bolts, hold the nut

with 10 mm ring spanner.

3. Pull-out the thermostat housing along

with the hoses and gently remove the
thermostat valve.

6.7.3.4 Inspection:
• Check thermostat valve opening and closing temperatures, if found deviation from specified
value, replace the thermostat.
• Check travel of thermostat valve, if found deviation from specified value, replace the
thermostat.

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
558 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.3.5 Installation:

1. Place the thermostat valve into the

housing.

2. Refit the thermostat housing. Torque

tighten the mounting bolts to specified value.

3. Refill the coolant. For additional

information refer to Coolant filling and de-
aeration section.

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 559
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.4 Hose Radiator to Degassing tank R&R

6.7.4.1 Component Location Index

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
560 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Top up recommended coolant if found
• Open the bonnet. below MIN mark on degassing tank,
always maintain the coolant level between
MAX and MIN mark on degassing tank.
• Check for coolant leakage or seepage
from vent hose joints.

Removal steps:
1. Remove the hose mounted clamp from degassing tank end.
2. Remove the hose mounted clamp from radiator end.
3. Remove the hose radiator to degassing tank.
Tools Required

Size Type Quantity

- Hose clip plier 01

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 561
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.4.3 Removal:

1. Using hose clip plier loosen and remove

the hose mounted clamps from radiator outlet
and degassing tank end.

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
562 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.4.4 Inspection:
1. Check degassing tank vent hose for any damage, cracks, kinks and degradation. If found
replace the vent hose with a new one.
2. Check degassing tank vent hose clamps for proper tightness and damages, replace the
clamps if required.

6.7.4.5 Installation:

1. Refit the hose on radiator outlet and

degassing tank, fasten the hose using
mounting clamps.

Route the hose radiator outlet to

degassing tank, using the degassing
tank mounted locking brackets.

2. Check the coolant level and top-up if

required.

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 563
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.5 Hose assembly radiator outlet R&R

6.7.5.1 Component Location Index

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
564 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Top up recommended coolant if found
• Open the bonnet. below MIN mark on degassing tank,
always maintain the coolant level between
MAX and MIN mark on degassing tank.
• Check for coolant leakage or seepage
from hose joints.

Removal steps:
1. Disconnect bypass hose from thermostat housing.
2. Disconnect hose from degassing tank outlet.
3. Disconnect hose from radiator outlet
4. Disconnect hose from water pump inlet.
5. Remove radiator outlet hose assembly.
Tools Required

Size Type Quantity

- Hose clip plier 1

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 565
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.5.3 Removal:

1. Using hose clip plier compress and 4. Using a hose clip plier loosen the radiator
unclip the bypass hose from thermostat outlet mounted clamp, further disconnect the
housing end. hose.

2. Carefully take out the thermostat bypass 5. Using a hose clip plier loosen the water
hose from the shroud clamps. pump housing mounted hose clamp, further
disconnect the hose.

3. Using a hose clip plier loosen and

6. Remove hose assembly radiator outlet.
remove the mounting clamp further
disconnect the degassing tank outlet hose.

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
566 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.5.4 Inspection:
1. Check radiator outlet assembly hose for any damage, cracks, kinks and degradation. If
found replace the hose with a new one.
2. Check radiator outlet assembly hose clamps for proper tightness and inspect for
damages, replace if required.

6.7.5.5 Installation:

1. Connect the water pump housing inlet 3. Connect degassing tank outlet hose,
hose, fasten the hose using mounting clamp. fasten the hose using the mounting clamp.

2. Connect radiator outlet hose, fasten the 4. Connect the bypass hose on thermostat
hose using the mounting clamp. housing, fasten the hose using mounting
clamp.

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 567
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the thermostat bypass hose on the

shroud clamps.

6. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

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
568 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.6 Water Pump R&R

6.7.6.1 Component Location Index

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 569
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.6.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Alternator/Power steering pump
• Remove Viscous fan. accessory drive belt.
• Refit water pump/AC Compressor drive
• Remove Alternator/Power steering pump
belt.
accessory drive belt.
• Remove water pump/AC Compressor • Remove Viscous fan.
drive belt. • Carry-out coolant filling and de-aeration
procedure.
• Drain the coolant.
• Check for any coolant leakage from water
pump.

Tools Required

Size Type Quantity

12 mm Socket spanner 1

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
570 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.6.3 Removal:

1. Remove the viscous fan assembly. For

additional information refer to Viscous fan
R&R section.

2. Remove Alternator/Power steering pump

accessory drive belt. For additional
information refer. Auto Tensioner & Belt
(Alternator/Power Steering) - Replace
section.

3. Remove Water Pump/ AC Compressor

accessory drive belt. For additional
information refer Auto Tensioner & Belt
(Water Pump/ AC Compressor) - Replace
section.

4. Drain the coolant. For additional

information refer to Coolant draining section.

5. Using 12 mm socket spanner &

combination spanner remove the water pump
mounting bolts.

6. Remove the water pump assembly.

6.7.6.4 Inspection:
1. Check the water pump impeller for any cracks or damage, replace the water pump if
found any.
2. Check water pump mounting face on engine block for any damages.
3. Check water pump impeller for free rotation

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 571
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.6.5 Installation:

1. Apply recommended sealant on water

pump surface, Refer sealant pattern &
Loctite.

2. Refit the water pump assembly, torque

tighten the mounting bolts to specified value.

3. Refit Water Pump/ AC Compressor

accessory drive belt. For additional
information refer to Auto Tensioner & Belt
(Water Pump/ AC Compressor) - Replace
section.

4. Refit Alternator/Power steering pump

accessory drive belt. For additional
information refer to Auto Tensioner & Belt
(Alternator/Power Steering) - Replace
section.

5. Refit the viscous fan assembly. For

additional information refer to Viscous fan
R&R section.

6. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

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
572 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.7 Radiator R&R

6.7.7.1 Component Location Index

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 573
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.7.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit Front Grill assembly
• Open the bonnet. • Refit the degassing tank assembly
• Remove the degassing tank assembly • Fill recommended coolant in degassing
• Remove Front Grill assembly tank and maintain level between MIN &
MAX mark. Check radiator joints and
radiator for any coolant leakage.

Removal steps:
1. Disconnect the hose radiator outlet to degassing tank .
2. Remove the thermostat bypass hose from thermostat end.
3. Disconnect the radiator inlet hose.
4. Disconnect the radiator outlet hose.
5. Remove the top seal mounting bolts and the press fit buttons.
6. Remove the top seal.
7. Remove the radiator bracket mounting bolts.
8. Remove the condenser LH & RH seal mounting bolts.
9. Remove the condenser mounting bolts.
10. Remove the radiator assembly.
Tools Required

Size Type Quantity

10 mm / 13 mm Socket spanner 1

— Hose clip plier 1

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
574 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.7.3 Removal:

1. Drain the coolant. For additional 6. Using a hose clip plier loosen the
information refer to Coolant draining section. mounting clamp and disconnect the radiator
inlet hose from thermostat.
2. Remove the degassing tank assembly.
For additional information refer to Degassing
tank R&R section.

3. Remove the front grill assembly. For

additional information refer to Front grill R&R
section.

4. Using a hose clip plier, loosen the

mounting clamp and disconnect the hose
radiator to degassing tank.

7. Using a hose clip plier loosen the

mounting clamp and disconnect the radiator
outlet hose.

5. Using a hose clip plier loosen and

disconnect the mounting clamp of bypass
hose from thermostat end.

8. Remove the radiator shroud mounting

bolts using 10 mm socket spanner.

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 575
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Using a 10 mm socket spanner loosen 12. Using 10 mm socket spanner remove

and remove the radiator top seal mounting the condenser LH and RH seal mountings.
bolts and press fit mounting buttons.

13. Using 10 mm socket spanner remove

10. Using a 10 mm socket spanner loosen the condenser LH and RH mounting bolts.
and remove the radiator top metal bracket
mounting bolts and remove.

11. Using 13 mm socket spanner loosen • Slightly lift the condenser and radiator
and remove the radiator bracket mounting assembly together and remove the
bolts. condenser from the snap fit lock.

• Further rest the condenser assembly

on the frame.

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
576 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14. Carefully lift the radiator assembly and

remove from the vehicle.

6.7.7.4 Inspection:
1. Check radiator fins for damage, replace if found any.
2. Check radiator for coolant leakage, replace if found.
3. Check radiator for dust accumulation, clean with compressed air if dust accumulation is
noticed.
4. Check for free flow of water from radiator top to bottom.
5. Check radiator drain plug for any leakage.

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 577
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.7.5 Installation:

1. Position the radiator back to the vehicle. 3. Refit the condenser seal LH & RH
mountings, torque tighten the mounting bolts
to specified value.

Refit the condenser to the radiator snap

fit lock.
Ensure proper care while installation,
chances for damaging condenser and
radiator is more if not installed properly.

4. Refit the radiator bracket mounting bolts,

torque tighten the bolts to specified value.

2. Refit the condenser mountings, torque

tighten the mounting bolts to specified value.

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
578 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the radiator top metal bracket 7. Refit the shroud side mounting bolts,
mounting bolts, torque tighten the bolts to torque tighten the bolts to specified value.
specified value.

6. Refit the radiator top seal mounting bolts

and the press fit buttons, torque tighten the • Ensure the shroud bottom mountings
bolts to specified value. are snap fitted properly on radiator.

8. Connect the radiator outlet hose, fasten

the hose using the mounting clamp.

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 579
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Connect the radiator inlet hose on 11. Connect the radiator to degassing tank
thermostat fasten the hose using the hose, fasten it using the mounting clamp.
mounting clamp.

12. Refit the front grill assembly. For

10. Connect the bypass hose on thermostat additional information refer to Front grill R&R
end, fasten the hose using the mounting section.
clamp.
13. Refit the degassing tank assembly. For
additional information refer to Degassing tank
R&R section.

14. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

Ensure to mount the thermostat bypass

hose on shroud locking brackets.

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
580 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.8 Coolant Temperature Sensor R&R

6.7.8.1 Component Location Index

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 581
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.8.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check the cluster for proper updation of
• Open the bonnet. coolant temperatures.
• Check and ensure working of viscous fan
at normal and high speed.
• Top up the coolant if required.

Removal steps:
1. Disconnect coolant temperature sensor electrical connector.
2. Remove coolant temperature sensor.
Tools Required

Size Type Quantity

19 mm Open end spanner 01

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
582 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.8.3 Removal:

1. Press the lock and disconnect coolant

temperature sensor electrical connector.

2. Using a 19 mm open end spanner,

loosen and remove the coolant temperature
sensor.

6.7.8.4 Inspection:
1. Check resistance value of coolant temperature sensor at different temperatures,
compare the values with the recommended values.

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 583
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.8.5 Installation:

1. Refit the coolant temperature sensor,

torque tighten the sensor to specified value.

2. Connect coolant temperature sensor

electrical connector.

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
584 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.9 Thermostat Inlet Hose R&R

6.7.9.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Carry-out coolant filling and de-aeration
procedure.
• Check for coolant leakage or seepage
from Thermostat Inlet hose joints.

Tools Required

Size Type Quantity

— Hose clip plier 01

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 585
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.9.2 Removal:

1. Using a hose clip plier unclip the

mounting spring band clamps.

2. Disconnect the Thermostat Inlet Hose

from Thermostat housing and cylinder head
outlet pipe.

3. Remove the thermostat inlet hose.

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
586 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.9.3 Inspection:
1. Check Thermostat Inlet Hose for any damage, cracks, kinks and degradation. If found
replace the hose with a new one.
2. Check Thermostat Inlet Hose clamps for proper tightness and damages, replace if
required.

6.7.9.4 Installation:

1. Connect Thermostat Inlet Hose on

Thermostat housing and cylinder head outlet
pipe, fasten the hose with the help of
mounting spring band clamps.

2. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

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 587
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.10 Oil Cooler Inlet Hose R&R

6.7.10.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Carry-out coolant filling and de-aeration
procedure.
• Check for coolant leakage or seepage
from Oil Cooler Inlet hose joints.

Tools Required

Size Type Quantity

— Hose clip plier 01

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
588 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.10.2 Removal:

1. Using a hose clip plier unclip the

mounting spring band clamps.

2. Disconnect the Oil Cooler Inlet hose from

Oil cooler and cylinder block.

3. Remove the oil cooler inlet hose.

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 589
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.10.3 Inspection:
1. Check Oil Cooler Inlet Hose for any damage, cracks, kinks and degradation. If found
replace the hose with a new one.
2. Check Oil Cooler Inlet Hose clamps for proper tightness and damages, replace if
required.

6.7.10.4 Installation:

1. Connect Oil Cooler Inlet on Oil cooler

and cylinder block, fasten the hose with the
help of mounting spring band clamps.

2. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

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
590 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.11 Oil Cooler Outlet Hose R&R

6.7.11.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the Oil Cooler Inlet Hose.
• Remove the Oil Cooler Inlet Hose. • Carry-out coolant filling and de-aeration
procedure.
• Check for coolant leakage or seepage
from Oil Cooler Outlet hose joints.

Tools Required

Size Type Quantity

— Hose clip plier 01

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 591
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.11.2 Removal:

1. Remove the Oil Cooler Inlet Hose. For

additional information refer to Oil Cooler Inlet
Hose R&R section.

2. Using a hose clip plier unclip the

mounting spring band clamps.

3. Disconnect the oil cooler outlet hose

from oil cooler and oil cooler pipe.

4. Remove the oil cooler outlet hose.

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
592 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.11.3 Inspection:
1. Check Oil Cooler Outlet Hose for any damage, cracks, kinks and degradation. If found
replace the hose with a new one.
2. Check Oil Cooler Outlet Hose clamps for proper tightness and damages, replace if
required.

6.7.11.4 Installation:

1. Connect oil cooler outlet on oil cooler

and oil cooler pipe, fasten the hose with the
help of mounting spring band clamps.

2. Refit the oil cooler inlet hose. For

additional information refer to Oil Cooler Inlet
Hose R&R section.

3. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

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 593
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.12 EGR Cooler Inlet Hose R&R

6.7.12.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Carry-out coolant filling and de-aeration
procedure.
• Check for coolant leakage or seepage
from Oil Cooler Inlet hose joints.

Tools Required

Size Type Quantity

— Hose clip plier 01

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
594 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.12.2 Removal:

1. Using a 10 mm deep socket remove the

NVH mounting bolt & take out the cover.

2. Using a hose clip plier remove the EGR

cooler inlet hose mounted clamps.

3. Remove the EGR cooler inlet hose.

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 595
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.12.3 Inspection:
1. Check EGR cooler inlet hose for any damage, cracks, kinks and degradation. If found
replace the hose with a new one.
2. Check EGR cooler inlet hose clamps for proper tightness and damages, replace if
required.

6.7.12.4 Installation:

1. Refit the EGR cooler inlet hose, fasten

the same using hose clamp.

2. Refit the NVH cover.

3. Carry-out coolant filling and de-aeration

process. For additional information refer to
Coolant filling and de-aeration section.

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
596 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.13 Heater Inlet Hose R&R

6.7.13.1 Component Location Index

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 597
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.13.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on flat surface. • Top up the coolant.
• Remove the NVH cover. • Refit the NVH cover.

Tools Required

Size Type Quantity

10 mm Deep socket spanner 1

– Hose clip plier 1

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
598 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.13.3 Removal

1. Using a 10 mm deep socket remove the

NVH mounting bolt & take out the cover.

2. Using a hose clip plier remove the EGR

cooler outlet hose.

3. Using a hose clip plier remove the heater

inlet hose clamp further detach it.

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 599
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.13.4 Inspection
• Check for any external damage, if found please replace.

6.7.13.5 Installation

1. Refit the heater inlet hose on EGR cooler 4. Carry-out coolant filling and de-aeration
end, fasten the same using hose clamp. process. For additional information refer to
Coolant filling and de-aeration section.

2. Refit the heater inlet hose on heater end,

fasten the same using hose clamp.

3. Refit the NVH cover.

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
600 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.14 Heater Outlet Hose R&R

6.7.14.1 Component Location Index

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 601
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.14.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on flat surface. • Top up the coolant.
• Remove the NVH cover. • Refit the NVH cover.

Tools Required

Size Type Quantity

10 mm Deep socket spanner 1

– Hose clip plier 1

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
602 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.14.3 Removal

1. Using a 10 mm deep socket remove the

NVH mounting bolt & take out the cover.

2. Using a hose clip plier remove the heater

outlet hose clamp and further detach it.

3. Using a hose clip plier remove the heater

outlet hose clamp and further detach it.

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 603
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.7.14.4 Inspection
• Check for any external damage, if found please replace.

6.7.14.5 Installation

1. Refit the heater outlet hose, fasten the 4. Carry-out coolant filling and de-aeration
same using hose clamp. process. For additional information refer to
Coolant filling and de-aeration section.

2. Refit the heater outlet hose on other end,

fasten the same using a hose clamp.

3. Refit the NVH cover.

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
604 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.8 Specifications & Wear Data

Component Description Specification

Type Cross Flow

Coolant BASF MAKE "GLYSANTIN" G 30 #

Filling Volume ~ 7.5 Litres

Radiator Coolant Mixture # Mix non-conductive (de
mineralized) water with coolant
externally & fill upto the max level.
Ratio : 30% Coolant + 70% water for
temperatures up to -10°C, Below -10°
C use 50% Coolant + 50% water

Type Viscous

Fan & Shroud Max fan speed (rpm) – 4500 ±10 %

Speed
Min fan speed (rpm) – 600Approx.

Type of Thermostat Wax type

Thermostat starts opening @ 92 + 2°C with 0.1mm travel

Thermostat
Thermostat complete @ 98 + 2°C with 8mm lift
opening

Max coolant volume 1.1

Min Coolant Volume 0.83

Degassing tank
Expansion Volume 1.23

Total Volume 2.33 Litre

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 605
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6.9 Tightening Specifications & Sequence

Location Torque Nm

Radiator hose clip mounting 5.5 ± 1

Radiator sub assembly worm clip 6±1

Radiator sub assembly and RD1 pipe 4.5 ± 0.5

Radiator and PAS oil tank 18 ± 2

Radiator intake hose 6±1

Degassing tank bracket 15 ± 2

Degassing tank mounting on body 6.5 ± 1.5

Radiator electric fan mounting bolts 4.5 ± 0.5

Recovery tank fit/ top seal condenser 6±1

Thermostat housing mounting bolts 7.5 ± 0.5

Water pump mounting bolts 25 ± 3

Radiator top bracket mounting bolt 18 ± 2

Condenser mounting bolt on radiator 4.5 ± 0.5

Intercooler Duct 2.5 ± 0.5

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
606 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7 CHARGING SYSTEM

7.1 Description and Operation

7.1.1 Charging System Overview
The charging system consists of battery, alternator, voltage regulator, interconnecting wiring
and alternator drive belt. The charging system maintains the charge of vehicle's battery and
provides main source of electrical energy while the engine is running. If the charging system
stops working, the battery's charge would soon get depleted, leaving a "dead battery” in the
vehicle. If the battery is weak due to malfunctioning of charging circuit, the engine may not
have enough electrical current to start the engine.
As long as the engine is running, entire power for the accessories is delivered by the
alternator. The battery would supply power while engine running only if the current capacity of
the alternator is exceeded or when engine is at a very low idle. Charging system malfunction is
indicated through the warning indicator in instrument cluster.

7.1.2 Battery

The battery is an electrochemical

device which converts the chemical
energy into the electrical energy.

The battery system is designed to

function as a resource of electrical
energy to supplement the charging
system for short durations while the
engine is running and when the
electrical current demands of the
vehicle exceed the output of the
charging system.

7.1.3 Alternator (With OAP) & Voltage Regulator

An alternator consists of two main

components rotor and stator. The rotor
is connected directly to the Over
running Alternator Pulley (OAP). The
drive belt drives the pulley by taking
power from engine, which in turn spins
the rotor. The stator is mounted to body
of the alternator and remains stationary.

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 607
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

The rotor is an electromagnet which

rotates past the stator windings, and
thus the rotor induces an alternating
current in the stator. The induced
current is proportional to the energizing
current of the electromagnet.
Alternating current cannot be used to
recharge the battery, so it must be
converted to direct current before use.
The voltage regulator incorporated in
the alternator adjusts the electricity
produced to the requirements of the
battery and the vehicle. If the alternator
output voltage is too low, the regulator
increases the energizing current in the
rotor windings. If the output voltage is
too high, the regulator decreases the
energizing current in the rotor windings.

Voltage regulator ensures the alternator

voltage upper limit to 14.0 V.

7.1.4 Alternator Drive Belt

Alternator is driven by engine

crankshaft, It gets the driver from the
crankshaft through the accessory belt.
The power transmission is from
crankshaft pulley to alternator pulley
through drive belt.

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
608 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.2 Component Location Index

7.2.1 Charging System
Refer below illustration for charging system layout

A. Battery negative cable. E. Battery.

B. Tray battery separator. F. Battery positive cable.

C. Clamp battery hold down. G. Alternator.

D. Nut Hex.

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 609
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.3 Trouble Shooting

Refer below chart for various symptoms, causes and there remedial actions -

Symptom Causes Remedial action

1. Wiring connections are ● Tighten the connections.
loose.

2. Defective voltage regulator. ● Replace the voltage regulator.

Charging indicator 3. Loose battery connectors. ● Tighten the battery connections.

lamp does not glow
when the ignition is 4. Loose alternator connectors. ● Tighten the alternator
switched ON connections.

5. Indicator Lamp burned out. ● Replace the instrument cluster.

5. Indicator Lamp burned out. ● Investigate through diagnostic

tool.

1. Defective batteries or ● Check the battery, if found

battery terminal connections. damaged, replace the battery. Also
check the battery terminal
connections for proper fitment and
corrosion, clean or replace
accordingly.

2. Blown fuse. ● Check the fuse and replace if

needed.
Battery low or not
charging 3. Defective wiring harness. ● Replace the wiring harness.

4. Faulty alternator. ● Replace the alternator.

5. Loose battery connectors. ● Tighten the battery connections.

6. Loose alternator connectors. ● Tighten the alternator

connections.

7. Defective auto-tensioner. ● Replace the autotensioner.

1. Battery is faulty. ● Replace the faulty battery.

2. Poor contact at voltage ● Tighten the connection

Electrolyte spillage
detection point of the mounting.
(battery electrolyte
alternator.
is depleted in a
short time)
3. Faulty voltage regulator. ● Replace the voltage regulator.

4. Loose or defective cell caps. ●Replace the caps.

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
610 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

1. Faulty/damaged belt. ● Replace the accessory drive
belt.

2. Faulty/damaged alternator– ● Replace the alternator pulley.

Abnormal noise pulley.
from alternator
3. Damaged/defective ● Rectify or replace the alternator
tensioner. belt auto tensioner.
4. Worn alternator bearing. ● Replace the alternator.

7.3.1 Component Inspection and Action Table

Component Inspection Action

1. Physical Damage. ● Replace the alternator assembly.
Alternator
2. Undercharging or ● Replace the alternator assembly.
Overcharging.

1. Physical Damage. ● Replace the battery.

2. Battery dead or no charge. ● Charge the battery as per

recommendation.

3. Electrolyte leakage from top. ● Check for blocked vent hole and
Battery
clean.

4. Electrolyte leakage from ● Check for cracks on body and

sides. replace battery.

5. Electrolyte discoloration. ● Replace the battery.

1. Check for any sulphation at ● Clean the connectors.

connectors.
Wiring Harness
2. Check for any kinks, ● Replace the wiring harness
chaffing or any other damage assembly
to the wiring harness.

1. Check for physical damage. ● Replace the belt if damaged.

FEAD Belt
2. Check for slackness of the ● Replace the belt if required.
belt.

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 611
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.3.2 Diagnosis and Testing

7.3.2.1 Inspection and Verification

1. Verify the customers concern.
2. Visually inspect the charging system for any noticeable signs of mechanical or electrical
damage.
3. If any obvious cause is found, correct the same before proceeding to the next step.

Mechanical Electrical

1. Check for cracks in the battery case and 1. Check whether the main fuse is blown.
for broken terminals.
2. Check the alternator cable terminal for
2. Check the electrolyte level in the battery. corrosion.
3. Check for loose electrical connectors in
the alternator.
4. Inspect the battery terminals for corrosion
and loose connection.
5. Check the charging system warning
indicator connector for loose connection.

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
612 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.4 Standard Checking Procedure

7.4.1 Visual Inspection
Battery service should begin with thorough visual inspection. This inspection may reveal
simple and easily correctable problems.
1. Check for cracks in the battery case and broken terminals which allows electrolyte
leakage. Replace the battery if necessary.
2. Check for any cracked or broken cables/connections, and replace the cables if
necessary.
3. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the
terminals and the battery case top with mixture of water and baking soda. A battery wire
brush tool can also be used to clear heavy corrosion on the terminals. Prevent further
corrosion by applying petroleum jelly to the outside of the terminals.
4. Check for a loose battery hold down and tighten it if necessary.
5. Check the electrolyte level by viewing through the translucent plastic case or removing
the vent caps and looking directly into the battery.
Once battery is dis-connected, following needs to be reset
1. Clock.
2. AM, FM (channels memory).
3. Express Up and Down (For applicable model).

7.4.2 Open Circuit Voltage Test

Digital voltmeter checks the battery’s open circuit voltage. Analogue meters do not
show accurate readings and should be avoided.

1. Turn ON the head lamp high beam for 30 2. Turn OFF the head lamp, disconnect the
seconds to remove any surface charge. battery and connect the digital voltmeter
across the battery terminals.

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 613
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Note the readings in the voltmeter. A fully

charged battery will have an open-circuit
voltage based on below table value

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
614 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.4.3 Dark Current Test.

When the engine is stopped and the ignition switched off, the battery feeds accessories which
are directly connected to battery, such as alarms, clock, radio code and certain computers that
operate continuously. Dark currents are considered normal if they do not exceed a few tens of
milli amperes. If the value is more than that, one or more permanent electrical component is
drawing too much current. They can be isolated by withdrawing the fuses one by one until the
faulty circuit is identified.
A multimeter is the best tool for these measurements. A current clamp cannot accurately
measure currents of less than 1 A. The measurement must be taken at the battery itself.

Before carrying out leakage current test,

• Turn all accessories OFF.
• Switch OFF the ignition and remove the key.
• Close all doors and windows.
• Wait for min. 10 sec and then do the checking procedure.
• In multimeter, current selection should be in millimetre

1. Disconnect the negative terminal from 3. Read the value in multimeter.

the battery.

• Ensure that multimeter in milliampere

mode.

2. Connect the positive terminal of

multimeter (Red one) with the negative
terminal removed from the battery and
connect the negative terminal of multimeter
(black) with negative pole of the battery.

4. If the current measured is more than

permissible value (11 mA), follow diagnostic
procedure mentioned in diagnostic manual.

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 615
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.5 Care of the System

7.5.1 Do’s and Don’ts of Charging System

Do’s Don’ts
1. Ensure that all the charging system 1. Do not short circuit the alternator output
electrical connections are clean enough and leads to check the working of the alternator.
secured properly.

2. Ensure that no electrical connection in the 2. Do not run the alternator when battery is
circuit including the battery is open. disconnected since it might damage the
electronic components.

3. Observe correct polarity while connecting 3. Do not disconnect any lead of the
the battery to alternator i.e. connect negative alternator with the engine in running
to negative and positive to positive. condition.
Otherwise the alternator will be damaged.

4. Disconnect all alternator terminals, while 4. Do not disconnect the battery cables when
carrying out any form of welding on the the engine is running.
vehicle.

5. Disconnect the battery earth cable before 5. Never add acid to the battery.
removing the alternator.

6. Don't use unregulated high output battery

chargers to charge batteries.

7. Don't disconnect battery cables while the

engine is running.

8. Don't add tap water to battery as it may

contain minerals that will contaminate the
electrolyte.

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
616 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.5.2 Service Tips and Precautions

The following points must be considered while handling the charging system and its
components.
1. Swapping the battery connections even for a short period can result in a nonreversible
damage or functional failure of the alternator and this is strictly prohibited.
2. At any case, the alternator should be handled carefully. It should not be dropped or
exposed to any shocks out of normal conditions. Even with little stress caused by hitting,
an invisible pre-damage can occur, which leads to malfunction.
3. The operation of the alternator is only permissible with an assembled regulator and with
connected 12V battery.

• Do not reverse the connections to the alternator and never to disconnect the output
terminal when the alternator is operating.
• Do not short across or ground any of the terminals in the charging circuit.
• Use only approved terminal probe adapters to connect the meter leads and the
jumper wires with the connector terminals. Using improper adapters may damage
the terminals and the charging system.
• Batteries produce toxic gases which may cause personal injury, do not allow
flames, sparks or lighted substances near the battery.
• While charging or working near the battery always shield your face and protect your
eyes. Failure to follow these instructions may result in personal injury.

• In case of acid contact with the skin or eyes, flush immediately for minimum of 15
minutes and seek prompt medical attention. If the sulphuric acid is swallowed
accidentally, immediately make a call for the physician. Failure to follow these
instructions will result in personal injury.

7.5.3 Maintenance
Ensure correct electrolyte level in the battery.
• Check the general conditions of the battery.
• Cables should be examined for cuts, particularly where the strands enter the terminal lugs
and also terminals should be checked for proper fitment.
• Cables should not be ribbing against any sharp corner.
• Ensure that battery ventilation slots are clear.
• Keep the alternator clean.
• Check and ensure the mounting bolts are torque tightened.
• Ensure that belt of alternator is in good condition.

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 617
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Be sure the engine and all accessories are turned OFF before performing
maintenance.
• When washing, ensure that the washing solution does not get into the battery.
• Do not remove the battery connection while engine is running. This may cause
damage to ECU and to other electronic equipment’s.
• Always disconnect the negative terminal cable first from the battery. But when
reconnecting, always connect positive cable first.
• Add only distilled water to the battery.
• Do not fill distilled water beyond the upper mark level. Excessive electrolyte could
squirt out of the battery during heavy charging, causing corrosion or damage.
• Do not fill distilled water beyond the upper mark level. Excessive electrolyte could
squirt out of the battery during heavy charging, causing corrosion or damage.
• The battery with frozen electrolyte can explode if it is used or charged. To prevent
the battery from freezing, maintain full charge in the battery.

• Do not expose the battery to flames or electrical sparks. Hydrogen gas generated by
battery is explosive. Do not allow battery fluid to contact your skin, eyes, fabrics, or
painted surfaces. After touching a battery or battery cap, do not touch or rub your
eyes. Thoroughly wash your hands. If the acid contacts your eyes, skin or clothing,
immediately flush with water for at least 15 minutes and seek medical attention.

7.5.4 Factors Affecting Battery Life

7.5.4.1 Overcharging
Any charging over and above the specified level will result in overcharging. It severely
corrodes positive plate grids which weaken and finally disintegrate. Overcharging decomposes
electrolyte into hydrogen and oxygen which causes excessive concentration of the electrolyte
because of loss of water from the mixture of the battery fluid. This damages the plates and
separators. High temperatures also show adverse effects on plates, separators and container.

7.5.4.2 Undercharging
Perpetual undercharging results in sulphation of plates and running down of cells. Sulphate
deposits are seen on the cell separators, which leak through and create short circuits between
positive and negative plates. Undercharging also leads to buckling of plates.

7.5.4.3 Idle battery

When the battery is not used for a long time or if left idle, self-discharge takes place and
sulphation is observed on battery terminals. Sulphation of the battery reduces the life span of
the battery.

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
618 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.5.4.4 High Specific Gravity

High specific gravity destroys positive and negative plates and also reduces life of the battery.

7.5.4.5 Impure water top-up

Impure water introduces impurities in the battery. Iron and Chlorine in the impure water attack
the plates which affects overall life of the battery. Chlorine bleaches the separators.

7.5.5 How to Handle the Battery

• After connecting the battery cables, ensure that they are securely clamped to
battery terminals.
1. The battery surface (particularly its top) should always be kept clean and dry.
2. The terminal connections should be clean and secure. At every routine maintenance,
clean, tighten and apply petroleum jelly on the terminals.
3. When the vehicle is not going to be used over a long period of time, disconnect the
negative battery terminal. Check the charge condition of the battery.

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 619
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.5.6 How to Recharge a Battery

1. Disconnect the battery and remove it

from the vehicle.

2. Connect the positive terminal of the

charger to the positive terminal of the battery
(red wire).

3. Connect the negative terminal of the

charger to the negative terminal of the
battery (black wire).
There are different types of charge:
• A slow charge is carried out with a low current, usually between 1/20th and 1/40th of the
battery's capacity. This method should be used for batteries in very bad condition (battery
discharged for several weeks).
• A normal charge is carried out with a current of 1/10th of the nominal capacity of the battery.
A full recharge takes several hours.
• A rapid charge can be used to recharge batteries that are approximately 80 % charged,
without damaging them.

• If charging continues on a fully charged battery, bubbles are produced in the battery
cells, which may result in battery explosion.

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
620 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.5.7 Checking Electrolyte Level

1. Remove the vent plugs. 5. Refit the vent plugs properly

• 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.

6. Tighten terminals to specified torques.

2. Check the electrolyte level.

• Check battery electrolyte level at every
3. Add distilled water to all the cells which 10000 kms / 6Months (Distance
require water. Covered in km / Months in service
whichever is earlier).
4. Ensure the electrolyte level between
MINand MAX marks.

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 621
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Specific Gravity v/s With% Charge Specific Gravity v/s With OCV

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
622 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.5.8 Specific Gravity Test

Hydrometer is a float-type device used to determine the State-of-Charge by measuring the
specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's
state of charge and weak or dead cells.

• Wear suitable eye protectors (goggles).

1. With the help of a flat end screw driver,

remove the vent caps or covers from the
battery.

2. Squeeze the hydrometer bulb and insert

the pickup tube into the cell close to the
battery positive terminal.

3. Slowly release the bulb to draw in only

enough electrolyte to cause the float to rise.
Do not remove the tube from the battery.

4. Read the specific gravity indicated on the

float. Be sure the float is drifting free, and
does not contact with sides of the barrel.
Read the hydrometer at eye level. Disregard
the slight curvature of liquid on the float.

5. Note the reading for all the cells. The

difference in specific gravity readings should
not be more than 0.05.
The specific gravity for fully charged battery is as follows:
1. AMARON -1.270±0.010 at 27oC.
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 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 623
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Specific gravity varies with the temperature. If the electrolyte temperature is

substantially above 27° C add seven points (0.007) to the observed specific gravity
reading for every 10° C by which the actual temperature is above 27° C.
• Deduct seven points per 10° C where the observed reading is below 27° C to obtain
the temperature corrected reading at 27° C.
• Check battery specific gravity and conditions of battery terminals at every 10000
kms / 6Months (Distance Covered in km / Months in service whichever is earlier).

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
624 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6 In Car Repairs

7.6.1 Battery R&R

7.6.1.1 Component Location Index

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 625
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.1.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Reset clock.
• Open the bonnet. • Reset AM, FM (channels memory).

Removal steps:
1. Disconnect negative battery terminal.
2. Disconnect positive battery terminal.
3. Remove battery hold clamp.
4. Remove battery.
Tools Required

Size Type Quantity

10 mm Socket spanner 01

13 mm Socket spanner 01

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
626 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.1.3 Removal:

1. Using 10 mm socket spanner, loosen the

mounting nut and disconnect battery
negative terminal first and then the positive
terminal.

2. Using 13 mm socket spanner, remove

the mounting nuts first and then remove
battery hold down clamp.

3. Remove the battery.

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 627
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.1.4 Inspection:
1. Check for cracks in the battery case and broken terminals which allows electrolyte
leakage.
2. Check for any cracked or broken cables/connections, and replace the cables if
necessary.
3. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the
terminals and the battery case top with mixture of water and baking soda. A battery wire
brush tool can also be used to clear heavy corrosion on the terminals. Prevent further
corrosion by applying petroleum jelly to the outside of the terminals.

7.6.1.5 Installation:

1. Place battery in its position. 3. Connect battery positive terminal first

and then negative terminal. Torque tighten
both the terminal nuts to specified value.

2. Refit the battery hold down clamp with

the help of mounting nuts. Torque tighten the
nuts to specified value.

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
628 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.2 Alternator R&R

7.6.2.1 Component Location Index

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 629
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.2.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a 2 post / 4 post • Connect negative terminal of the battery.
lift. • Check and ensure proper functioning of
• Disconnect negative terminal of the charging system.
battery.

Removal steps:
1. Remove alternator drive belt.
2. Remove alternator mounting bolts.
3. Remove alternator charging cable.
4. Remove alternator WL connector.
5. Remove alternator.
Tools Required

Size Type Quantity

8 mm Socket spanner 01

17 mm Open end spanner 01

Socket spanner / Ring

12 mm spanner Each 01

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
630 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.2.3 Removal:

1. Using a 10 mm socket spanner, loosen 4. Press the lock and disconnect alternator
the mounting nut and detach negative excitation current supplying connector.
terminal from battery post.

5. Using 12 mm socket spanner, remove

2. Remove power steering reservoir the mounting nut and detach alternator
mounting bolt using 8 mm socket spanner, output cable.
pull out the reservoir and keep it a side.

3. Remove alternator drive belt. For

additional information refer to Auto tensioner
& belt (Alternator/Power Steering) - Replace)

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 631
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Remove alternator by removing its

mounting bolts using 12 mm socket spanner.

• Hold alternator bottom mounting

bolt’s nut using 12 mm ring/open end
spanner while loosening the bottom
mounting of alternator.

7.6.2.4 Inspection:
1. Check alternator pulley for any damage.
2. Check free play of alternator pulley.
3. Check alternator drive belt for any damage. If found replace with a new one.

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
632 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.2.5 Installation:

1. Refit the alternator with the help of 3. Connect alternator electrical connector.
mounting bolts. Torque tighten the bolts to
specified value.

• While tightening the bottom mounting,

hold the nut using 12 mm ring
spanner.

4. Refit alternator/power steering pump

drive belt. For additional information refer to
Auto tensioner & belt (Alternator/Power
Steering) - Replace)

5. Refit power steering reservoir.

2. Connect alternator main charging

connector with the help of mounting nut,
torque tighten the nut to specified value.

6. Connect battery negative terminal and

torque tighten the nut to specified value.

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 633
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.3 Battery separator tray R&R

7.6.3.1 Component Location Index

7.6.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Refit the battery.
• Turn the ignition OFF and remove the key. • Reset clock, AM, FM (channels memory)
& Express Up and Down (For applicable
• Remove the battery.
model).
• Check and ensure proper functioning of all
electrical systems.

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
634 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.3.3 Removal:

1. Remove the Battery. For additional

information refer to Battery R&R section.

2. Remove the Battery separator tray.

7.6.3.4 Inspection
1. Check battery separator tray for any cracks, degradation. Replace if found.

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 635
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.3.5 Installation:

1. Place the battery separator tray back in

its position.

2. Refit the Battery. For additional

information refer to Battery R&R section.

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
636 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.4 Battery Negative Cable R&R

7.6.4.1 Component Location Index

Tools Required

Size Type Quantity

10 mm Socket spanner 01

14 mm Socket spanner 01

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 637
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.4.2 Removal:

1. Using a 10 mm socket spanner loosen

the mounting nut and remove battery
negative cable from battery.

2. Remove starter motor top mounting bolt

with the help of 14 mm socket spanner and
detach negative battery cable.

3. Remove battery negative cable.

7.6.4.3 Inspection:
1. Check cable for any damage, replace if found.
2. Check terminals for corrosion or sulphation, clean if found.

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
638 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.4.4 Installation:

1. Route the battery negative cable

assembly and attach the clip.

1. Connect negative terminal lower end on

starter motor using mounting bolt and torque
tighten the bolt to specified value.

• While tightening the nut, hold the bolt

with the help of 16 mm ring spanner.

2. Refit cable on battery, also refit engine

wiring harness cable. Torque tighten both the
nuts to specified value.

3. Check and ensure proper working of

electrical systems.

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 639
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.5 Battery Positive Cable R&R

7.6.5.1 Component Location Index

Tools Required

Size Type Quantity

10 mm Socket spanner 01

13 mm Combination spanner 01

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
640 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.5.2 Removal:

1. Using a 10 mm socket spanner, loosen 4. Detach positive cable from battery side
the mounting nut and detach negative by loosening its mounting nut with the help of
terminal from battery post. 10 mm socket spanner.

2. Pull out battery positive cable terminal

5. Using a 13 mm combination spanner,
cover.
remove battery positive cable mounting nut
from starter motor solenoid.

3. Disconnect engine compartment wiring

harness connector by removing its mounting
6. Remove battery positive cable.
nut with the help of 10 mm socket spanner.

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 641
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.6.5.3 Inspection:
1. Check cable for any damage, replace if found.
2. Check terminals for corrosion or sulphation, clean if found.

7.6.5.4 Installation:

1. Refit battery positive cable back on 3. Attach engine wiring harness cable with
starter motor solenoid with the help of the help of mounting nut, torque tighten the
mounting nut. mounting nut to specified value.

2. Insert battery positive cable on battery 4. Place the cover back.

positive pole and torque tighten the locking
nut to specified value.

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
642 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the negative terminal on battery

post.

6. Check and ensure proper functioning of

starting system and other electrical systems.

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 643
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.7 Technical Specification

7.7.1 Battery Specifications

Battery Specifications:

Variant Make Rating Model/Part No Specific Gravity

All Amaron 90AH 105D31R 1.270 ± 0.010 at 27 oC

7.7.2 Alternator Specification

Description Specification

Rating 110 A

Rated output
speed 6000 RPM

Operating speed 1000 to 18000 RPM

Polarity Negative Earth

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
644 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7.8 Torque Specification

Location Torque Nm

Battery mounting on fender 5±1

Battery positive cable 3 ± 0.5

Battery negative cable 4.5 ± 0.5

Earthing cable fit on fender 25 ± 5

Short link mounting negative cable 12 ± 2

Alternator cable mounting regular 10 ± 2

Alternator cable mounting regular RH 10 ± 2

All earthling mounting 9±2

Negative cable mounting on starter motor 12 ± 2

Alternator mounting bracket 30-35

Alternator on Alternator bracket 25±3

PSP on Alternator bracket 25±3

Brace with Alternator 25±3

Auto tensioner WP Side upper end 30-35

Auto tensioner WP Side lower end 25±3

Positive cable mounting on starter motor 12 ± 2

Negative Cable Mtg. On Block 41 ± 7

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 645
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
646 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8 STARTING SYSTEM

8.1 Description and Operation

8.1.1 Starting System Overview
The starting system consists of:
1. Starter Motor
2. Starter Relay
3. Ignition Switch and key
4. Battery
5. Immobiliser
6. Battery Cables
The starting system enables the cranking of the engine when the authorized key is turned to
START position. The Starting system includes a starter motor and starter solenoid that is
attached to the starter motor. The starter motor requires very high current to crank the engine
and is connected to the battery with high tension cables.
The solenoid switch works as an electric switch which when actuated, closes the circuit and
connects the starter motor to the battery and simultaneously it pushes the pinion gear of the
starter motor forward to mesh with the ring gear, thus rotates the flywheel and in turn the
engine.

For cranking the vehicle, the following conditions need to be satisfied:

1. The original vehicle keys should be used.
2. Battery should have the nominal recommended voltage.
3. The wiring harness should be securely connected.

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 647
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.1.2 Battery

The battery is an electrochemical device

which converts the chemical energy into
electrical energy.

The 12V battery is designed to provide safe,

efficient, reliable and mobile means of
delivering and storing electrical energy. This
electrical energy operates the engine starting
system and other vehicle accessory systems
for limited durations while the engine and/or
the charging system are not operating.

Battery absorbs most abnormal or transient

voltages caused by the switching of any of
the electrical components or circuits in the
vehicle.

8.1.3 Starter Motor

The starter motor is composed of three parts,

which are:
● The solenoid, which moves the starter
pinion by means of a fork and at the same
time closes the power circuit to feed the
electric motor.
● The direct current electric motor, which
cranks the engine.
● The fork and pinion assembly, which
makes the connection between the starter
motor and the ring gear on the flywheel.

8.1.4 Ignition Key barrel

The ignition key barrel consists of ignition

switch and steering lock .It is located on the
steering column. The ignition barrel when
switched ON by the mechanical key,
switches the power supply to all controllers.

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
648 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.1.5 Starter Relay

The starter relay is an electromechanical

device that switches battery current to the
starter solenoid when the ignition switch is
turned to the Start position. The starter relay
is made of two separate circuits.

• The control circuit which includes the

electromagnet,
• The power circuit which includes the
contact blade.

The relay has several advantages such

as:
• Reducing the voltage drop caused by very
long circuits.
• Reducing the intensity of the current in
passenger compartment switches and
wiring harnesses.
• Reducing the section of wires in the
system control circuit.

8.1.6 TBI Based Immobilizer System

The immobilizer is a vehicle safety system which immobilizes the vehicle when a wrong key is
inserted into the ignition even if the access into the vehicle is gained. The Immobilizer ECU
prevents the vehicle from being started unless it recognizes signals from a right ignition key

Transponder is a battery less chip moulded

into key fob and communicates with
Immobiliser control unit thru Radio
Frequency signal. Each transponder is
configured with Mahindra Specific codes
during manufacturing. Only the Mahindra
specific codes can be used with immobiliser

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 649
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.1.7 ICU & Transponder Ring (Antenna)

Immobiliser control unit (ICU) is fitted on the

ignition lock barrel. The following are the
functions of ICU:
1. Supplies power to antenna.
2. Receives and analyses signal from the
key via antenna.
3. Conveys the key status information to
EMS ECU thru CAN
The transponder ring is fitted in the ignition
socket, when the ignition key inserted in the
key cylinder, the ignition key transponder
which is configured with Mahindra specific
codes will send a radio frequency (RF) signal
to transponder ring. The transponder ring
securely communicates the code to the
immobilizer ECU

8.1.8 EMS ECU

Engine management system (EMS) ECU is

fitted on the firewall of the engine
compartment. During Ignition ON,
1. ECU sends a challenge to ICU.
2. Analyse the response signal from ICU.
3. Activates the fuel injection and starter
motor if the signal from ICU and key is
authentic

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
650 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.1.9 Immobilizer System Working Flow

Fuel Injection & Cranking:

If the ID code transmitted from the (transponder) does not match the pre-registered code in the
immobilizer control unit (ICU), fuel injection and cranking are not performed by the engine
ECU.
Features of the Immobilizer System:
• Prevents the vehicle being started by anyone not in possession of the correct vehicle key.
• The vehicle is automatically protected after the key is removed from the ignition. At every
ignition ON, if the vehicle does not recognize the correct key code, the engine check lamp
will be illuminate/blink and the engine cannot be started.
• The vehicle will not be protected until the key has been taken out of the ignition.
• If the ID code transmitted from the (transponder) does not match the preregistered code in
the immobilizer control unit (ICU), injection and cranking are not performed by the engine
ECU.

• If the engine check lamp flashes or remains continuously illuminated after the
ignition being switched ON, there is a system malfunction.

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 651
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• In the event of the vehicle not starting with the correct key, switch off the ignition for
a minimum of 1 minute and attempt to start the vehicle again.
Elements involved in the system
1. Transponder based keys.
2. Active Transponder Ring
3. EMS ECU
4. Immobilizer ECU
The transponder ring is fitted in the ignition socket, when the ignition key inserted in the key
cylinder, the ignition key transponder which is configured with Mahindra specific codes will
send a radio frequency (RF) signal to transponder ring. The transponder ring securely
communicates the code to the immobilizer ECU.

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
652 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.2 Micro Hybrid Technology (Engine Stop/Start System, ESS)(If

equipped)
8.2.1 Introduction
Micro hybrid automatically “stops” and “starts” the engine when idle at signals or long traffic
jams. This in turn gives a better fuel efficiency. Engine Stop/Start system is activated by the “
Engine Stop/Start” button in the on IP Center area (Top of the Center bezel). The LED on the
button indicates the status of the button.
Engine Start / Stop System aids in attaining better fuel efficiency on your vehicle and thus
reducing your running costs. However, the mileage improvement will depend upon various
parameters such as prevailing traffic, driving pattern etc.
• When a vehicle is stationary and engine is idling particularly at traffic signals/traffic jams,
considerable amount of fuel is consumed and emission (CO2) is caused.
• If the engine is stopped during idling, we can save fuel and reduce emission.

8.2.2 How does the Engine Start / Stop System work?

Let’s take a simple example of driving in traffic conditions within city. Assume that the vehicle
has stopped at a traffic junction due to a red signal. The following steps illustrate how the
system functions.
• The vehicle has come to a halt at a traffic signal, is in the neutral gear and the clutch pedal
is released.
• The “ Stop/Start” lamp in the cluster will blink indicating that the engine is going to stop
shortly. The engine will shut down automatically after a specific time period.
• The “Stop/Start” lamp will illuminate in the instrument cluster indicating the engine was
stopped by the Stop/ Start System.
• Once the signal turns green, press the clutch pedal and the engine starts immediately.
• The indicator in the cluster goes OFF indicating that the engine has started again and you
are ready to drive on.

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 653
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.2.3 The following inputs are required for Start Stop system to function
1. Mode selection Switch condition
2. Bonnet switch condition
3. Clutch pedal sensor signal (15% & 85% switch)
4. Accelerator pedal input
5. Engine speed
6. Vehicle speed
7. Battery Condition
8. Fuel temperature
9. Coolant temperature

8.2.4 For auto stop to happen the following conditions are to be met:
• ESS system is activated using the selection switch.
• Bonnet is fully closed.
• In the current ignition cycle, the vehicle has crossed 2 kmph at least once
• Current status of the engine is idling.
• Vehicle speed is zero.
• Accelerator pedal and clutch pedal are fully released.
• Vehicle battery should be in healthy condition.
• Engine is warm. This is an extra precaution to ensure safe working of the engine.
• Fuel temperature is less than 60 °C.
• Gear in neutral.

8.2.5 For auto start to happen the following conditions are to be met
• Vehicle should have been stopped by the ESS system
• Gear lever is in the neutral position, Clutch pedal is fully de-pressed.
• Vehicle speed is zero.
• Stop/Start system is in active state.
• Bonnet should be closed

8.2.6 Frequently Asked Questions (FAQ)

1. What is the advantage of the system?
The Stop/Start System aids in attaining better fuel efficiency on your vehicle and
thus reducing your running costs. However, the mileage improvement will depend
upon various parameters such as prevailing traffic, driving patterns, etc.
2. What are the other advantages of the system?

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
654 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Since the engine is switched off during traffic signals/ jams, considerable
amount of CO2 release to the atmosphere is avoided. This reduces global
warming and thus provides us with a cleaner atmosphere to live.
• Ability to start the engine by pressing the clutch pedal.
• Reduces noise pollution at traffic signals.
3. Is it possible to start the engine through the clutch pedal for the first time?
No, the engine can be cranked only with the ignition key for the first time. If the
engine is stopped automatically by the system, only then it is possible to start the
engine through clutch pedal.
4. How to activate/deactivate the system?
The system is activated whenever the Start/Stop switch is pressed. The LED
indication on the Stop/Start switch indicates the status of the system. The system
can be turned OFF or back ON using the Stop/Start switch.
5. Whether the system will get activated as soon as the engine is started the first time with
the ignition key?
No, the Stop/Start system can be activated only by the Stop/Start switch, provided
all listed conditions (in the previous section) are met. This is to ensure better
performance of the engine in terms of fuel economy and durability.
6. What is to be done, if I don’t want the system to stop my engine at traffic signals/Jams?
The system can be turned OFF by the Stop/Start button in the IP center area.
7. Whether the A/C will function, if the engine is switched off?
No, the A/C will not work. However the blower will be in operation when the
ignition is ON.
8. What will happen if I keep the clutch continuously pressed at traffic signals/jams?
The system will not stop the engine if the clutch is continuously pressed since it
indicates the driver’s intention of moving the vehicle immediately.
9. When the battery charge is low, whether the engine will be switched off?
If the battery charge drops below a certain threshold level, the system will not stop
the engine so as to preserve the battery from further draining.
10. Whether I will be able to operate the engine with the normal ignition key?
Yes, normal operation with the ignition key is always possible.
11. Whether the vehicle will start (or) stop in gear?
The vehicle will not start or stop automatically in gear to ensure safety. It will do so
only in the neutral position of the gear lever.
12. Whether the system will stop my engine in moving traffic?
No, the engine will be stopped only when the vehicle speed is zero.
13. Whether the audio system will be switched OFF, when the engine shuts down?
No, the audio system will not be switched OFF and you can continue to enjoy the
music.
14. Whether the engine will re-crank whenever the clutch pedal is pressed?
No, when the engine is running, the starter motor will not attempt to re-crank.
15. If any component involved in the system fails, what will happen?

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 655
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

The system has a built-in diagnostic module which understands the failure and
immediately goes to bypass mode. In the bypass mode the engine can be turned
ON and OFF by ignition key as usual.
16. If the start stop lamps keep blinking at different rate, but does not stop when the
conditions are met, then what does it indicating?
It is indicating that the battery charge/ voltage is coming below a threshold
voltage.

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
656 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.3 Component Location Index

8.3.1 Starting System Overview 1

A. Key Barrel.
B. ICU (Immobilizer Control Unit).

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 657
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.3.2 Starting System Overview 2

A. Solenoid.
B. Starter Motor Mounting Bolts.
C. Starter Motor.
D. Starter Motor Mounting Nuts.

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
658 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.4 Trouble Shooting

8.4.1 Refer below chart for various symptoms, causes and there remedial
actions -

Symptom Possible Causes Remedial action

The battery seems weak or 1. The electrical system • Refer to the Dark current
dead when attempting to ignition-off Dark Current is test Standard Procedure for
start the engine. excessive. the proper test procedures.
• Repair the excessive
ignition-off draw, as required.

2. The charging system is • Determine if the charging

faulty. system is performing to
specifications.
• Refer to Charging System
for charging system
diagnosis and testing
procedures. Repair the faulty
charging system, as
required.

3. The battery is discharged. • Determine the battery state-

of-charge. Refer to the
Standard procedures in this
section for additional test
procedures. Charge the
faulty battery, as required.

4. The battery terminal • Clean and tighten the

connections are loose or battery terminal connections,
corroded. as required.

5. Incorrect battery rating for • Refer to Battery System

this vehicle. Specifications for the proper
size and rating. Replace an
incorrect battery, as required.

6. The battery is faulty. • Replace the faulty battery,

as required.

7. The starting system is • Determine if the starting

faulty. system is performing to
specifications. Repair the
faulty starting system, as
required.

8. The battery is physically • Inspect the battery for loose

damaged. terminal posts or a cracked
and leaking case. Replace

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 659
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedial action

the damaged battery, as
required.

The starter motor does not 1. Faulty battery. • Recharge the battery, or
operate when the ignition replace if required.
is cranked
2. Battery terminals are • Clean the internal surface of
corroded. the connecting lugs and
battery terminal posts.

3. Starter supply is broken or • Check the battery earth.

in poor state.
• Check cable connection at
the starter motor and battery.
• Change the solenoid switch
or rectify the circuit.

4. Starter motor is short • Replace the starter motor.

circuited.

5. Wrong key is inserted. • Check the key and use the

authenticated key.

Starter motor rotates at 1. Starter motor drive • Replace the starter motor
high/low speed but does assembly meshes with the drive assembly.
not crank the engine. gear but does not drive.

2. Starter motor drive • Ensure proper connection

assembly does not mesh of the solenoid and the shift
with the ring gear. lever.

3. Brushes are jammed. • Ensure free movement of

the brushes.

4. Brushes are worn out. • Replace all brushes.

Starter motor rotates in low High electrical resistance • Inspect the internal wiring
speed with normal or low caused by poor connections, electrical connections and
current defective leads or dirty armature commutator.
commutator.

Starter motor cranks the 1. Poor function of the • Replace the solenoid
engine normally, and the solenoid switch. switch.
cranking of the engine
continues though the 2. Short circuit in the wiring • Check and replace the
solenoid switch is released harness. wiring harness.
(ignition back to ON
position) 3. Solenoid shunt winding is • Replace the defective
open. solenoid switch.

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
660 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.4.2 Component Inspection and Action Table

Symptom Possible Causes Remedial action

Starter motor 1. Check the Terminal • If the terminal is damaged,

clamps (+ ve) for damage/ then replace the starter
corrosion. motor.

2. Check for external • If external damage is

damages to the starter motor. noticed on the body / housing
of the starter motor, then
replace the starter motor.

Starter relay 1. Check the starter relay for • If the starter relay fails to
operation. operate, then replace it.

2. Check the starter relay • If the terminals are

terminals for damage. damaged then replace the
relay.

3. Check the starter motor • Clean the terminals with a

relay terminals for corrosion. suitable agent and check the
operation of the starter relay.
If the relay fails to function,
then replace it.

4. Check the seating area of • If there is corrosion on the

the starter motor relay for seating area of the starter
corrosion. relay, then clean the area
with a suitable agent and
check the operation of the
starter relay.

Starter high tension cables 1. Check for damages • If damages are found on the
/splice/ brittleness. high tension cable / wire,
then replace the cable.

2. Check for corrosion at the • Clean the starter high

contact point. tension cable terminal with a
suitable agent.

Mechanical key & Barrel 1. Check for damages to the • If there are damages
mechanical key track. noticed to the track of the
key, then replace the key.

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 661
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedial action

2. Check the ease of key (s) • If the key is hard to remove/

insertion & removal into the install, then inspect the
ignition switch. ignition switch first for debris.
If not, use the second key
and check again. If the same
problem is noticed, then
replace the ignition switch
assembly.

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
662 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.5 Standard Checking Procedure

8.5.1 Diagnosis and Testing
Inspection to be carried out visually for obvious signs of electrical damages in the following
components.
• Check the battery condition and battery terminals.
• Check whether the fuse is blown.
• Check the electrical wiring harness for looseness.
• Check the starter motor connection for looseness.
• Inspect the continuity in the starter motor relay.
• Check the starter motor drive gears.
• Check the wiring harness and connectors in the starter circuit. Physical damage due to
breaking of wires or short circuits.
• Check the earth. Specifically look for rusting especially in older vehicle. Also look for paint/
in earth area (more so if the vehicle had accidents or paint job).

8.5.2 Feed and Earth Checks

It is also necessary to check the feeds and earthing points on the starting circuit. This check
may reveal electrical connections that have deteriorated. Clean and tighten connections if
required. Replace the damaged wiring and components if required.

8.5.3 Wiring and Switches

Visually inspect all wires and switches in the starting circuit for damages, loose or corroded
connections. This includes all ground connections. Clean and tighten connections if required.
Replace the damaged wiring and components if required.

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 663
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.5.4 Starting Relay Check

1. Remove the relay from fuse box. 4. Using a multimeter, check for continuity
between pin numbers 30 and 87 (No power
given to pin number 86 and no earth given
to pin number 85).
• If continuity is there which indicates power
circuit is NOT OK (Short internally).
Replace the relay.
• If continuity is not there, relay is OK.

2. Give 12 volt supply to pin number 86

and earth pin number 85.
• Once supply is given sound can be
noticed which indicated control circuit is
perfect.
• If sound is not noticed, replace the relay.

3. Using a multimeter, check continuity

between pin number 30 & 87. (Power given
to pin number 86 and earth given to pin
number 85).
• If continuity is there, which indicates that
the power circuit is perfect.
• If Continuity is not there then replace the
relay.

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
664 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.5.5 Cranking Voltage Test

The cranking voltage test measures the voltage available for ignition while the starting motor
cranks the engine.
Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the
voltage reading.
1. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking
voltage is normal.
2. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit
or starting motor.
3. Low cranking speed and low voltage may indicate a discharger battery. If the battery is
charger, look for trouble in the starter motor or engine.

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 665
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.5.6 Diagnosis and Testing — Battery Cables.

A voltage drop test will determine if there is excessive resistance in the battery cable terminal
connections or the battery cable. If excessive resistance is found in the battery cable
connections, the connection point should be disassembled, cleaned of all corrosion or foreign
material, then reassembled. Following reassembly, check the voltage drop for the battery
cable connection and the battery cable again to confirm repair.

8.5.6.1 Voltage Drop Test

• The following operation will require a voltmeter accurate to 1/10 (0.10) volt.
• The battery should be fully-charged .
• Engage the parking brake.
• Position the gearshift selector lever in the neutral position and lock the clutch pedal
in the fully depressed position.
• Verify that all lamps and accessories are turned off.
• In-order to avoid the engine from starting, remove the starter relay.

1. Connect the positive lead of the 2. Connect the positive lead of the
voltmeter to the battery negative terminal voltmeter to the battery positive terminal
post and then connect the negative lead of post. Connect the negative lead of the
the voltmeter to the battery negative cable voltmeter to the battery positive cable
terminal clamp . Rotate and hold the ignition terminal clamp. Rotate and hold the ignition
switch in the Start position. Observe the switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the voltmeter. If voltage is detected, correct the
poor connection between the battery poor connection between the battery positive
negative cable terminal clamp and the cable terminal clamp and the battery positive
battery negative terminal post. terminal post.

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
666 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Connect the voltmeter to measure

between the battery positive cable terminal
clamp and the starter solenoid terminal stud .
Rotate and hold the ignition switch in the
Start position. Observe the voltmeter. If the
reading is above 0.2 volt. Clean and tighten
the battery positive cable eyelet terminal
connection at the starter solenoid terminal
stud. Repeat the test

4. If the reading is still above 0.2 volt,

replace the faulty battery positive cable.

5. Connect the voltmeter to measure

between the battery negative cable terminal
clamp and ground on the body. Rotate and
hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is
above 0.2 volt, clean and tighten the battery
negative cable eyelet terminal connection to
the engine block.

6. Repeat the test. If the reading is still

above 0.2 volt, replace the faulty battery
negative cable.

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 667
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.5.7 Starter Solenoid Testing

This test can only be performed with starter motor removed from vehicle.

1. Remove starter motor from vehicle. For

additional information refer to Starter motor
R&R section.

2. Disconnect wire from solenoid field coil

terminal.

3. Check for continuity between solenoid

terminal and solenoid field coil terminal with a
continuity tester. There should be continuity.
If OK, go to Step 4. If not OK, replace faulty
starter motor.

4. Check for continuity between solenoid

terminal and solenoid case. There should be
continuity. If not OK, replace faulty starter
motor.

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
668 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.6 Care of the System

8.6.1 Service Tips and Precautions
The following points must be adhered to when starting the engine
1. Check that the battery cables are connected to the correct terminals.
2. Ensure that all electrical connections to the starter are secure.
3. Turn or crank the ignition switch and immediately release after the engine is started.
4. If the engine does not start, wait for 30 seconds before trying again otherwise battery
may drain or starter motor may damage.

• Do not operate the starter when the engine is running, this may cause serious
damage to the starter pinion and the ring gear teeth.
• Never disconnect the battery while the engine is running.
• Do not operate the starter with a low charged battery.
• If a vehicle uses nonstandard or more than one floor mat. It may reduce the pedal
travel which will lead to malfunction of clutch sensor. Hence it is strictly
recommended to have floor mat as recommended by M&M This will affect ESS
working.

8.6.2 Maintenance
• Ensure that the starter motor mounting bolts to the engine are securely fastened.
• Check the battery terminals for corrosion and presence of acids, then clean the terminals
with water.
• Cables should be examined for damage, particularly where the strands enter the terminal
lugs.
• Inspect the fixing brackets for any cracks.

• Do not operate the starter if the vehicle is submerged or flooded. Failure to follow
this instruction may cause damage to the engine.

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 669
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.6.3 Cleaning
The following information details the recommended cleaning procedures for the battery and
related components. it is recommended that these procedures be performed any time the
battery or related components must be removed for vehicle service.

1. Clean the battery cable terminal clamps 3. If the removed battery is to be reinstalled,
of all corrosion. Remove any corrosion using clean the outside of the battery case and the
a wire brush or a post and terminal cleaning top cover with a sodium bicarbonate (baking
tool, and a sodium bicarbonate (baking soda) soda) and warm water cleaning solution
and warm water cleaning solution. using a stiff bristle parts cleaning brush to
remove any acid film. Rinse the battery with
clean water.

Ensure that the cleaning solution does

not enter the battery cells through the
vent holes.

2. Clean the corrosion on battery tray and

battery hold down hardware using a wire
brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution.
Paint any exposed bare metal.

4. Clean the battery thermal guard with a

sodium bicarbonate (baking soda) and warm
water cleaning solution using a stiff bristle
parts cleaning brush to remove any acid film.

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
670 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Clean any corrosion from the battery

terminal posts with a wire brush or a post and
terminal cleaner, and a sodium bicarbonate
(baking soda) and warm water cleaning
solution.

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 671
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.6.4 Jump Starting

Follow below steps while jump starting the vehicle:

• Use only a 12V supply to start the vehicle.

• If the booster battery is in another vehicle, position the two vehicles to bring their
batteries near each other. Do not allow the two vehicles to touch each other.
• Apply the parking brake. Turn OFF all electrical systems which are not primarily
required.
• Always use jump start cables with crocodile clips for connecting the terminals /
grounding.

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
672 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Attach the positive clamp (Red one) of 3. Using the other cable (black one), attach
the jumper cable to the positive terminal of one end of the clamp to the negative terminal
the discharged battery. of the booster battery.

2. Then attach the other end of the same 4. Then attach the other end of that cable to
cable to the positive terminal of the booster negative terminal of the discharged battery.
battery.

5. Now crank the engine for starting.

6. Once the vehicle gets started, carefully

• Loosely connected battery cables remove the jumper cables in the reverse
could damage the electronic control order of attachment.
units.

• Improper jump starting procedure can

result in battery explosion and acid
burn hazard
• Connecting a jumper cable near
moving parts (cooling fans, belts) is
dangerous. The cable could get
caught when the engine starts and
cause serious injury

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 673
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7 In Car Repairs

8.7.1 Starter Motor R&R

8.7.1.1 Component Location Index

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
674 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.1.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a 2 post lift. • Check and ensure proper cranking of the
• Open the bonnet. engine.

• Start the vehicle and turn the steering

wheel to extreme right position.
• Disconnect negative terminal of the
battery.

Removal steps:
1. Remove starter motor mounting bolts.
2. Disconnect starter motor electrical connections.
3. Remove starter motor.
Tools Required

Size Type Quantity

13 mm Combination spanner 01

10 mm Combination spanner 01

16 mm Ring spanner 01

14 mm Socket spanner 01

16 mm Socket spanner 01

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 675
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.1.3 Removal:

1. Using a 10 mm socket spanner, loosen 3. Remove starter motor mounting bolts

the mounting nut and disconnect battery using 16 mm socket spanner and then gently
negative terminal. pullout and remove the starter motor
assembly.

• While removing the bolt, hold the nut

using 14 mm ring spanner.

2. Using a 13 mm combination spanner,

loosen mounting nut and disconnect the
main positive cable and then using a 10mm
combination spanner, loosen mounting nut
from the solenoid and disconnect solenoid
connection.
4. Remove the starter motor assembly.

8.7.1.4 Inspection:
1. Check starter motor pinion for any damages.
2. Check flywheel ring gear for any damage.
3. Check starter motor terminals for corrosion, if found clean.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
676 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.1.5 Installation:

1. Refit the starter motor with the help of 3. Connect battery negative terminal,
mounting bolts and nuts. Torque tighten the torque tighten the mounting nut to specified
bolts to specified value. value.

• While removing the bolt, hold the nut

using 14 mm ring spanner.

2. Connect both the connectors and fasten

using nuts. Torque tighten both the nuts to
specified values.

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 677
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.2 Starter Relay R&R

8.7.2.1 Component Location Index

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
678 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.2.2 Removal:

1. Park the vehicle on a flat surface and

open the bonnet.

2. Open engine fuse box cover.

3. 3. Remove the starter relay.

• Proper care need to be taken while removing relay, chances for braking relay legs
are high.

8.7.2.3 Inspection:
1. Check and ensure proper functioning of relay. For additional information refer to Relay
checking procedure.
2. Check relay pins for any damages, bending.
3. Check relay casing for any cracks.

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 679
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.2.4 Installation:

1. Refit the starter relay in its position.

2. Install engine fuse box cover.

3. Close the bonnet and check and ensure

proper working of starting system.

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
680 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.3 Immobilizer Control Unit (ICU) R&R

8.7.3.1 Component Location Index

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 681
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Carry out ICU learning if ICU is replaced
• Turn the ignition OFF. with a new one.

• Disconnect battery negative terminal.

Removal steps:
1. Remove airbag.
2. Remove steering wheel.
3. Remove clock spring.
4. Remove combination switch.
5. Remove ICU.
Tools Required

Size Type Quantity

- Small star screw driver 01

- Flat end screw driver 01

10 mm Socket spanner 01

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
682 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.3.3 Removal:

1. Remove the combination switch. For

additional information refer combination
switch R&R section.

2. Remove immobilizer control unit

mounting screws using small star screw
driver and then gently pullout and remove the
ICU.

3. Disconnect ICU electrical connector and

remove ICU.

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 683
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.3.4 Inspection:
1. Inspect the ICU for any physical damage. Replace if found any.
2. Inspect ICU connector for any damage or loose connection. Rectify if found.

8.7.3.5 Installation:

1. Connect ICU electrical connector back. 3. Refit the combination switch. For
additional information refer combination
switch R&R section.

• Ensure the wheels are straight ahead.

Also the steering rack should be in
center. For additional information refer
wheel alignment section.
• Check and ensure both the front
wheels for straight ahead position
while fitting the steering wheel and
also after fitting.
2. Refit immobilizer control unit, mounting • Carefully install the clock spring
screws one on top and one on bottom using without damaging the locks.
small star screw driver. • When installing the DAB, make sure
that all electrical connectors are fixed
in proper position.
• When installing the driver airbag into
steering wheel, make sure the horn
pad buttons are fixed properly and
correct position.

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
684 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.4 Key Barrel R&R

8.7.4.1 Component Location Index

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 685
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.4.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Insert key and confirm key illumination
• Open the bonnet. ON, and other features.

• Turn the ignition OFF.

• Disconnect battery negative terminal.

Removal steps:
1. Remove airbag.
2. Remove steering wheel.
3. Remove clock spring.
4. Remove combination switch.
5. Remove ICU.
6. Remove key barrel.
Tools Required

Size Type Quantity

- Chisel 01

- Hammer 01

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
686 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.4.3 Removal:

1. Remove immobilizer control unit. For

additional information refer immobilizer
control unit R&R section.

2. Remove the key barrel wiring harness

clip.

3. Disconnect key barrel electrical

connector.

4. Break key barrel mounting studs using a

chisel and remove the key barrel.

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 687
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.7.4.4 Installation:

1. Refit new key barrel. 4. Refit immobilizer control unit. For

additional information refer immobilizer
control unit R&R section.

• You may require to shear off the stud

of key barrel.

2. Fix key barrel wiring harness clip back.

3. Connect key barrel electrical connector

back.

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
688 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.8 Technical Specification

8.8.1 Starter Motor Non - ESS Specification

Description Specification

Type R78-M45 12V

Nominal output 2.628KW

Engaging system 12 V

Operating voltage 8V MAX at 20oC

Internal gear ratio 3.92

Rotation Clockwise viewed from pinion end

8.8.2 Starter Motor ESS Specification

Description Specification

Type S78-M 10 V (R)

Nominal output 2.252 KW

Engaging system 12 V

Operating voltage 8V MAX at 20oC

Internal gear ratio 3.92

Rotation Clockwise viewed from pinion end

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 689
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8.9 Tightening Specifications & Sequence

Description Torque Nm

Starter motor mounting 41 ± 7

Starter solenoid mounting regular 4 ± 0.5

Negative cable mounting on block 41 ± 7

Positive cable mounting on starter 12 ± 2

Relay mounting starter 8±2

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
690 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9 CLUTCH

9.1 Description and Operation

9.1.1 Clutch System Overview
The clutch system provides the mechanical, link between the engine and the transmission.
The main function of clutch is to transmit torque from engine to transmission without slippage.
In this arrangement, the engine torsional vibrations are dampened by DMF (dual mass
flywheel).
The clutch system consists of a flywheel, dry type disc, diaphragm type pressure plate and
hydraulic linkage. The Dual Mass flywheel is bolted to the rear flange of the crankshaft. The
clutch pressure plate is bolted to the flywheel with the clutch disc between these two
components.
The diaphragm spring is held in the deep-drawn housing by means of locating pins and two
fulcrum rings.
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. The complete actuation system comprises of a clutch
master cylinder with reservoir. The master cylinder is connected to the concentric slave
cylinder (CSC) by high pressure hydraulic pipe. The travel of the push rod in master cylinder
results in linear movement of the release bearing which is integrated to the CSC through the
cylinder & piston arrangement.
The CSC pushes the diaphragm spring center towards the flywheel. The diaphragm spring
pivots at the fulcrum, relieving the load of pressure plate from 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.

9.1.2 Dual Mass Flywheel

The DMF is integrated between the engine and the clutch. The flywheel is divided into a
primary and a secondary mass. The primary side is bolted onto the crankshaft, and carries the
starter ring gear. The secondary mass is mounted on the primary mass via separate axial and
radial slide mounts that allow it to rotate independently. Between these two masses, there is a
highly efficient spring damping system filled with lubricating grease that consists of different
springs units guided by spring seats and caps. These also prevent the spring from blocking.
Tthe DMF features a multi-stage characteristic curve. The first stage uses soft springs to
ensure outstanding engine starting and stopping performance. The second stage has a firmer
springs to provide excellent decoupling of torsional vibrations during normal driving
operations.

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 691
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.1.3 Advantages of DMF

1. Good driving comfort due to strong vibrational damping for sudden load changes.
2. Quieter thanks to optimum decoupling of vibrations throughout the entire rpm range.
3. Lower shifting forces, i. e. greater comfort due to reduced inertia of clutch discs without
torsional dampers.
4. Higher durability of other power train components.

9.1.4 Self Adjusting Technology (SAT) of the Clutch Cover Assembly

Self Adjusting Technology (SAT) clutch is designed to deliver a constant clutch actuation force
during the entire life of the vehicle. SAT is designed for maintenance-free automatic operation
and compensates for clutch wear with adjustment in the pressure plate and detection by
position.
Improved driving experience is felt since the clutch actuation force will remain constant over
the entire life of the vehicle and the life of the clutch itself will be extended.

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
692 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.1.5 Clutch Plate

The clutch disc is a single, dry type without

torsion springs in the hub. The clutch disc’s
friction material is riveted to the hub. This
friction material helps in transmitting torque
from engine to transmission

9.1.6 Clutch Cover

The clutch cover is a diaphragm type with

single-piece construction and Self adjusting
technology (SAT).
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, thus
clutch disc is held strongly in between
flywheel & clutch pressure plate. This
enables the engine torque to be transmitted
to the input shaft of the gearbox, without any
slip / loss.

9.1.7 Clutch Master Cylinder

The clutch master cylinder push rod is

connected to clutch pedal. The clutch master
cylinder converts driver's foot effort to
hydraulic pressure and transmits the
pressure to the slave cylinder through clutch
bundy tube.

Master cylinder has an integrated reservoir,

which is used to store clutch fluid.

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 693
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.1.8 Concentric Slave Cylinder

The Concentric Slave Cylinder (CSC)

combines the slave cylinder and the release
bearing into one integrated unit. The CSC is
fitted inside the bell housing When clutch
pedal is pressed, the hydraulic pressure
pushes the release bearing of the CSC
towards the diaphragm spring center in the
direction of the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load
on the clutch plate.

9.1.9 Clutch Bundy Tubes

Clutch bundy tubes connects clutch master

cylinder with clutch slave cylinder, and is
used to transmit the hydraulic pressure.

9.1.10 Clutch Pedal Assembly

Clutch pedal allows the driver to control the

engagement and dis-engagement of the
clutch.

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
694 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.1.11 Clutch Sensor

Clutch sensor is a hall-effect sensor and

senses the clutch pedal position. It senses
both 15% and 85% of the clutch pedal travel.
Clutch sensor input is used for engine start
stop function and engine drivability.

9.1.12 Clutch Pedal Return Spring

Clutch pedal return spring helps in returning

the clutch pedal as soon as the load on pedal
is released.

9.1.13 Flywheel Pilot Bearing

The pilot bearing is mounted in the

crankshaft and supports and locates the
input shaft of the transmission. Use of a
rolling bearing in place of the conventional
bush, reduces the rolling resistance.
However it should be noted that because of
the bearing, it gives less leeway during
assembly procedure.

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 695
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.2 Component Location Index

9.2.1 Clutch Assembly layout 1

A. Clutch Master Cylinder Assembly F. O - Ring Clutch Tube

B. Washer Clutch Master Cylinder G. Bleeder CSC

C. Gasket Clutch Master Cylinder H. Concentric Slave Cylinder

D. Clutch Bundy Tube I. Mounting bolts.

E. Clip Brake Bundy Tube

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
696 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.2.2 Clutch Assembly Layout 2

A. Clutch Plate
B. Screw Hex
C. Clutch Cover Assembly

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 697
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.2.3 Clutch Assembly Layout 3

A. Clutch Housing Mounting Bolt.

B. Clutch Housing.
C. Dust Shield.

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
698 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.3 Clutch Master Cylinder

A. Master Cylinder Housing.

B. Master Cylinder Spring.
C. Valve Retainer.
D. Piston.
E. Push Rod.
F. Primary Seal.
G. Seal Retainer.
H. Up Stop Clip.
I. Boot.

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 699
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.4 Concentric Slave Cylinder

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
700 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.5 Trouble Shooting

Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will
require a road test to confirm whether the problem exists or not.
During the road test, drive the vehicle at normal operating speeds, shift the gears and observe
the clutch action. If chatter, grab, slip or improper release is experienced, check clutch free
pedal play, clutch fluid leakages, also do clutch bleeding, if the problem still persists, then
remove & inspect the suspected parts. However if problem is noise or hard shift then the
problem may not be in clutch only but also with the transmission or the drive line.
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.
To find out the actual root cause of the problem, the failed parts needs to be examined.

9.5.1 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 engine rear oil 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 loosen bolt or torn rubber boot.

9.5.2 Clutch misalignment /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 hubs well as the clutch splines
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.
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.

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 701
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.5.3 Noisy gearshift

A noisy gearshift operation especially in 1st and 2nd gear can be due to clutch not getting
disengaged completely. To check, turn the engine OFF, shift the gear lever to 1st or 2nd gear
and then jack up the rear axle till both the wheels gets lifted enough from the ground.
Now press the clutch pedal completely and start the engine, the wheels should not be
spinning after that 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.
Do clutch bleeding and, then check for the pressure plate lift. To check the clutch housing
misalignment bell housing run out will also need to be checked.

9.5.4 Clutch slippage:

Refer below chart for various symptoms, causes and there remedial actions of clutch
system -

Symptom Causes Remedial action

Clutch plate facing worn 1. Normal wear. ● Replace clutch plate.

out
2. Clutch riding. ● Replace clutch plate.

3. Insufficient diaphragm ● Replace clutch plate &

spring clamp load. cover assembly.

4. Faulty release mechanism. ● Replace the concentric

slave cylinder and bleed the
clutch system.

5. Vehicle being driven ● Customer to be informed.

despite slipping clutch.

6. Bad driving practice of ● Driver to be informed about

allowing the clutch to slip far correct driving practice.
too long.

Clutch disc facing 1. Check for oil leakage at ● Replace seal & clutch
contaminated with oil, crankshaft rear end oil seal. plate.
grease or clutch fluid.
● Clean clutch cover
assembly.

2. Check for oil leakage ● Replace seal & clutch

through the transmission plate.
input shaft.
● Clean clutch cover
assembly.

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
702 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

3. Excess amount of grease ● Remove the excess

applied to the input shaft grease, replace clutch plate.
splines.
● Clean cover assembly.

Clutch is running partially Release bearing sticky. ● Replace concentric slave

disengaged. cylinder.

Wrong disc or pressure Use the correct parts. ● Replace the parts after
plate used. comparison.

Clutch plate/ cover or 1. Improper tightening or ● Replace the parts and

diaphragm spring warped. loosening procedure. tighten as per sequence.

2. Rough handling of clutch ● Replace the parts, ensure

plate or cover assembly. that the rough handling is
avoided.

Flywheel side clutch facing Flywheel surface, scored and ● Reduce the scoring and
surface – torn/ nicked/ having light notch. nicks by sand paper.
worn
● Replace the flywheel if
scoring is deeper.

Clutch plate facing burnt. 1. Frequent operation under ● Roughen the flywheel face
Excessive glazing of the high loads or hard with sandpaper. Replace
flywheel & pressure plate. acceleration conditions. clutch plate & cover
assembly.

2. Frequent clutch riding by ● The driver has to be alerted

the driver. to avoid repeat failure.

Clutch facing broken Improper storage- clutch ● Replace clutch plate.

plate dropped prior to fitting.

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 703
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.5.5 Clutch grab/chatter:

Observation Causes Remedial action

Clutch disc facing 1. Check for leak at ● Replace seal & clutch
contaminated with oil, crankshaft rear end oil seal. plate.
grease or clutch fluid.
● Clean cover assembly.

2. Check for leak through the ● Replace seal & clutch

transmission input shaft. plate.
● Clean cover assembly.

3. Excess amount of grease ● Remove the excess

applied to the input shaft grease, replace clutch plate.
splines
● Clean clutch cover
assembly.

Clutch disc / pressure plate 1. Incorrect or substandard ● Replace disc and cover
warped. parts. with the correct parts.
Disc facing show unusual
wear. 2. Improper tightening or ● Replace the parts and
loosening procedure. tighten as per sequence.

3. Rough handling of clutch ● Replace the parts, ensure

plate or cover assembly that the rough handling is
avoided.

Partial engagements of 1. Clutch cover, spring or ● Replace clutch cover &

clutch disc (One side worn release fingers bent or clutch plate.
– opposite side glazed and distorted due to rough
lightly worn.) handling or improper
assembly.

2. Clutch plate damaged or ● Replace clutch plate.

distorted.

3. Clutch misalignment. ● Check the clutch plate

alignment and run out of
flywheel. Replace the clutch
plate & cover assembly if
required.

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
704 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Observation Causes Remedial action

No fault found with clutch Problem related to ● Further diagnosis required.
components. suspension or driveline Check engine and
components. transmission mounting
insulators. U Joint, tyres,
body attaching parts.

Clutch master cylinder or Piston/ bore damaged or ● Overhaul the master &
slave cylinder piston corroded slave cylinder.
jammed/ scuffing.

9.5.6 Improper clutch release:

Observation Causes Remedial action

Clutch plate warped. 1. Misalignment. ● Replace the clutch plate.
● Check for misalignment.

2. Improper docking of ● Do the docking correctly

transmission with clutch

Clutch plate is binding on 1. Clutch plate hub splines ● Replace the clutch plate.
the input shaft’s splines. damaged during installation.

2. Input shaft splines rough ● Replace the input shaft.

or damaged.

3. Corrosion or rust formation ● Replace the clutch plate.

on splines of disc and input
shaft. ● Replace the input shaft if
the scaling cannot be
removed.
● Check if the AC drain water
is falling inside. Correct if
required

Clutch not getting 1. Low fluid in the clutch ● Top off the fluid and check
disengaged properly. master cylinder. for leaks.

2. Air in the hydraulic system ● Bleed & refill the system.

3. Clutch cover loose. ● Tighten the cover bolts to

specified torque.

4. Wrong clutch disc. ● Replace disc.

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 705
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Observation Causes Remedial action

5. Clutch cover diaphragm ● Replace the cover
spring bent / warped during assembly.
transmission installation.

6. Clutch disc fitted ● Fit the clutch plate correctly

backwards. the hub should be facing the
pressure plate side & the
flywheel side mark towards
the flywheel

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
706 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.5.7 Hard gear shift:

Observation Causes Remedial action

Clutch fluid less and or 1. Leaks. ● Rectify.
contaminated
2. Reservoir strainer missing. ● Stop leaks and avoid
contamination.

Clutch plate warpage 1. Warpage due to handling ● Replace.

or assembly.

2. Warpage due to ● Replace.

misalignment.

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 707
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.6 Standard Checking Procedure

9.6.1 DMF (Dual Mass Flywheel Troubleshooting)
Possible causes of DMF failure:
1. Frequent engine stalling.
2. Extremely low-revving driving style.
3. Irregular performances of injection system or different compression pressures.
4. Extreme vibration levels due to worn power train components.
5. Clutch slip causing overheating.

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
708 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Thermal Overload
Thermal overload is the result of an overheated clutch. The DMF is not the root cause for the
damage. If the clutch was thermally overloaded the DMF must not inevitably be destroyed

Observation Causes Remedial action

Localized dark hot spots on No need to replace DMF

friction surface. assembly
No discolouration of rivet
area and outer ring

Friction surface discoloured No need to replace DMF

(yellow/blue) due to assembly
temporary thermal load (220°
C).
No discolouration of rivet
area and outer ring

Discolouration (blue/purple) Replace the DMF assembly.

of the secondary flywheel,
typically on the friction
surface both in internal than
in external diameter and /or
on the riveting surface. This
degradation is due to the
high thermal load seen by the
part (> 280°C).

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 709
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Evaluate Roughness

OK— No need to replace DMF assembly NOT OK- Replace the DMF assembly.

If the machining traces can be felt with nail, If the machining traces can not be felt with
surface roughness can be considered as OK. nail (shiny/glazed surface), then Replace
DMF.
Root cause (for such type of surface): Half
clutch driving/ driving in wrong gear
selection.

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
710 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Visual Checks

Concerns Observation Causes Remedial action

Noise when starting Starter ring Replace the DMF

the engine. excessive wear or assembly.
broken tooth.

DMF strong noise. Secondary flywheel Replace the DMF

blocked in both ways, assembly.
very hard to spin or
completely free for
360°.

DMF malfunction, In-between Replace the DMF

noise. secondary and assembly.
primary flywheels,
Burnt residues of
abraded friction
material in ventilation
holes.

DMF malfunction, Riveting surface Replace the DMF

noise. Contamination by assembly.
external substance.
• Liquid traces (oil
or DOT).
• Rust.

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 711
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.6.2 DMF Inspection Procedure

DMF - Secondary Rotational Play Test

1. Remove and keep the DMF on 3. Mark the secondary flywheel position
workbench/ flat surface, secondary flywheel compared to the primary, marking a ring gear
up tooth.

Using a chalk do marking on primary and

secondary flywheel as shown in the
below illustration

2. Rotate the secondary flywheel clockwise

until it touches the spring.

Do not compress the springs.

4. Rotate the secondary flywheel
anticlockwise until it touches the other spring.

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
712 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Mark the secondary flywheel position

and count the no. of teeth between the 2
marks.

6. If there are more than 5 teeth(about 12°)

between the 2 marks then, DMF must be
replaced.

7. If the difference is less than or equal to 5

teeth then DMF should be considered as ok.

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 713
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.6.3 Secondary Flywheel axial play

1. Keep the DMF on flat surface and hold 5. Now measure this parameter at 120 deg
primary flywheel firmly. from the 1st point of measure. Again
measure at 120 deg from the 2nd point of
2. Place a vernier on the secondary mass measure. (Measure at 3 equidistant points
as shown in picture. making 120 degree at centre with each other)

Don’t place on the friction surface, put it

on the secondary flywheel outer ring.

6. If the average value of the 3 measures is

greater than 2.3 mm then replace DMF.

3. Place a 10 kg weight on the friction

surface of the secondary mass else use • Do not check the axial play in mounted
thumb to apply the load. condition on engine & Keeping it
vertically.
4. Measure the distance between the • Do not check the axial play by pulling
secondary flywheel and the outer ring at that the secondary mass. Check only by
position. pushing as shown in above picture.
• Ensure primary flywheel fixed rigid
such that it does not tilt or lift during
the measurement.
• Axial play is not related to vibration or
judder concerns. This is only to
confirm the internal components of
DMF is ok or not. Once the DMF is
installed under CSC pre- load, its axial
play will be taken care and it will
function normally.

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
714 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.6.4 DMF run out

The flywheel run out needs to be checked whenever misalignment is suspected. Flywheel run
out should not exceed 0.4 mm.
To measure the run out, mount the base of the magnetic dial gauge on the block and then
locate the dial gauge’s needle on the outer surface of the DMF.
Some of the common reasons for excessive run out are –
• Heat warpage
• Improper machining
• Incorrect bolt tightening
• Foreign material on crankshaft flange or DMF
• Improper seating on crankshaft

9.6.5 DMF — Do’s & Don’ts

If the DMF 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 DMF bolts have been replaced.
• Always replace the DMF when replacing the clutch for second time.
• Torque tightened as per sequence and perform angular torquing as per the specifications.

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 715
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Don’t rework the Secondary flywheel friction area.

• Don’t use High pressure cleaners, steam jets, cleaning spray or compressed air to clean the
DMF. This could lead dirt or cleaning agents getting inside the DMF and cause damage.
• Absence of any of the above mentioned activities, may result in bolt loosening causing
flywheel run out.

9.6.6 Clutch cover & Plate run out

A warped cover or diaphragm spring will result in clutch grab and /or incomplete release of
clutch plate. If the clutch alignment tool is not used then the misalignment of the clutch plate
can cause distortion of the cover and also plate 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.

9.6.7 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 hubs as 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.

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
716 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.6.8 Clutch Pedal Effort

1. Assemble the extension shaft and flat 3. Position the push & pull gauge at the
head to the push rod (Push end) of the Push centre of the clutch pedal pad with gauge’s
& pull gauge. flat surface touching the pedal pad surface in
parallel.

2. Switch OFF the Push & Pull gauge and

adjust the gauge dial to zero. Now switch ON
the gauge. Ensure engine is in running
condition at idle speed. • The push & pull gauge should be in
line with the clutch pedal travel
direction.
• Measurement taken by hitting the
pedal to the bottom stopper would be
wrong.
• Do not push the gauge by holding the
top end. It would give us a wrong
reading due to the extra force applied.

4. Push the gauge by holding the gauge at

the sides (as shown the figure) till the pedal
moves down, stop before the pedal hits the
bottom stopper.

5. Note the peak values on the push & pull

gauge during the clutch pedal travel.

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 717
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Repeat the procedure for another 2

times and record the peak values. The
average of the three values would be the
pedal effort in Kgf.

• New clutch assembly 9–12 Kgf (88–118

N)
• The maximum allowable clutch pedal
effort is Worn – 13 Kgf (127 N) Max.

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
718 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.6.9 Clutch Sensor Setting

Clutch Sensor setting is to be done whenever
1. Clutch sensor related error is registered in EMS ECU or
2. The gap between magnetic holder and the sensor body is more than 2 mm.

9.6.9.1 Clutch Sensor Setting Procedure:

1. Switch off the ignition. 4. Insert a 2 mm spacer in the gap between

magnetic holder and sensor body.
2. Loosen the lock nut with the help of 13
mm open end spanner.

5. Adjust the magnetic holder till it touches

the surface of spacer, thus maintain 2 mm
3. Using a 12 mm open end spanner, gap between sensor body and magnetic
tighten the magnetic holder if required for holder.
inserting 2 mm washer.

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 719
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Tighten the lock nut.

7. After completing the clutch sensor

setting, connect i-SMART and navigate to
Scorpio.

8. Select “EMS ECU”.

9. Click on “LIVE DATA” and select

“Driveability”.

10. Release the clutch pedal fully, the value

of clutch status should be “64”.

11. Press the clutch pedal to 10%, the

value of clutch status should be “65”.

12. Press the clutch pedal fully, the value of

clutch status should be “81”.

13. If the clutch status value is not changing

according to different clutch pedal position,
readjust the clutch sensor.

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
720 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.7 Care of the System

9.7.1 Clutch Fluid Level & Leak – Inspect

Clutch Fluid - Fluid Meeting SAE J 1703 FMVSS No.116; DOT 4 specifications
Capacity –0.12 Litres. (Excludes bleeding quantity).

1. Check clutch fluid reservoir level, if

found less than top up to MAX mark.
2. Clutch reservoir for leakage and check
the level of clutch fluid, if found less top
up till MAX mark.
3. Always maintain clutch fluid level at
MAX mark on reservoir.

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 721
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.7.1.1 Check for leakage in Clutch system at:

1. Clutch bundy tube connection to master

cylinder.

2. Clutch bundy tube connection to

concentric slave cylinder bleeder.

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
722 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Use recommended fluid & do not mix different brand fluids.

• In case fluid reservoir replaced, clutch system needs bleeding.
• Use the same brand fluid for top up; do not top up brake fluid from used and
unsealed brake fluid container.
• The clutch fluid reservoir cap/ container should not be opened with dirty hands.
• Avoid direct water spray on reservoir while washing engine compartment.
• Clutch fluid need to be inspected first at 10000 Kms/6M & 20,000 Kms/12M, then
every 20,000 Kms/12M (Distance Covered in kms/Months in service whichever is
earlier).
• Always use clutch oil specification for Fluid Meeting SAE J 1703 FMVSS No.116;
DOT 4 specifications..
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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 723
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.7.2 Clutch Fluid – Replace

9.7.2.1 Clutch Fluid Draining Procedure:

Clutch Fluid - Fluid Meeting SAE J 1703 FMVSS No.116; DOT 4 specifications
Capacity –0.12 Litres. (Excludes bleeding quantity).

1. Position the vehicle on level ground /2 3. Open the clutch reservoir cap by rotating
post lift /4 post lift. it in anti-clockwise direction.

2. Open the bonnet.

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
724 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Using a flat end screw driver lift the

bleeder lock upwards and pull-out the clutch
bundy tube outward from bleeder.

• Keep a tray beneath, pull-out the

clutch bundy tube and collect the
drained fluid in the tray.

5. Drain the complete clutch fluid.

• Press the clutch pedal gently for

draining the entire fluid.
• Collect the fluid drained in a tray.
Avoid spilling on floor.

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 725
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.7.2.2 Clutch Fluid Re-Filling and Bleeding Procedure

1. Connect the bundy tube back on bleeder 3. Press and release the clutch pedal gently
and press the lock down to lock the bundy to full stroke for fluid to enter completely in
tube. the circuit.

4. Connect a transparent tube into the

bleeding nipple, insert the other end of
transparent tube immersed in a container
with clutch fluid.

2. Fill recommended clutch fluid up to MAX

mark on clutch fluid reservoir.

• If the bleeding operation is done

without connecting a tube and in the
open air then the chance of air
remaining trapped in the system is
high.
• Ensure that the other end of the tube is
fully immersed in the bottle having
clean clutch fluid.

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
726 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Press and release the clutch pedal 3-4 8. Tighten the bleeder screw as soon as
times slowly to the full stroke and hold the there is no air bubbles visible in the
pedal in depressed condition. transparent tube.

• Ensure sufficient fluid level in

reservoir throughout the bleeding
procedure.

6. Using 13mm open end spanner, rotate

the bleeder screw by 90 degree in anti-
clockwise rotation and allow all the air
bubbles to escape into the container.

9. Continue procedure 5-8 till there are no

air bubbles visible in the transparent pipe.

10. Remove the transparent tube.

11. Tighten the bleeding screw firmly.

12. Check fluid level in reservoir, maintain

clutch fluid at MAX level mark.

7. Fluid starts flowing through the

transparent tube into the container.

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 727
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Close the reservoir cap back and tight

properly.

14. Check and ensure proper working of

clutch.

15. If pedal sponginess is present do the

entire bleeding procedure again.

• Make sure, no any leaks from clutch pipe and joints.

• Do not spill clutch 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 clutch fluid.
• At all times during the bleeding process, it has to be ensured that the fluid level in
the reservoir does not drop below minimum.
• The clutch fluid reservoir cap should not be opened with dirty hands.
• Avoid direct water spray on reservoir while washing engine compartment.
• During the bleeding operation ensure the container and pipe used is of transparent
for better visual.
• Clutch fluid need to be inspected first at 10000 Kms/6M & 20,000 Kms/12M, then
every 20,000 Kms/12M (Distance Covered in kms/Months in service whichever is
earlier).
• Clutch fluid need to be replaced first at 30,000 kms/18 Months and then every 30,000
kms/18 Months (Distance Covered in km / Months in service whichever is earlier).
• Always use clutch oil specification for Fluid Meeting SAE J 1703 FMVSS No.116;
DOT 4 specifications.

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
728 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8 In Car Repairs

9.8.1 Clutch Master Cylinder R&R

9.8.1.1 Component Location Index

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 729
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.1.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Fill the reservoir with fresh clutch fluid as
• Drain the clutch fluid. per specification and carry out clutch
bleeding.
• Check for any leakage in the system.
• Check and ensure proper working of
clutch system.

Removal steps:
1. Remove master cylinder mounting nuts.
2. Remove master cylinder push rod mounting bolt on pedal.
3. Remove clutch bundy tube.
4. Remove clutch master cylinder.
Tools Required

Size Type Quantity

12 mm Socket spanner 01

13 mm Open end spanner 01

11 mm Open end spanner 01

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
730 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.1.3 Removal:

1. Drain the clutch fluid. For additional 5. Pull out the clutch master cylinder and
information refer to Clutch fluid draining detach clutch bundy tube by loosening the
section. nut, with the help of 11 mm open end
spanner.
2. Remove the vacuum reservoir. For
additional information refer to vacuum
reservoir assembly R&R section.

3. Remove the clutch master cylinder

mounting nuts using 12 mm socket spanner.

6. Remove the clutch master cylinder

assembly.

4. Detach clutch master cylinder push rod

from clutch pedal assembly by removing the
bolt shown in illustration using 13 mm open
end spanner.

9.8.1.4 Inspection:
1. Inspect clutch master cylinder for any damage or leak.
2. Inspect clutch master cylinder reservoir for any damage.
3. Inspect clutch master cylinder reservoir cap for proper fitment and for any damage.

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 731
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.1.5 Installation:

1. Refit the clutch bundy tube on clutch 3. Mount clutch master cylinder with the
master cylinder and position the clutch help of mounting nuts and torque tighten to
master cylinder back in its original position. specified value.

4. Fill recommended clutch fluid to specified

quantity in clutch master cylinder reservoir.
• Ensure that bundy tube is fixed back
properly, else fluid may leak.

2. Refit clutch master cylinder push rod with

clutch pedal with the help of bolt.

5. Fill the clutch fluid and carry out bleeding

procedure. For additional information refer to
Clutch fluid filling and bleeding section.

6. Refit the vacuum reservoir. For additional

information refer to vacuum reservoir
assembly R&R section.

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
732 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.2 Clutch Cover/Plate R&R

9.8.2.1 Component Location Index

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 733
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.2.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on 2 post / 4 post lift. • Fill the reservoir with fresh clutch fluid as
• Open the bonnet. per specification and carry out clutch
bleeding.
• Remove the transmission assembly.
• Check and ensure proper working of
clutch system.

Removal steps:
1. Remove clutch cover mounting bolts.
2. Remove clutch cover assembly.
3. Remove clutch plate.
Tools Required

Size Type Quantity

13 mm Socket spanner 01

Master clutch plate assembly-

MST 546 diesel ( aligner) 01

0301BM0008ST Flywheel Locking Tool 01

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
734 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.2.3 Removal:

1. Remove the transmission assembly. For 3. Remove clutch cover assembly mounting
additional information refer to Transmission bolts using 13 mm socket spanner.
(4WD) R&R section.

2. Lock the flywheel using MST

(0301BM0008ST).

• Insert MST 546 (Master clutch plate

assembly), before loosening the clutch
cover bolts to prevent clutch plate
falling down and getting damage.

4. Remove the clutch cover assembly along

with the clutch disc.

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 735
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Detach the clutch disc from clutch cover

assembly.

9.8.2.4 Inspection:
1. Check for Diaphram Spring wear and Fingers misalignment.
2. Check pressure plate face-out and run-out.
3. Check for Pressure Plate cracks and surface condition.
4. Check thickness of clutch plate, replace if found below MIN. value.

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
736 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.2.5 Installation:

1. Fix back clutch disc back on clutch cover. 3. Fix the clutch cover assembly with the
help of mounting bolts and torque tighten the
bolts to specified value.

• The projected part of clutch disc

should come towards transmission
side only, false installation can lead to
clutch disc damage.

4. Refit transmission assembly. For

additional information refer to Transmission
(4WD) R&R section.

5. Fill the clutch fluid and carry out bleeding

2. Using MST 546 (Master clutch plate procedure. For additional information refer to
assembly), align the clutch cover assembly Clutch fluid filling and bleeding section.
and clutch disc.

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 737
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.3 Clutch Concentric Slave Cylinder R&R

9.8.3.1 Component Location Index

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
738 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a 2post/4post lift. • Fill fresh recommended clutch fluid and
• Open the bonnet. carryout clutch circuit bleeding.
• Check for any leaks in the clutch circuit.
• Remove the transmission assembly.

Removal steps:
1. Remove CSC bleeder.
2. Remove CSC mounting bolts.
3. Remove CSC.
Tools Required

Size Type Quantity

12 mm Socket spanner 01

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 739
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.3.3 Removal:

1. Remove the transmission assembly. For 3. Remove concentric slave cylinder

additional information refer to Transmission mounting bolts using 12 mm socket spanner.
(4WD) R&R section.

• Put the dust cap/cotton cloth in CSC

nozzle port during clutch or
transmission service.

2. Pull the locking clip outwards and then

disconnect concentric slave cylinder upper
part of bleeder.

4. Remove the concentric slave cylinder

assembly.

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
740 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.3.4 Inspection:
1. Inspect clutch slave cylinder for any leakages.
2. Check the clutch slave cylinder Axial movement (Up & down) & bearing rotational
movement (Right & left) for any abnormality..

3. Inspect clutch slave cylinder boot condition for any damages.

4. Inspect clutch slave cylinder mountings for any damages.

9.8.3.5 Installation:

1. Place the concentric slave cylinder 2. Install concentric slave cylinder mounting
assembly in its position. bolts, torque tighten the bolts to specified
value.

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 741
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Insert the bleeder upper part first and

press gently to get locked in position with
concentric slave cylinder.

• After new CSC fitment, remove the

dust cap at the time of hydraulic tube
fitment only.

4. Refit transmission assembly. For

additional information refer to Transmission
(4WD) R&R section.

5. Fill the clutch fluid and carry out bleeding

procedure. For additional information refer to
Clutch fluid filling and bleeding section.

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
742 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.4 Dual Mass Fly Wheel (DMF) —R&R

9.8.4.1 Component Location Index

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 743
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.4.2 Removal & Assembly Summary

Pre removal Post Installation

• Position the vehicle on a 2 post / 4 post • Refit the transmission assembly.
lift. • Fill fresh recommended clutch fluid and
• Remove the transmission assembly. carry out clutch circuit bleeding.
• Check for any leaks in the clutch circuit.
• Check and ensure proper working of
clutch system.

Removal Steps:
1. Pressure plate mounting bolts.
2. Pressure plate.
3. Clutch plate.
4. Fly wheel mounting bolts.
5. Fly wheel mounting bolt washer.
6. Fly wheel assembly.
Tools Required

Size Type Quantity

13 mm / 19 mm Socket spanner Each 01

0301BM0008ST Flywheel Locking Tool 01

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
744 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.4.3 Removal:

1. Remove the transmission assembly. For 4. Using a 19 mm socket spanner remove

additional information refer to Transmission the fly wheel mounting bolts & remove the
(4WD) R&R section. flywheel assembly.

2. Lock the flywheel using MST

(0301BM0008ST)

3. Using 13 mm socket spanner remove the

pressure plate mounting bolts and the
remove the pressure plate and clutch disc.

9.8.4.4 Inspection:
• Check DMF face-out and run-out.
• Check DMF Surface Thermal Cracks Condition.
• Check the flywheel ring gear for worn-out or damage, Refer DMF Inspection procedures for
more 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 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 745
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.4.5 Installation:

1. Mount the dual mass fly wheel on the 3. Tighten the dual mass fly wheel as per
crank shaft sequence and Torque tighten the bolts to
specified value.

• Always replace flywheel mounting

bolts with new one before installation.

4. Install the pressure plate & clutch disc by

mounting bolts, tighten as per sequence and
Torque tighten the bolts to specified value.

2. Lock the flywheel using MST

(0301BM0008ST).

5. Remove the fly wheel locking tool.

6. Refit the transmission assembly. For

additional information refer to Transmission
(4WD) R&R section.

7. Fill the clutch fluid and carry out bleeding

procedure. For additional information refer to
Clutch fluid filling and bleeding section.

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
746 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.5 Clutch Bundy Tube R&R

9.8.5.1 Component Location Index

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 747
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.5.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a 2post/4post lift. • Fill fresh recommended clutch fluid and
• Open the bonnet. carryout clutch circuit bleeding.
• Check for any leaks in the clutch circuit.
• Drain the clutch fluid.
• Check and ensure proper working of
clutch system.

Removal steps:
1. Disconnect bundy tube from slave cylinder.
2. Detach bundy tube from clutch master cylinder.
3. Remove the clutch bundy tube.
Tools Required

Size Type Quantity

- Flat end screw driver 01

12 mm Socket spanner 01

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
748 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Size Type Quantity

13 mm Open end spanner 01

11 mm Open end spanner 01

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 749
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.5.3 Removal:

1. Drain the clutch fluid. For additional

information refer to Clutch fluid draining
section.

2. Remove the vacuum reservoir. For

additional information refer to vacuum
reservoir assembly R&R section.

3. Open the lock first by lifting it up with the

help of a screw driver and pull out the clutch
bundy pipe from slave cylinder bleeder.

4. Pull out the clutch master cylinder and

detach clutch bundy tube by loosening the
nut, with the help of 11 mm open end
spanner.

5. Detach tube from routing holder &

Remove the clutch bundy tube.

9.8.5.4 Inspection:
1. Inspect clutch bundy tube for any damage or crack.
2. Inspect clutch bundy tube for any bend or dent.

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
750 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.5.5 Installation:

1. Route the clutch bundy tube with the

help of holder and Fit the clutch bundy tube
to clutch master cylinder.

2. Place the clutch master cylinder in its

original position.

3. Connect the bundy tube back on bleeder

and press the lock down to lock the bundy
tube.

• Ensure that bundy tube is fixed back

properly, else fluid may leak.

4. Refit the vacuum reservoir. For additional

information refer to vacuum reservoir
assembly R&R section.

5. Carry-out clutch system air bleeding. For

additional information refer to Clutch fluid
filling and bleeding section.

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 751
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.6 Clutch Pedal Assembly R&R

9.8.6.1 Component Location Index

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
752 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.6.2 Removal & Assembly Summary

Pre removal Post Installation

• Position the vehicle on a flat horizontal • Close the bonnet.
surface. • Check and ensure proper working of
• Open the bonnet. clutch system.

Removal steps:
1. Remove pedal assembly mounting nuts.
2. Remove push rod mounting bolt on pedal.
3. Disconnect clutch sensor electrical connector.
4. Remove pedal assembly inner top mounting bolt.
Tools Required

Size Type Quantity

12 mm / 13 mm Socket spanner 01

13 mm Open end spanner 01

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 753
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.6.3 Removal:

1. Remove the vacuum reservoir. For 4. Disconnect clutch sensor electrical

additional information refer to vacuum connector.
reservoir assembly R&R section.

2. Remove the clutch pedal assembly

mounting nuts using 12 mm socket spanner.

5. Remove clutch pedal assembly mounting

bolt using 13 mm socket spanner.

3. Detach clutch master cylinder push rod

from clutch pedal assembly by removing the
bolt using 13 mm open end spanner.

6. Remove the clutch pedal assembly.

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
754 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using the outer circlip plier compress the 9. Remove clutch sensor mounting bolts
circlips and detach the circlips. using 8 mm socket spanner. Remove the
sensor.

8. Compress the clutch pedal return spring

and remove the return spring.

10. Remove the clutch pedal.

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 755
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.6.4 Installation:

1. Refit clutch sensor using the mounting 4. Position the clutch pedal assembly in its
bolts and torque tighten to specified value. position and tighten the inner mounting bolt.

2. Compress the clutch pedal return spring 5. Connect clutch sensor electrical
and refit the return spring. connector back.

3. Using the outer circlip plier compress the 6. Refit clutch master cylinder connecting
circlips and refit the circlips. rod with clutch pedal with the help of
mounting bolt.

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
756 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit clutch pedal assembly mounting

nuts and torque tighten to specified value.

8. Refit the vacuum reservoir. For additional

information refer to vacuum reservoir
assembly R&R section.

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 757
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.7 Clutch Sensor R&R

9.8.7.1 Component Location Index

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
758 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.7.2 Removal & Assembly Summary

Pre removal Post Installation

• Position the vehicle on a flat horizontal • Connect diagnostic tester and check
surface. proper working of clutch sensor at
• Open front driver door. different clutch pedal positions.

Removal steps:
1. Remove sensor electrical connector.
2. Remove sensor mounting bolts.
3. Remove the sensor.
Tools Required

Size Type Quantity

8 mm Socket spanner 01

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 759
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.7.3 Removal:

1. Disconnect clutch sensor electrical

connector.

2. Remove clutch sensor mounting bolts

using 8 mm socket spanner.

3. Remove the clutch sensor.

9.8.7.4 Inspection:
1. Inspect clutch sensor, wiring and connector for any physical damage.

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
760 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.7.5 Installation:

1. Refit clutch sensor using the mounting

bolts and torque tighten to specified value.

2. Connect the sensor electrical connector.

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 761
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.8 Clutch Pedal Return Spring R&R

9.8.8.1 Component Location Index

Tools Required

Size Type Quantity

— Circlip plier 01

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
762 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.8.2 Removal:

1. Position the vehicle on a flat horizontal

surface.

2. Open front driver door.

3. Using the outer circlip plier compress the

circlips and detach the circlips.

4. Compress the clutch pedal return spring

and remove the return spring.

9.8.8.3 Inspection:
1. Check return spring for proper stiffness.
2. Check for any damage or crack.

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 763
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.8.4 Installation:

1. Compress the clutch pedal return spring

and refit the return spring.

2. Using the outer circlip plier compress the

circlips and refit the circlips.

3. Check and ensure proper working of

clutch pedal.

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
764 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.9 DMF Pilot Bearing R&R

9.8.9.1 Component Location Index

Tools Required

Size Type Quantity

MST 543 Extractor flywheel bearing 01

MST 544 Drift flywheel bearing 01

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 765
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.9.2 Removal:

1. Remove flywheel assembly. For

additional information refer to Dual Mass
Flywheel (DMF) R&R section.

2. Remove the flywheel pilot bearing with

the help of MST 543 (Extractor flywheel
bearing).

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
766 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.9.3 Installation:

1. Place the flywheel pilot bearing in its

position.

2. With the help of MST 544 (Drift flywheel

bearing) and mallet install flywheel bearing.

3. Refit flywheel assembly. For additional

information refer to Dual Mass Flywheel
(DMF) R&R section.

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 767
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.10 Dust Shield R&R

9.8.10.1 Component Location Index

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
768 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.10.2 Removal:

1. Remove the Dual mass flywheel. For

additional information refer to Dual Mass
Flywheel (DMF) R&R section.

2. Gently pullout and remove the dust

shield.

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 769
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.8.10.3 Installation:

1. Refit the dust shield with the help of

dowels.

2. Refit the Dual mass flywheel. For

additional information refer to Dual Mass
Flywheel (DMF) R&R section.

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
770 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.9 Specifications & Wear Data

Figure Description Value/

Type

Clutch control Hydraulic-

type- self
adjusting

Pressure plate Diaphragm

type

Clutch plate 260±1

Outer Diameter
(mm)

Clutch plate Inner 170±1

Diameter (mm)

Clutch Disc 7.8 ±0.2 @

Clamped 8250 N
Thickness

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 771
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value/

Type

Clutch disc run 1mm Max

out

Clutch Disc Outer Min is 1 at

Face to Rivet new
Head Distance condition

Clutch pedal Suspended

Type

Clutch pedal 8.5mm

Ratio

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
772 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value/

Type

Clutch Pedal 165 + 5 mm

Height above
carpet thickness
of 10 mm.

Clutch pedal free 10 - 25 mm

play

Duel Mass 0.40

Flywheel
Run out

Duel Mass 40.8 ± 0.5

Flywheel mm
Width of flywheel
butting face
(Crankshaft
touch face) to
clutch disc face

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 773
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value/

Type

Pressure plate 32.35 ± 1.5

finger height ( mm
mm)

Diaphragm 0.5 mm (
spring tip non finger to
alignment.(Max) finger)

Diaphragm Max depth

spring finger 0.5 mm
wear
Max width 5
mm

9.10 Lubricants & Sealants

Specification: Fluid Meeting SAE J 1703 FMVSS No.116; DOT 4 specifications
Quantity: 120 ml (0.12 Litres).

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
774 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.11 Tightening Specifications & Sequence

Location Torque Nm

PRESSURE PLATE MTG. Stage 1 - 9 Nm

Stage 2 - 15 Nm
Stage 3 – 25 Nm
(Sequence - Star pattern)

CLUTCH SLAVE CYLINDER MOUNTING Pre Torque 5 Nm

BOLTS ON GEAR BOX.
Post Torque 25 Nm

BOLT FLYWHEEL 50±3NM +60O±1O

CLUTCH PEDAL MTG. ON DASH PANEL 27.5 ± 2.5

Clutch sensor 15 ± 1

CLUTCH TUBE SUB ASSLY. 15 ± 3

CLUTCH TUBE MTG ON BRKT ON TRANS. 15 ± 3

CLUTCH BUNDI FIT. NEAR SLAVE 15 ± 2

CYLINDER

CLUTCH TUBE MTG. ON MASTER 15 ± 2

CYLINDER

Clutch pedal sensor lock nut 25

CLUTCH TUBE SUB ASSY 15 ± 3

CLUTCH TUBE MTG. ON BRKT ON 15 ± 3

TRANS.

CLUTCH TUBE MTG. ON MASTER 15 ± 2

CYLINDER

CLUTCH BUNDY FIT NEAR SLAVE 15 ± 2

CYLINDER

BELL HOUSING MTG. ON ENGINE LH/RH 80 ± 12

FULCRUM PIN MTG. ON FRAME LH/RH 130 ± 20

(W)

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 775
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Location Torque Nm

BELL HOUSING COMPOSITE OIL SUMP 80 ± 12

BOTTOM LH/RH

BELL HOUSINF BRKT. LH OIL SUMP LH/ 27 ± 5

RH

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
776 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9.12 Mahindra Special Tools (MST)

Description/ Part No. / Sketch Usage View

Master clutch plate assembly- diesel

(aligner)
MST 546

Extractor Flywheel bearing

MST 543

Drift Flywheel bearing

MST 544

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 777
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Description/ Part No. / Sketch Usage View

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
778 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10 TRANSMISSION — 6MT

10.1 Description & Operations

10.1.1 Transmission System

6MT 320 is a 6- speed gearbox. The 1st & 2nd gear is having triple cone type synchronizer
while the 4th, 5th & 6th are having single cone type synchronizer. The 3rd & reverse gear is
double cone type synchronizer.
The gear selection is by a direct shift lever operating a 4- rail system. 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 two-piece with rubber isolation provided on to the top half.
The gearbox housing is 3 piece aluminum with an intermediate plate. The Gearbox is mounted
directly on the flywheel through the integral clutch housing and supported at rear on the cross
member. The gearbox also has a gear neutral switch (GNS) which give signal to ECU when
vehicle is in neutral gear position.

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 779
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.1.2 Shifter Lever Assembly

Shifter lever assembly is for gear selecting

and shifting. It is connecting element
between gear shift lever and shift rail.

10.1.3 Synchronizers

Synchronizers is used to synchronize speeds

of two objects rotating in different speeds.
Objective of synchronizer is provide smooth
shifting during engagement and
disengagement of gears.

10.1.4 Shift Fork

Shifter fork is used to provide linear motion

for synchro sleeve during engagement and
disengagement of gears.

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
780 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.1.5 Clutch Housing

Clutch housing is a housing used to protect

clutch components and clutch actuating
members from external environment . It
provides support for mounting clutch
actuating components. It is in between
engine and Transmission front housing.

10.1.6 Front Housing

Front housing is used to provide support for

mounting transmission shafts by using of
bearings. It is mounted in between clutch
housing and Intermediate plate.

10.1.7 Intermediate Plate

Intermediate plate is located in between front

& rear housings.
It is used to hold the counter shaft & output
shaft bearings

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 781
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.1.8 Rear Housing

Rear housing is used to protect rear parts of

transmission components from external
environment. It is used to hold the shift lever
assembly & detent block.

10.1.9 Input Shaft

Input shaft is used to get power input from

engine through clutch disc. Input shaft
splined area is connected to clutch disc. It
has primary reduction gear in the other side
which is connected to counter shaft 4th gear.

10.1.10 Output Shaft

Output shaft is used to give power output

from transmission. The end part of splined
area is connected to propeller shaft.

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
782 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.1.11 Counter shaft

Counter shaft consist of various drive gears.

1sst,2nd,3rd,4th is integral with shaft & 5th,
6thand Reverse drive gear is splined.
Counter shaft front end gear (4th gear) is
connected to input shaft gear. It is called as
primary gear pairs.

10.1.12 Drive Gear

Drive gear are fixed gears. Which is usually

splined or integral with shaft. It is used to
provide speed reduction and varying the
torque.

10.1.13 Driven Gear

Driven gear are freely rotating gears in the

output shaft. Needle bearing is positioned
between gears & shaft. Gear and shaft
speed will be different. Synchro assembly will
match the speed of the particular gear and
shaft when that gear is engaged.

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 783
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.1.14 Reverse Idler

Reverse idler gear is positioned between

reverse drive & driven gear. It is used to
reverse the rotation of the driven gear this
will make output shaft to rotate in reverse.

10.1.15 Shift Block Actuator

Block shift actuators is used to control the

shift & select movement of the shift lever. It
has the shift & select ramp profile. Detent ball
is placed in both ramp profiles. Which is used
to position the gear selection and shifting
accurately. The Detent block another one
end is attached with shift lever and another
end is attached with common rail.

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
784 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.2 Component Index

10.2.1 Transmission View 1 (Gear Components)

1. Input shaft oil seal 27. Thrust Washer Reverse driven gear

2. Snap ring 28. CR Bearing

3. Circlip 29. Output shaft lock nut

4. DGB Bearing 30. Snap ring

5. Input shaft 31. Circlip

6. Pilot bearing 32. Counter shaft DGB Bearing

7. Circlip 33. Counter shaft

8. Synchro pack Assy 3rd 4th 34. Counter shaft DGB Bearing

9. 3rd driven gear 35. Thrust Washer 6th drive gear

10. NRB 3rd driven gear 36. NRB 6th gear

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 785
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Output shaft 37. 6th drive gear bush

12. NRB 2nd driven gear 38. 6th drive gear

13. 2nd driven gear 39. Synchro pack Assy 5th 6th

14. Synchro pack Assy 1st & 2nd 40. 5th drive gear

15. 1st driven gear 41. NRB 5th gear

16. NRB 1st gear 42. 5th drive gear bush

17. 1st driven gear bush 43. Thrust Washer 5th drive gear

18 DGB bearing 44. Reverse drive gear

19. Snap ring 45. DGB bearing rear

20. 6th driven gear 46. Counter shaft Lock bolt

21. Sleeve 5th 6th driven gear 47. Plastic support idler gear

22. 5th driven gear 48. Reverse idler shaft

23. Synchro pack Assy Reverse 49. Reverse idler gear

24. Reverse driven gear 50. NRB reverse idler shaft

25. NRB reverse gear 51. Thrust Washer reverse Idler

26. Reverse driven gear bush

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
786 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.2.2 Transmission View 2 (Casing Components)

1. Semi remote shifter bolts 8. Rear housing bolts

2. Semi remote shifter assembly 9. Front housing bolts

3. Torx bolt 10. Speed sensor

4. Actuator shifter block 11. Rear housing

5. Reverse lamp switch 12. Intermediate plate

6. Neutral switch sensor 13. Front housing

7. Clutch housing bolts 14. Clutch housing

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 787
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.2.3 Transmission View 3 (Shifter Assembly)

1. Allen bolt 11. Shifter fork 3rd and 4th

2. Actuator shift block 12. Shifter rail 1st and 2nd

3. Inter lock finger 13. Dowel spring pin

4. Shift finger 4 th rail 14. Shifter fork 1st and 2nd

5. Linear bearing rail guide 15. Shifter rail 5th and 6th

6. Stop end washer 16. Dowel spring pin

7. Common rail 17. Shifter fork 5th and 6th

8. Stop end washer 18. Shifter rail reverse

9. Shifter rail 3rd and 4th 19. Dowel spring pin

10. Dowel spring pin 20. Shifter fork reverse

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
788 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.3 Trouble Shooting

10.3.1 Symptom Possible Causes

Symptom Possible Causes Remedy

1. Low oil level. 1. Top up oil.

Gear Whine 2. Worn teeth gears. 2. Replace gears.

3. Worn bearings. 3. Replace bearings.

1. Chipped gear teeth. 1. Replace gears.

2. Foreign material inside 2. Remove the foreign

transmission. material and locate how the
Knocking or ticking entry of foreign e.g. missing
breather and ensure it is
rectified to avoid recurrence.

3. Defective bearings. 3. Replace the bearings.

1. Defective detent springs. 1. Replace the detent

springs.

2. Worn out grooves in shift 2. Replace the shift rails.

rail.
Jumping out of gear
3. Shaft misalignment. 3. Replace the gears.

4. Worn dog teeth in gear. 4. Replace the forks/pads.

5. Worn out fork/fork pads. 5. Replace the body.

1. Clutch defective. 1. Replace the clutch.

Unable to select gear
2. Worn out selector 2. Rectify the gear selector
mechanism. mechanism.

1. Clutch defective. 1. Rectify the clutch/clutch

with drawl mechanism.
Hard gear shifting
2. Improper or contaminated 2. Replace the lubricant with
Lubricants. specified lubricant.

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 789
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.4 Care of the System

10.4.1 Service Tips & Precautions
Service Diagnosis –
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. Substantial lubricant leak can result in gear, shift rail, synchronizer 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 it can result in gear clash during shifts.
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 synchronizer rings can cause gear clash when shifting any forward
gear. In some new or rebuilt transmissions, new synchronizer 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.
Severe obviously audible transmission noise is generally the result of a lubricant problem.
Insufficient, improper or contaminated lubricant can promote rapid wear of gears,
synchronizer, shift rail, forks and bearing’s. The overheating caused by a lubricant problem
can also lead to gear breakage.

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
790 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.4.2 Transmission Oil Replacement

10.4.2.1 Component Location Index

Transmission Oil – Manual Transmission Fluid (Viscosity Grade SAE 75W-90 (Upto -10°C) &
SAE 75W-90 (-10°C & below)
Capacity – 2.25 Liters.

10.4.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Check and ensure proper functioning of
transmission system.

Tools Required

Size Type Quantity

8 mm Square bit 01

— Mechanical hand pump 01

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 791
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.4.2.3 Transmission Oil Draining Procedure

1. Remove the filler plug.

2. Remove the drain plug using 8 mm

square bit & allow the oil to drain out
completely.

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
792 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.4.2.4 Transmission Oil Filling Procedure

1. Refit the drain plug. Torque tighten the 3. Refit the filler plug. Torque tighten the
drain plug to specified value. filler plug to specified value.

• Always replace the drain plug washer

with a new one.

• Always use specification of Manual

Transmission Fluid (Viscosity Grade
SAE 75W-90 (Upto -10° C) & SAE 75W-
2. Fill recommended oil using an oil filling 90 (-10°C & below)
machine or by clean transparent pipe
attached to the mechanical hand pump. • Transmission oil to be replaced first at
10,000 kms/6 Months and then every
30,000 kms/18 Months (Distance
Covered in kms / Months in service
whichever is earlier).
• Replace washer with a new one
whenever you remove the filler plug. • Transmission oil level to be inspected
first at 5,000 kms/3 Months, 20,000
• Ensure that the oil level is up to lower kms/12 months (Distance Covered in
most point of the filler plug. kms / Months in service whichever is
earlier) and then every service exclude
oil replacement Interval.
• Never mix two different oils.
• For Non – ABS vehicles, 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
the correct LSPV setting height.

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 793
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5 In Car Repairs

10.5.1 Transmission Gear Shift Lever R&R

10.5.1.1 Component Location Index

10.5.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
• Turn the engine OFF. gear lever.

Tools Required

Size Type Quantity

17 mm Open end spanner 01

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
794 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.1.3 Removal:

1. Loosen and remove the knob from the 4. Using 17 mm open end spanner loosen
gear lever. the gear shift lever locking nut and then
loosen and remove the gear shift lever.

2. Pull out the gear gaiter assembly with

bezel.

3. Disconnect the power socket connectors

and remove the gear gaiter assembly.

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 795
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.1.4 Inspection:
1. Inspect the gaiter for any damage. Replace if found any.
2. Inspect the gear shift lever for any damage. Replace if found any.

10.5.1.5 Installation:

1. Rotate in clockwise direction and mount 3. Refit the gear gaiter assembly with bezel.
the gear shift lever. Lock the lever by
tightening the locking nut on bottom to
specified value.

4. Refit the knob.

2. Connect the power socket connectors

and refit the gear gaiter assembly.

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
796 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.2 Transmission Gear Shifter Assembly R&R

10.5.2.1 Component Location Index

10.5.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the Gear Shifter Lever.
• Turn the engine OFF. • Check and ensure proper functioning of
• Remove the Gear Shifter Lever. gear lever.

Tools Required

Size Type Quantity

— Star Screw driver 1

12 mm Socket spanner 01

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 797
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.2.3 Removal:

1. Remove Gear Shifter Lever. For

additional information refer to Gear Shifter
Lever R&R section.

2. Using a star screw driver remove the

grommet mounting screws and detach the
grommet.

3. By using 12 mm socket spanner remove

the gear shifter assembly mounting bolts and
remove the gear shifter assembly.

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
798 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.2.4 Inspection:
1. Inspect the gear shifter assembly for any damage. Replace if found any.
2. Inspect the lever grommet for any damage. Replace the grommet if found.

10.5.2.5 Installation:

1. Refit the gear shifter assembly mounting

bolts torque tightening the bolts to specified
value.

2. Refit the grommet and tighten the

mounting screws.

3. Refit the Gear Shifter Lever. For

additional information refer to Gear Shifter
Lever R&R section.

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 799
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.3 Transmission Assembly (2WD) R&R

10.5.3.1 Component Location Index

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
800 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Install the starter motor.
• Remove the shifter lever. • Refit the propeller shaft.
• Disconnect clutch fluid pipe from slave • Install the shifter lever.
cylinder and drain the fluid. • Bleed the clutch system.
• Remove the starter motor.
• Remove the propeller shaft.

Tools Required

Size Type Quantity

14 mm Ring spanner 01

10 mm / 12 mm / 13 mm/ Socket spanner 01 each

14 mm / 16 mm

- Screw driver/ Start Screw

01 each
driver

- Hose Clip Plier 01

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 801
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.3.3 Removal

1. Using a 10 mm socket spanner, loosen 6. Using a hose clip plier unclip the spring
the mounting nut and disconnect battery band clamp and detach the radiator inlet
negative terminal. hose from thermostat.

Ensure that the coolant is not in hot

condition.

2. Remove the gear shift lever. For

additional information refer to Gear Shifter
Lever R&R section.

3. Remove the starter motor assembly . For

additional information refer to Starter motor 7. Detach the clutch pipe from clutch slave
R&R section. cylinder and drain the clutch fluid completely .

4. Remove the propeller shaft. For

additional information refer to propeller shaft
R&R section.

5. Using start screw driver remove the gear

lever grommet mounting screws and remove
the gear lever grommet.

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
802 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Using a 13 mm socket spanner remove 11. Disconnect vehicle speed sensor

the exhaust upper pipe mounting bracket. connector and also detach the wiring harness
mounting clips on transmission .

9. Press the lock and disconnect the gear

neutral sensor connector . 12. By using 14 mm socket / ring spanner ,
remove clutch housing mounting bolts .

10. Disconnect reverse lamp switch

connector . 13. Using a 12 mm socket spanner remove
the transmission assembly mounting bolts on
bed .

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 803
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14. Using hydraulic stand support the

transmission assembly.

15. Using a 16 mm socket spanner remove

the cross member mounting bolts and then
remove the cross member .

16. Remove the transmission assembly

with care .

1.

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
804 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.3.4 Inspection
• Check for any external oil leakage . Rectify if found .

10.5.3.5 Installation

1. Lift and attach the transmission 4. Refit the cross member with the help of
assembly using hydraulic stand. mounting bolts , Torque tighten the bolts to
specified value .

2. Position the transmission assembly with

the help of dowels . 5. Install the transmission rear mounting
bolts on bed , torque tighten the bolts to
3. Install clutch housing mounting bolts. specified value .
Torque tighten the bolts to specified value.

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 805
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Install the exhaust upper pipe mounting 9. connect the gear neutral sensor
bracket, torque tighten the bolt to specified connector .
value .

10. Install the radiator inlet hose and fasten

7. Route the wiring harness through using spring band clamp and topup the
transmission assembly first and then connect coolant upto Max level.
vehicle speed sensor .

11. Refit the gear lever grommet mounting

8. Connect reverse lamb switch connector . screws by using start screw driver.

12. Refit the propeller shaft. For additional

information refer to propeller shaft R&R
section.

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
806 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Refit the starter motor assembly . For

additional information refer to Starter motor
R&R section.

14. Refit the gear shift lever. For additional

information refer to Gear Shifter Lever R&R
section.

15. Connect the clutch pipe on clutch slave

cylinder and carry-out clutch fluid filling and
bleeding procedure. For additional
information refer to Clutch fluid filling and
bleeding section.

16. Connect battery negative terminal,

torque tighten the mounting nut to specified
value.

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 807
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.4 Transmission Assembly (4WD) R&R

10.5.4.1 Component Location Index

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
808 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Install the starter motor.
• Remove the shifter lever. • Install the shifter lever.
• Disconnect clutch fluid pipe from slave • Connect clutch fluid pipe on slave cylinder
cylinder and drain the fluid. and bleed the clutch system.
• Remove the starter motor.

Tools Required

Size Type Quantity

Ring spanner/ Open end

14 mm spanner 01 each

10 mm / 12 mm / 13 mm/ Socket spanner 01 each

14 mm / 16 mm/ 18 mm

- Screw driver/ Start Screw

01 each
driver

- Hose Clip Plier 01

13 mm Ring spanner 01

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 809
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.4.3 Removal

1. Using a 10 mm socket spanner, loosen 5. Using a hose clip plier unclip the spring
the mounting nut and disconnect battery band clamp and detach the radiator inlet
negative terminal. hose from thermostat.

Ensure that the coolant is not in hot

condition.

2. Remove the gear shift lever. For

additional information refer to Gear Shifter
Lever R&R section.

3. Remove the starter motor assembly .For

additional information refer to Starter motor 6. Detach the clutch pipe from clutch slave
R&R section. cylinder and drain the clutch fluid completely.

4. Using start screw driver remove the gear

lever grommet mounting screws and remove
the gear lever grommet.

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
810 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using a 13 mm socket spanner remove 10. Remove front propeller shaft U- clamp
the exhaust upper pipe bracket. mounting nuts on transfer case using 13 mm
ring spanner.

8. Remove rear propeller shaft mounting

bolts on transfer case by holding the bolt 11. With the help of flat screw driver and
head with 14 mm open end then loosen the mallet, tap slightly and remove the U-Clips of
nut with the help of 14 mm ring spanner. front propeller shaft on transfer case side and
keep aside the propeller shaft assembly and
hang on the chassis.

9. By using 18 mm / 16 mm socket spanner

remove rear propeller shaft centre bearing
mounting bolts/nuts and keep aside the 12. Press the lock and disconnect the gear
propeller shaft assembly and hang on the neutral sensor connector .
chassis.

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 811
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Disconnect reverse lamp switch 16. By using 14 mm socket / ring spanner ,
connector . remove clutch housing mounting bolts .

14. Disconnect transfer case motor 17. Using a 12 mm socket spanner remove
connectors. the transmission assembly mounting nuts on
bed .

15. Disconnect vehicle speed sensor

connector and also detach the wiring 18. Using hydraulic stand support the
harness mounting clips on transmission. transmission assembly.

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
812 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19. Using a 16 mm socket spanner remove

the cross member mounting bolts and then
remove the cross member .

20. Remove the transmission and transfer

case assembly with care.

21. Using a 14 mm socket spanner remove

the transfer case mounting nuts and then
remove the transmission assembly from
transfer case.

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 813
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.4.4 Inspection
1. Check for any external oil leakage . Rectify if found.

10.5.4.5 Installation

1. Refit the transfer case on transmission 4. Install clutch housing mounting bolts.
assembly, Torque tighten the bolts to Torque tighten the bolts to specified value.
specified value.

5. Refit the cross member with the help of

2. Lift and attach the transmission mounting bolts, torque tighten the bolts to
assembly with transfer case using hydraulic specified value.
stand.

3. Position the transmission assembly with

the help of dowels .

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
814 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Install the transmission rear mounting 9. Connect reverse lamb switch connector.
bolts on bed , torque tighten the bolts to
specified value .

10. connect the gear neutral sensor

connector .
7. Install the exhaust upper pipe mounting
bracket, torque tighten the bolt to specified
value .

11. Mount front propeller shaft on transfer

case by inserting the U-Clips and fasten the
U-clips with the help of mounting nuts.
8. Route the wiring harness through Torque tighten the nuts to specified value.
transmission assembly first and then connect
vehicle speed sensor .

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 815
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Refit the propeller shaft on transfer 15. Refit the gear lever grommet mounting
case with the help of mounting bolt + nut screws by using start screw driver .
combination, torque tighten the bolts to
specified torque value.

16. Refit the starter motor assembly . For

additional information refer to Starter motor
13. Refit the propeller shaft centre bearing R&R section.
with the help of mounting bolt + nut
combination, torque tighten the bolts to 17. Refit the gear shift lever and gaiter. For
specified torque value. additional information refer to Gear Shifter
Lever R&R section.

18. Connect the clutch pipe on clutch slave

cylinder and carry-out clutch fluid filling and
bleeding procedure. For additional
information refer to Clutch fluid filling and
bleeding section.

14. Install the radiator inlet hose and fasten

using spring band clamp and topup the
coolant upto Max level.

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
816 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19. Connect battery negative terminal,

torque tighten the mounting nut to specified
value.

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 817
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.5 Neutral Sensor R&R

10.5.5.1 Component Location Index

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
818 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.5.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Connect the electrical connector.
• Disconnect the electrical connector. • Check & confirm the neutral selection
through i-Smart.

Removal Steps:
1. Disconnect the electrical connector.
2. Remove the neutral sensor .
3. Remove the neutral sensor bracket .
Tools Required

Size Type Quantity

22 mm Open end spanner 1

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 819
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.5.3 Removal

1. Disconnect the electrical connection of

the neutral sensor.

2. Using a 22 mm open end spanner loosen

& remove the neutral sensor.

10.5.5.4 Inspection
• Check for any external damage, if found please replace.

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
820 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.5.5 Installation

1. Install the GNS sensor using 22 mm

open end spanner and torque tighten the
sensor to specified value .

2. Connect the GNS sensor electrical

connection.

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 821
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.6 Vehicle Speed Sensor (2WD) R&R

10.5.6.1 Component Location Index

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
822 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.6.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Connect the electrical connector.
• Disconnect the electrical connector.

Removal Steps:
1. Vehicle sensor mounting bolt.
2. Remove the vehicle speed sensor
Tools Required

Size Type Quantity

10 mm Socket spanner 1

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 823
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.6.3 Removal

1. Press the lock and disconnect the

electrical connector from vehicle speed
sensor .

2. Using a 10 mm socket spanner remove

the mounting bolt & then gently pullout and
remove the vehicle speed sensor .

10.5.6.4 Inspection
• Check for any external damage, if found please replace.

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
824 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.6.5 Installation

1. Install the vehicle speed sensor and

mount with the help of mounting bolt torque
tighten the bolt to specified value .

2. Connect the electrical connector.

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 825
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.7 Vehicle Speed Sensor (4WD) R&R

10.5.7.1 Component Location Index

10.5.7.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Connect the electrical connector.
• Disconnect the electrical connector.

Tools Required

Size Type Quantity

24 mm Socket spanner 1

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
826 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.7.3 Removal

1. Press the lock and disconnect the

electrical connector from vehicle speed
sensor.

2. Using a 24 mm socket spanner remove

the speed sensor & then gently pullout and
remove the vehicle speed sensor .

10.5.7.4 Inspection
1. Check for any external damage, if found please replace.

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 827
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.7.5 Installation

1. Install the vehicle speed sensor and t

torque tighten the sensor to specified value .

2. Connect the electrical connector.

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
828 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.8 Reverse Switch R&R

10.5.8.1 Component Location Index

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 829
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.8.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a two/ four post. • Connect the reverse switch electrical
• Disconnect the reverse switch electrical connector .
connector . • Select reverse gear & check whether the
reverse lamp is working.

Removal Steps:
1. Loosen and remove the reverse switch.
Tools Required

Size Type Quantity

22 mm Ring spanner 1

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
830 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.8.3 Removal

1. Disconnect reverse switch electrical

connector.

2. Using a 22 mm ring spanner loosen and

remove the reverse switch.

10.5.8.4 Inspection
1. Check for any external damage, if found please replace.

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 831
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.5.8.5 Installation

1. Refit the reverse switch and torque

tighten to specified value.

2. Refit the electrical connectors.

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
832 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6 Disassembly and Assembly

10.6.1 Clutch Housing and Input Shaft Oil Seal

10.6.1.1 Component Location Index

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 833
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Remove the transmission assembly. • Refit the transmission assembly.

Removal Steps:
1. Remove the Clutch housing mounting bolts.
2. Remove the Clutch housing assembly.
3. Remove the Input shaft oil seal .
Tools Required

Size Type Quantity

- MST (0703AAD0027H037) 1

14 mm Socket spanner 1

- Mallet 1

- Flat screw driver 1

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
834 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.1.3 Removal

1. Remove the transmission assembly .For

additional information refer to Transmission
(4WD) R&R section.

2. Using a 14 mm socket spanner remove

the clutch housing mounting bolts and then
detach and remove the clutch housing .

3. Using a screw driver remove the input

shaft oil seal .

10.6.1.4 Inspection
• Check for any external cracks, if found replace
• Check the oil seal for deformation, if found replace

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 835
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.1.5 Installation

1. Position the oil seal on MST 4. Refit the clutch housing with the help of
(0703AAD0027H037) as shown in the mounting bolts torque tighten the bolts to
illustration . specified value .

2. Using the MST refit the input shaft oil 5. Refit the transmission assembly . For
seal on the clutch housing . additional information refer to Transmission
(4WD) R&R section.

3. Check for correct seating of oil seal on

clutch housing .

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
836 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.2 Front Housing

10.6.2.1 Component Location Index

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 837
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Remove the transmission assembly. • Refit the clutch housing .
• Remove the clutch housing assembly. • Refit the transmission assembly. .

Removal Steps:

1. Remove the Input shaft snap ring. 4. Remove the gear neutral sensor.
2. Remove the counter shaft snap ring. 5. Remove the rear housing bolt.
3. Remove the Housing bolt (Front housing 6. Remove the front housing.
side).

Tools Required

Size Type Quantity

- Snap ring removal tool 1

14 mm Socket spanner 1

- Mallet 1

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
838 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.2.3 Removal

1. Remove the Clutch housing assembly . 5. Using 14 mm socket spanner remove the
For additional information refer to Clutch housing mounting bolt (Front housing side).
housing assembly R&R section.

2. Using a snap ring removal tool remove

the snap ring from the counter shaft bearing .

6. Using a 14 mm socket spanner remove

the rear housing bolts.

3. Using a snap ring removal tool remove

the snap ring from the input shaft bearing .

7. Remove the front housing assembly.

4. Using a 22 mm ring spanner loosen and

remove the neutral sensor .

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 839
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.2.4 Inspection
1. Check for any external damage, if found replace.

10.6.2.5 Installation

1. Apply loctite 5188 and insert the front 3. insert the rear housing bolt (front housing
housing . side ) and tighten the bolt to specified value .

2. insert the mounting bolts and torque 4. Refit the neutral sensor . torque tighten
tighten the bolts to specified value . the sensor specified value .

5. Refit the input shaft snap ring .

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
840 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit the counter shaft snap ring .

7. Refit the Clutch housing assembly. For

additional information refer to Clutch housing
assembly R&R section.

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 841
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.3 Rear Housing and Rear End Oil Seal R&R

10.6.3.1 Component Location Index

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
842 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the transmission assembly.
• Remove the transmission assembly.

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 843
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Removal Steps:
1. Remove gear shifter assembly mounting bolts.
2. Remove the gear shift lever assembly.
3. Remove the shift block torx bolt.
4. Remove the vehicle speed sensor.
5. Remove the reverse lamp switch.
6. Remove the rear housing mounting bolts.
7. Remove the idler shaft bolts.
8. Remove the rear housing bolts on front housing side.
9. Remove the rear housing assembly.
10. Remove the shift block actuator.
11. Remove the rear end oil seal.
Tools Required

Size Type Quantity

10 mm / 12 mm / 14 mm / Socket spanner Each 1

13 mm

14 mm Open end spanner 1

22 mm Ring spanner 1

MST 0703AD2720H074 1

T30 Torx Spanner 1

- Flat Screw driver 1

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
844 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.3.3 Removal

1. Remove the transmission assembly . For 4. Using a 10 mm socket spanner remove

additional information refer to Transmission the speedo sensor mounting bolt and then
(4WD) R&R section. gently pull out and remove the vehicle speed
sensor.
2. Using a 12 mm socket spanner, remove
the gear shifter mounting bolts and then
gently detach and remove the gear shifter
assembly.

Yellow colored bolts are fitted with dowel

inside, this bolts should be removed first.

5. Using a 12 mm socket spanner remove

the idler shaft front mounting bolt & using a
13 mm socket spanner remove the bottom
idler shaft bolt.

3. Using a T30 torx spanner remove the

shift block actuator allen bolt.

For 4WD

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 845
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Using a 22 mm ring spanner loosen and 9. Turn the shift block actuator & release
remove the reverse switch. from the spring support.

7. Using a 14 mm socket spanner remove 10. By using screw driver remove the rear
the rear housing bolt on front housing side . housing dowels and using open end spanner
detach the rear housing.

8. Using a 14 mm socket spanner/Open

end spanner remove the rear housing
mounting bolts .

Use the open end spanner on both the

side simultaneously.

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
846 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Lift the rear housing assembly along 14. Using a 12 mm socket spanner remove
with the shift block actuator & remove the the H plate mounting bolts & the H plate
block actuator. assembly.

12. Remove the rear housing assembly. 15. Using hydraulic press remove the
detente press from outside to inside for
removing .

13. Using a screw driver remove the rear

end oil seal.

10.6.3.4 Inspection
• Check for any external damage, if found replace.

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 847
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.3.5 Installation

1. Using suitable tool and hydraulic press fit 3. Position the MST along with the oil seal &
the detent (press from outside to inside) press fit the oil using a mallet.

2. position the rear end oil seal on the MST-

0703AD2720H074

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
848 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Check for the rear end oil seal correct 7. While installing the rear housing install
seating. the shift block actuator.

5. Refit the H plate mounting bolts & torque 8. Insert the rear housing mounting bolts .
tighten the bolts specified value. torque tighten the bolts specified value .

6. Apply loctite 5188 and insert the rear 9. Insert the rear housing mounting bolt
housing assembly . from front housing side torque tighten the bolt
to specified value .

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 849
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10. Refit the reverse light switch. torque 12. Refit the vehicle speed sensor with the
tighten the switch to specified value . help of mounting bolt torque tighten the bolt
specified value .

11. Insert the front & the bottom idler shaft

mounting bolts. torque tighten the bolts to 13. Position the shift block actuator & insert
specified value . the torx bolt. torque tighten the bolt to
specified value .

For 4WD
14. Refit the shifter lever assembly & the
mounting bolts. torque tighten the bolts to
specified value .

15. Refit transmission assembly . For

additional information refer to Transmission
(4WD) R&R section.

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
850 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4 Transmission

10.6.4.1 Dis-assembly and Assembly Summary

Pre Removal Post Installation

• Remove the Transmission from the • Refit the Transmission.
vehicle.
• Refill the Transmission fluid.
• Drain the Transmission fluid.

Tools Required

Size Type Quantity

10 mm / 12 mm / 13 mm Socket spanner/ combination

spanner 1
/14 mm

5 mm Allen key 1

Ring Spanner/ Open end

22 mm spanner 1

- Flat Screw driver & Mallet 1

0703AD2720H116 Lock Nut Dolly 1

0703DBA0001ST Lock Nut Special Tool 1

— Snap ring removal tool 1

— Circlip Plier 1

— Roll punch 1

CRB Bearing pressing Dolly-

0703AAD0027H009 1
1st 2nd side

0703AAD0027H017 & M.D. Gear Bearing pressing

Dolly & Guide 1
H019

0703AAD0027F010 Counter Shaft Bearing Dolly 1

0703AAD0027H007 Hub pressing Dolly 3rd Side 1

Counter Shaft top Bearing

0703AAD0027H010 Dolly 1

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 851
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Size Type Quantity

Rear end oil seal installation

0703AD2720H074 1
tool

- Puller set 1

10.6.4.2 Dis-assembly

1. Drain the Transmission fluid. For 3. Using a T30 torx spanner remove the
additional information refer to Transmission allen bolt from the shift block actuator.
fluid Drain Section.

2. Using a 12 mm socket spanner, remove

the gear shifter mounting bolts and then
gently detach and remove the gear shifter
assembly.

Yellow colored bolts are fitted with dowel

inside, this bolts should be removed &
refit first.

4. Using a 22 mm ring spanner remove the

reverse switch.

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
852 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Using a 22 mm open end spanner 7. Using a 12 mm socket spanner remove

remove the neutral sensor. the idler shaft front mounting bolt & using a
13 mm socket spanner remove the bottom
idler shaft bolt.

6. For 2WD, Using a 10 mm socket

spanner remove the speedo sensor For 4WD,
mounting bolt and then gently pull out and
remove the vehicle speed sensor .

8. Using a 14 mm socket spanner remove

the rear housing bolt from the front housing
side.

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 853
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Using a 14 mm socket spanner/Open 11. By using screw driver remove the rear
end spanner remove the rear housing housing dowels and using open end spanner
mounting bolts . detach the rear housing.

10. Turn the shift block actuator & release

from the spring support.

Use the open end spanner on both the

side simultaneously.

12. Lift the rear housing assembly along

with the shift block actuator & remove the
block actuator .

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
854 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Remove the rear housing assembly. 16. Using hydraulic press remove the
detente press from outside to inside for
removing .

14. Using a screw driver remove the rear

end oil seal.
17. Remove the idler gear, shaft & the
plastic support assembly.

15. Using a 12 mm socket spanner remove

the H plate mounting bolts & the H plate
assembly. 18. Remove idler gear, washer & needle
roller bearing from shaft.

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 855
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19. Remove main shift rod & the washers 22. Using a 14 mm socket spanner remove
on both sides. the counter shaft lock bolt in clock wise
direction.

Ensure Gear in neutral position

• The bolt is reverse threaded, hence
rotate in clockwise for removing.

20. Engage the 2nd gear.

21. Engage the 4th gear.

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
856 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23. Using MST loosen the output shaft lock 24. Using a bearing puller remove the
nut. counter shaft rear DGBB (Double Grove Ball
Bearing).

• For 4WD MST — 0703AD2720H116

(Lock Nut Dolly). • Use Counter shaft dummy bolt for
• For 2WD MST — 0703DBA0001ST support bearing puller.
(Lock Nut Special tool).

25. Using a puller remove the reverse

driven gear, washer & CRB (Cylinder Roller
Bearing) from output shaft .

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 857
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26. Remove the reverse driven gear needle 29. Using a puller remove the reverse drive
bearing & using screw driver remove the gear, thrust washer & 5th drive gear from
bush. counter shaft.

27. Remove reverse fork & rail shift 30. Remove the 5th drive gear NRB (Needle
assembly from output shaft. Roller Bearing).

28. Using a puller remove the reverse 31. Using a suitable puller remove the 5th
synchro hub from output shaft. driven gear & bush from output shaft .

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
858 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

32. Remove the 5th & 6 th synchro sleeve 35. Using 14 mm socket spanner remove
along with fork & rail shift. the clutch housing bolts.

33. Using a puller remove 6th drive gear, 5th 36. Using a mallet tap & remove the clutch
& 6th synchro hub & 5th drive gear bush from housing.
counter shaft.

37. Using a screw driver remove the input

34. Remove the 6th drive gear NRB and shaft oil seal from clutch housing.
bush.

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 859
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

38. Using a snap ring removal tool/ flat end 41. Using a roll punch & hammer remove
screw driver, remove the input shaft snap the pin spring dowel from the 1st & 2nd shifter
ring from the front housing. fork & rail assembly.

39. Using a snap ring removal tool/ flat end 42. Using a roll punch & hammer remove
screw driver, remove the counter shaft snap the pin spring dowel from the 3rd & 4th shifter
ring from the front housing. fork & remove fork rail assembly from
intermediate plate.

40. Using open end spanner detach the

front housing from the intermediate plate. 43. Using a snap ring removal tool/ flat end
screw driver, remove the output shaft snap
ring from the intermediate plate.

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
860 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

44. Using a mallet tap and remove the 47. Remove the pilot bearing from output
intermediate plate. shaft.

45. Remove the counter shaft assembly. 48. Using a circlip plier, remove the circlip
from input shaft.

46. Remove the input shaft assembly.

49. By using hydraulic press remove the
DGBB from input shaft.

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 861
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

50. Using a circlip plier, remove the circlip 53. Using a puller remove the 1st driven
from counter shaft front end. gear, 2 nd driven gear, 1st & 2 nd synchro pack
along with output shaft DGBB & 6th driven
gear.

51. By using hydraulic press remove the

DGBB from counter shaft front end.

• Engage puller legs in the 2nd driven

gear.
• Remove in the sequence of 6th driven
gear, output shaft DGBB, 1st driven
gear with bush, 1st driven gear NRB,
1st & 2nd synchro pack, 2nd driven gear.

52. By using hydraulic press remove the

DGBB, 6th drive gear bush & thrust washer
from counter shaft rear end.

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
862 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

54. Remove the 2 nd driven gear NRB. 57. Remove the 3rd driven gear NRB.

55. Using a circlip plier remove the circlip 58. Remove the output shaft.
from the output shaft.

56. Using puller remove the 3rd & 4th

synchro pack & the 3rd driven gear assembly.

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 863
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.3 Inspection

1. Shift Control Components

• Check contact and sliding surfaces of

fork rods for wear, scratches, projections
and other damage.

2. Gear Components

• Check shafts for cracks, wear and

bending.
• Check gears for excessive wear, chips
and cracks.

3. Gear Components

• Check shafts for cracks, wear and

bending.
• Check gears for excessive wear, chips
and cracks.

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
864 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Synchronizers

• Check spline portion of coupling

sleeves, synchronizer hubs, and gears
for wear, chips, and racks.
• Check ring for cracks and deformation.
• Check struts for wear and deformation.

5. Bearings

• Make sure all bearings roll freely and

are free from noise, cracks, pitting or
wear.

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 865
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.1 Synchro Installation — Direction/Position

10.6.4.1.2 Identification Overview

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
866 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.1.3 Synchro Sleeves

Location Cut — Section Iso - Image Identification

6MT Flat Chamfer Side

1st 2nd 1st gear

6MT Curved Chamfer

3rd 4th Side 3rd gear

Identification

3rd 4th sleeve is bigger in width

Location Cut — Section Iso - Image Identification

6MT Flat Chamfer Side

5th 6th 5th gear

6MT Projected teeth

Reverse side Reverse gear

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 867
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.1.4 Synchro Hub

10.6.4.1.5 Dual & Triple Cone Synchro Difference

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
868 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.1.6 Difference between Dual and Triple Cone Synchro

3rd Synchro Ring assy. 1st 2nd Synchro Ring assy.

Dual Cone synchro pack – inner ring should Triple Cone synchro pack – inner ring
not have thread should have thread

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 869
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.1.7 Triple & Dual Cone Synchro Pack

Assembly View Assembly View

Synchro Pack – Outer ring lug should be Synchro Pack – Outer ring lug is not
locked with inner ring slot. assembled in inner ring slot.

CORRECT ASSY. WRONG ASSY.

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
870 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.1.8 Hub to Sleeve position

Sleeve to hub – sleeve strut groove position Sleeve to hub – sleeve strut groove position
to be assembled in strut slot. is not assembled in strut slot.

CORRECT ASSY. WRONG ASSY.

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 871
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.6.4.9 Assembly

1. Clean & check the output shaft before 4. Assemble the 3rd & 4th synchro pack on
assembly. the 3rd driven gear.

2. Install the 3rd driven gear NRB. 5. Using MST: 0703AAD0027H009 &
mallet, press fit the assembly (3rd and 4th
synchro pack and 3rd driven gear).

3. Place the 3rd driven gear on the output

shaft.
6. Install the circlip on the output shaft.

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
872 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Install 2nd driven gear NRB. 10. Using MST: 703AAD0027H017 & H019
press fit the assembly.

8. Install 2nd driven gear assembly.

11. Install the 1st driven gear NRB.

9. Install the 1st & 2nd synchro pack along

with the 2nd driven gear. 12. Install the 1st driven gear assembly.

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 873
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Install the 1st driven gear bush. 16. Install the 5th & 6th driven gear bush on
output shaft.

14. Install the output shaft DGBB by using

hydraulic press. 17. Using MST: 0703AAD0027F010 press
fit the 5 th driven gear on output shaft.

• 5th driven gear and 6th driven gear

should not be Interchangeable.

15. Using MST: 0703AAD0027F010 press

fit the 6th driven gear on output shaft.

• 5 th driven gear and 6th driven gear

should not be Interchange. 18. By using hydraulic press refit the DGBB
on input shaft.

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
874 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19. Using a circlip plier, refit the circlip on 22. Install the counter shaft front DGBB by
input shaft. using hydraulic press and MST
(0703AAD0027H010 — Counter Shaft top
Bearing dolley)

20. Install the pilot bearing on output shaft.

23. Using a circlip plier, refit the circlip on

counter shaft front end.

21. Position the synchro ring and install the

Input shaft assembly.

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 875
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24. Install the counter shaft rear DGBB, 27. Refit the snap ring on the intermediate
thrust washer by using hydraulic press & plate.
Install the 6th drive gear bush.

• Heat the bush before pressing to

ensure proper fitment.

28. Install the 3rd & 4th gear shifter fork

along with rail & refit the pin spring dowel.

25. Assemble the counter shaft.

29. Install the 1st & 2nd gear shifter fork

along with rail & refit the pin spring dowel.

26. Install the intermediate plate & properly

lock snap ring.

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
876 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30. Apply loclite 5188 on the intermediate 32. Using a snap ring removal tool/ screw
plate front housing side. driver install the counter shaft snap ring.

31. Install the front housing assembly. 33. Using a snap ring removal tool/screw
driver install the input shaft snap ring.

• Use 3 nos. of 17 mm dummy bolts (

Appox. length of 40 mm) to tighten the
front housing to ensure proper sealant
application.
• Ensure to fix the dowels before tighten
the front housing.

34. Apply loclite 5188 on the front housing.

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 877
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

35. Install the clutch housing. 38. Install the 6th drive gear on counter
shaft.

36. Install the clutch housing mounting

bolts. Torque tighten the bolts to specified 39. Install the 6th gear synchro ring on
value. counter shaft.

37. Install the 6th drive gear NRB and bush 40. Install the 5th & 6th synchro sleeve on
on counter shaft. counter shaft.

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
878 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

41. Install the 5th & 6th gear synchro hub on 44. Install the 5th drive gear NRB on
counter shaft. counter shaft.

42. Install the 5th & 6th fork & shift rail on 45. Install the 5th drive gear on counter
counter shaft. shaft.

43. Install the 5th drive gear bush by press 46. Install the 5th gear thrust washer &
on the counter shaft. reverse drive gear on counter shaft.

• Heat the bush before pressing to

ensure proper fitment.

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 879
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

47. Install the reverse synchro hub on 50. Install the synchro rings on output shaft.
output shaft by using suitable dolly.

51. Install the reverse driven gear & washer

48. Install the reverse synchro sleeve along on output shaft.
with fork & shift rail on output shaft.

52. Install the CRB on output shaft.

49. Install the reverse gear bush & NRB on
output shaft.

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
880 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

53. Using MST: 0703AAD0027H007 press 56. Apply loclite 638 on the thread & then
fit the counter shaft rear bearing. rotate anti clock wise direction to tighten the
bolt, torque tighten the bolts to specified
value.

• The bolt is reverse threaded, hence

rotate in anti clockwise for refitting.

54. Engage the 2nd gear.

55. Engage the 4th gear.

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 881
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

57. Using MST tighten the output shaft lock 58. Install main shift rod along with the
nut, torque tighten the nut to specified value. interlock finger & washers in both sides.

• For 4WD MST — 0703AD2720H116 • Ensure gear in neutral position

(Lock Nut Dolly).
• For 2WD MST — 0703DBA0001ST
(Lock Nut Special tool).

59. Assemble the washer, NRB and Idler

shaft & install the reverse idler gear
assembly.

60. Remove the dummy bolts from front

housing assembly.

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
882 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

61. Using suitable tool and hydraulic press 64. Check for the rear end oil seal correct
fit the detent (press from outside to inside) seating.

65. Refit the H plate mounting bolts &

62. position the rear end oil seal on the torque tighten the bolts specified value.
MST- 0703AAD0027H074

66. Apply loctite 5188 and insert the rear

63. Position the MST along with the oil seal housing assembly .
& press fit the oil using a mallet.

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 883
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

67. While installing the rear housing install 70. Install the neutral sensor. Torque tighten
the shift block actuator. the nut to specified value.

68. Insert the rear housing mounting bolts, 71. Refit the reverse light switch. torque
torque tighten the bolts specified value. tighten the switch to specified value .

69. Insert the rear housing mounting bolt

from front housing side and torque tighten
the bolts to specified value .

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
884 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

72. Insert the front & the bottom idler shaft 74. Position the shift block actuator & insert
mounting bolts, torque tighten the bolts to the allen bolt. torque tighten the bolt to
specified value. specified value .

For 4WD,
75. Apply loctite on the rear housing to fit
shifter lever assembly.

73. For 2WD, Refit the vehicle speed

sensor with the help of mounting bolt torque
tighten the bolt specified value . 76. Refit the shifter lever assembly & the
mounting bolts. torque tighten the bolts to
specified value .

Yellow colored bolts are fitted with dowel

inside, this bolts should be refit first.

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 885
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

77. Refill the Transmission fluid. For

additional information refer to Transmission
fluid Drain & Filling Section.

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
886 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.7 Technical Specifications

General Specification

Transmission Model M&M 6MT 320

Number of Speed 6 forward, 1 Reverse

Shift Pattern Manual

Synchromesh Type Synchromesh in all gears

GEAR RATIOS

1st gear 3.777 : 1

2nd gear 2.214 : 1

3rd gear 1.425 : 1

4th gear 1.00 : 1

5th gear 0.791: 1

6th gear 0.71: 1

Reverse 3.559 : 1

Main Shaft Gear (Number of teeth) Drive

1st gear 12

2nd gear 21

3rd gear 31

4th gear 29

5th gear 47

6th gear 49

Reverse 16

Counter shaft Gear (Number of teeth) Driven

1st gear 39

2nd gear 40

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 887
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

General Specification

3rd gear 38

4th gear 25

5th gear 32

6th gear 30

Reverse 49

Reverse Idler Gear (Number of teeth) 27

10.8 Sealant Specification

Location Sealants/ Thread Locks

Front Housing & Intermediate Plate Loctite 5188

Intermediate Plate & Rear Housing Loctite 5188

Clutch Housing & Front Housing Loctite 5188

Counter shaft rear bolt Pre Coated

Pivot locking Loctite 5188

Between Clutch Housing & OD of Ft.

Loctite 5188
Bearing Retainer

Lock nut output shaft Loctite 648

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
888 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.9 Sealant Application Pattern

10.9.1 Clutch Housing — Front Housing

Bead width : 2±0.5mm

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 889
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.9.2 Front Housing — Intermediate Plate

Bead width : 2±0.5mm

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
890 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.9.3 Intermediate Plate — Rear Housing

Bead width : 2±0.5mm

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 891
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.9.4 Rear Housing — Lever Assembly Gear Shift

Bead width : 2±0.5mm

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
892 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10.10 Torque Specification

Descriptions Torque (NM)

OUTPUT SHAFT LOCK NUT 115±5

H- PLATE BOLT 27.5±2.5

4TH RAIL ALLEN BOLT 12.5±2.5

IDLER SHAFT AXIAL BOLT 27.5±2.5

IDLER SHAFT RADIAL BOLT 30±5

FRONT HOUSING TO REAR HOUSING

BOLT (7 NOS.) 30±5

FRONT HOUSING TO REAR HOUSING

BOLT (2 NOS.) 30±5

DRAIN PLUG 27.5±2.5

SPEEDO SENSOR BOLT 10±2

REAR PLUG 22.5±2.5

FILLER PLUG 27.5±2.5

REVERSE LAMP SWITCH 27.5±2.5

NEUTRAL SENSOR 27.5±2.5

CLUTCH- FRONT HOUSING BOLT 27.5±2.5

SHIFTER SHOULDER BOLT 27.5±2.5

SHIFTER BOLT 27.5±2.5

COUNTER SHAFT END BOLT 45±5

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 893
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
894 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11 TRANSFER CASE

11.1 Description & Operations

11.1.1 Electronic Transfer Case

The Divgi-Warner’s two speed, part time electronic shift transfer case consists of a shift motor,
speed sensor, electric clutch and transfer case electronic control unit (ECU). The mode
selector switch located on the center console, which is used to select the transfer case mode
and mode indicator (4H and 4L). The wiring harness connects the above parts with the power
input.
The power received by the input and is coupled to the two output shafts of the transfer case.
One of the output shaft is fixed to the rear axle and other is fixed to the front axle.
The planetary gear set provides gear reduction. The power is transferred to the front wheel
drive through a Morse HY- VO chain drive. The oil pump provides lubrication to the planetary
gear set and the upper output shaft components. The 2H,4H and 4L modes are obtained by
rotating the selector switch which in turn gives a signal to the transfer case ECU that controls
the operations. The transfer case ECU senses the conditions and shift the transfer case as per
selected mode.
The transfer case allows both two and four wheel drive operation. The HY-VO chain driven
output in the transfer case provides four wheel drive for the vehicle. The positive displacement
oil pump and filter in the transfer case assures full lubrication while driving or towing the

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 895
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

vehicle, reducing maintenance needs. The helical gearing provides quiet and low range
operation. The four wheel drive indicator light on dash board indicates the four wheel drive.
The electromagnetic shift-on-the-fly provides effortless engagement of four wheel drive high
mode at highway speeds. However the four wheel drive low engagement vehicle should be at
zero speed and should be in neutral.
Power to the road wheels is transferred via mechanical units called as auto locking hubs.
When 4WD is selected the auto locking hubs lock the axle shaft to the wheel hub. This
mechanical locking will occur when the vehicle is driven in either forward or reverse direction.
incase the mode is shifted to 2WD, the vehicle has to driven in either forward or reverse
direction for few feet. Disengagement of the auto locking hubs can be identified by clicking
sound from units.

11.1.2 Transfer Case Controller

Transfer case controller fitted on the floor at

the bottom of the driver seat. Its act as a
brain of the electronically shifted 4WD
systems. The controller processes the shift
request from the mode selector switch,
executes the shift, and verifies the shift was
completed. The Controller will executes
requested 4WD shifts by activating the
transfer case motor.

11.1.3 Transfer Case Motor

Transfer Case Motor fitted on the transfer

case and It’s a small electric motor that
moves parts within the transfer case itself to
activate the various modes of the 4WD
system.

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
896 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.1.4 Tuner Mass assembly

Transfer case Tuner mass assembly fitted on

the bottom of transfer case by brackets. This
act as a vibration damper and serves to
dampen the harmonic vibrations in the
drivetrain of the vehicle.

11.1.5 4H – Four Wheel High

All four wheels are driven at 1:1 speed ratio.

The four wheel drive lamp illuminates when
4H mode is selected. This mode provides
additional traction and maximum pulling
power for loose, slippery road surfaces such
as ice, snow, gravel, sand and dry pavement.
Front and rear drive shafts are locked
together in this mode which forces the front
and rear wheels to rotate at the same speed.

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 897
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.1.6 4L - Four Wheel Low

All four wheels are driven at 2.48:1 speed

ratio. Use this mode for maximum pulling
power and traction. Use 4L position for
climbing or descending steep hills, off- road
driving, hard pulling in sand, mud or deep
snow. Driving in the 4L position on dry hard
surfaced roads may cause increased tire
wear and damage to drive line components.
Front and rear drive shafts are locked
together in this mode which forces the front
and rear wheels to rotate at the same speed.
Take care not to over rev the engine and do
not exceed 20 mph when driving in this
mode. When operating your vehicle in 4L,
the engine speed is considerably higher than
that of the 4H position at a given road speed.

Because four- wheel drive provides

improved traction, there is a tendency to
exceed safe turning and stopping
speeds. Do not go faster than the
permitted road conditions. Do not shift to
a lower gear than necessary to maintain
forward motion. Over-revving the engine
can spin the wheels and traction will be
lost. Avoid abrupt down shifts on
slippery roads, engine braking may
cause skidding and loss of control.

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
898 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.1.7 Shifting Procedure

11.1.7.1 Shifting between 2H and 4H

Shift from 2H to 4H mode at any vehicle

speed from 0-60 mph. To shift from 2H to 4H
turn the selector switch to 4H position. Once
the shifting is complete 4WD HIGH lamp in
the instrument cluster illuminates. If the lamp
doesn't come on, drive straight ahead
accelerating or decelerating. If the lamp still
doesn't come ON, contact your an authorized
Mahindra dealer as soon as possible. There
may be a malfunction in the four wheel drive
system.
To shift from 4H to 2H, turn the selector
switch knob to 2H position. This can be done
at any speed from 0- 60 mph. 4WD HIGH
lamp in the instrument cluster goes out. If the
lamp continues to illuminate, drive straight
ahead accelerating or decelerating, or drive
forward and backward in a short distance. If
the lamp continues to illuminate, contact an
authorized Mahindra dealer as soon as
possible. There may be a malfunction in your
four wheel drive system.

Never operate the selector switch knob if

the wheels are slipping. Stop the slipping
or spinning before operating.

The vehicle uses automatic hub lock

system to engage or disengage the front
wheels. Once the 2H mode is selected
from either 4H or 4L, whenever possible
drive vehicle in reverse direction for 1 to
1.5 meters to disengage the automatic
locking Hubs. If the vehicle still seems to
be engaging the front wheels, drive the
vehicle in reverse for further few meters
to make sure that the auto hub locks are
disengaged completely.

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 899
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.1.7.2 Shifting from 4H to 4L

Bring the vehicle to a complete stop with the

brake pedal depressed. shift the TGS lever
into N (Neutral). Turn the four wheel drive
selector switch to 4L position. 4WD LOW
lamp in the cluster should illuminate and
4WD HIGH lamp goes out . If 4WD LOW
lamp doesn't illuminate within 10 sec. Repeat
the above steps again.

11.1.7.3 Shifting from 4L to 4H

Bring the vehicle to a complete stop with the

brake pedal depressed. Shift the TGS lever
into N (Neutral). Turn the four wheel drive
selector switch to 4H position. 4WD LOW
lamp in the cluster goes out and 4WD HIGH
lamp should illuminate. If 4WD LOW lamp
doesn't go out within 10 sec., drive forward or
reverse for short distance, stop the vehicle
completely, shift the TGS lever into N
(Neutral) and operate the selector switch
knob again. If the problem persists contact
an authorized Mahindra dealer as soon as
possible. There may be a malfunction in the
four wheel drive system.

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
900 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.2 Component Index

11.2.1 Transfer Case Overview

1. Tuner Mass assembly 4. Speed sensor

2. Transfer Case Motor 5. Speedo Body

3. Transfer Case Controller

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 901
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.3 Trouble Shooting

11.3.1 Inspection and Verification
1. Verify the customer concern.
2. Visually inspect the transfer case for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to
the next step.
4. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart.

Mechanical
• Check for any oil leakage in the transfer case.
• Check the yoke, flange, drive gear and shift motor for any damage.
• Check for loose mounting bolts.

11.3.2 Symptom Possible Causes

Symptom Possible Causes Remedy

1. Broken drive chain 1. Check the drive chain and

linkage. replace it if necessary

2. Shift motor faulty 2. Check the motor, replace if

necessary

No front wheel drive when 3. Selection switch faulty 3. Check the selection
shifted to 4WD. switch, replace if necessary

4. Controller Unit faulty 4. Check and replace the

Controller unit

5. Faulty wiring harness 5. Check the wiring harness

and rectify the problem.

1. Transfer case oil level is 1. Drain old oil and fill the
too low. transfer case with specified
Noise during 4WD operation. oil.

(Make sure that noise comes 2. Loose bolts or mounting 2. Tighten the bolts and nuts
from the transfer case and parts of transfer case. to the specified torque.
not from clutch, transmission,
drive shaft or other 3. Noisy or worn transfer 3. Disassemble the transfer
components case bearings. case parts, and check the
bearings for wear or damage,
and replace it if necessary.

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
902 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

4. Worn or damaged gears. 4. Check for wear and

damage of the gear including
speedometer gear and
replace necessary parts.

5. Worn or damaged 5. Disassemble and check

sprockets. the sprockets for wear and
damage, replace if it is worn-
out.

1. Cracked transfer case. 1. Replace the transfer case.

2. Clogged breather. 2. Remove and clean the

breather. Replace it if
necessary.

3. Oil level is high or 3. Use the recommended oil

improper brand of oil is used. and maintain correct oil level.
Transfer case oil leakage.
4. Sealing bolts are loose. 4. Tighten the bolts to the
specified torque.

5. Improper brand of sealant 5. Use recommended sealant

used or improperly applied and ensure proper
sealant. application.

6. Worn or damaged oil seal. 6. Replace the oil seal.

Electronic shift problems. 1. Faulty or damaged 1. For additional information

Controller unit, speed sensor, refer to Diagnostics Manual.
clutch or internal wiring.

2. Damaged or worn shift 2. Disassemble the transfer

cam, hub, fork or rail shaft. case and check for wear and
damage. Replace the
necessary parts.

3. 2WD/ 4WD shift motor 3. Check and replace the

malfunction shift motor if necessary.

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 903
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.3.2.1 Component Inspection and Action Table

Component Inspection Action

1. Check for external 1. If external damages are

damages. found replace the Transfer
Case.

2. Check for external 2. If wirings are damaged,

Electronic Transfer Case damages to the wirings of check and rectify if
Transfer case. necessary replace the
affected components.

3. Check for oil leakages. 3. Take suitable action and

replace the required seals.

1. Check for external 1. Replace the selector

damages to the switch. switch.

2. Check the rotary knob for 2. If the switch is hard to

Selector Switch ease of operation. operate the replace it.

3. Check the electrical 3. If the electrical connection

connection to the rotary to the rotary knob is burnt
knob. then replace the wiring.

1. Check for damages/ 1. If corrosion is observed

corrosion to the electrical then clean the terminals with
terminals of the ECU. the suitable agents. If
damages are observed to the
electrical connection to the
Electronic Transfer Case ECU, then replace the
ECU affected components.

2. Check for external 2. If external damages are

damages. found replace the affected
components.

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
904 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.4 Care of the System

11.4.1 Self diagnosis of ECU
Transfer Case Electric Shift Circuit Diagram
ECU detects transfer case system malfunctions and indicates malfunctioning part(s) through
flashing indicator lights. The operator will be alerted of fault condition by continuous
illumination of both 4WD HI and 4WD LO lights on dashboard when ignition is On.
A service connector is provided to indicate the fault codes in binary. Connect one end to the
pin hole number 8 in DLC (Interconnect with ECU pin no 9), and other end to the ignition
switch. The flashing of indicator light will show the defective code (as illustrated in the table).
Identify the malfunctioning part and replace it.

Bina- Decimal
Fault
L1 L2 L3 ry Equiva- Defective Code
With
Code lent

ECU
Off Off On 001 1
Module

Shift
Off On Off 010 2
Motor

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 905
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Bina- Decimal
Fault
L1 L2 L3 ry Equiva- Defective Code
With
Code lent

Synchron-
Off On On 011 3
izer Clutch

Speed
On Off Off 100 4
Sensor

Selector
On On Off 110 6
switch

Motor
On On On 111 7 Position
Switch

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
906 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Before replacing the malfunctioning parts with defective codes, check the wires and
connectors for proper condition.
• Use only 12V 3 - Watt bulb for diagnostic purpose.
If only one part is malfunctioning, the indicator light will display defective code three times
continuously. If more than two parts are malfunctioning, the first malfunctioning part will be
displayed three times and then the other malfunctioning parts will be displayed.
After repair clear the fault stored in the memory. Ground the service connector and keep
ignition 'On' for five seconds continuously to erase defective code.
Connect a service connector as described earlier. Turn the ignition switch On. 4WD CHECK
indicator will turn On for 0.6 seconds and turn Off for 3 seconds. Then it will display a defective
code 3 times continuously.

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 907
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.4.2 Transfer Case Oil Replacement

11.4.2.1 Component Location Index

Transfer Case Oil– ATF MEETING THE SPEC. OF DEXTRON III

Capacity – 1.2 Liters.

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
908 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.4.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Check and ensure proper functioning of
transmission system.

Tools Required

Size Type Quantity

8 mm Allen Key 1

— Mechanical hand pump 1

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 909
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.4.2.3 Transfer Case Oil Draining Procedure

1. Using a suitable spanner, remove the oil

filling plug from the transfer case.

2. Remove the drain plug and drain the

transfer case fluid into a suitable container.

3. Collect the drained oil in a suitable

container.

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
910 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.4.2.4 Transfer case Oil Filling Procedure

1. Refit the drain plug. Torque tighten the 4. Using a suitable spanner, tighten the oil
drain plug to specified value. filling plug in the transfer case.

2. Fill up oil in the transfer case and then

insert the 8 mm allen key.
• Recommend to use “ATF MEETING
THE SPEC. OF DEXTRON III” Transfer
Case Fluid.
• Transfer case oil to be replaced first at
20,000 kms or 12 Months and then
every 40,000 kms or 24 Months
(Distance Covered in km / Months in
service whichever is earlier).
• Transfer case oil level to be inspected
first at 5,000 kms/3 Months, 10,000
kms/6 months (Distance Covered in
kms / Months in service whichever is
earlier) and then every service exclude
3. Remove the allen key and check the oil oil replacement Interval.
level mark. Refill the oil into the oil filling plug • For Non – ABS vehicles, if the activity
if the oil level is below the maximum level is done on a 2 post lift, ensure that the
mark. LSPV spring is disconnected before
lifting the vehicle. After lowering, re-
connect the LSPV spring and ensure
the correct LSPV setting height.

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 911
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5 In Car Repairs

11.5.1 Transfer Case R&R

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
912 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refill the Transfer case oil.
• Drain the Transfer case oil.

Tools Required

Size Type Quantity

10, 13, 14, 15, 16, 18 mm Socket spanner 1

14 mm Open end spanner 1

14, 13 mm Ring spanner 1

- Flat end screw driver 1

- Mallet 1

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 913
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.2 Removal:

1. Disconnect battery negative terminal by 3. By using 18 mm / 16 mm socket spanner

using 10 mm socket spanner. remove rear propeller shaft centre bearing
mounting bolts/nuts and keep aside the
propeller shaft assembly and hang on the
chassis.

2. Remove rear propeller shaft mounting

bolts on transfer case by holding the bolt
head with 14 mm open end then loosen the
nut with the help of 14 mm ring spanner. 4. Remove front propeller shaft U- clamp
mounting nuts on transfer case using 13 mm
ring spanner.

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
914 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. With the help of flat screw driver and 8. Using a 13 mm socket spanner remove
mallet, tap slightly and remove the U-Clips of the transmission assembly mounting bolts on
front propeller shaft on transfer case side and bed.
keep aside the propeller shaft assembly and
hang on the chassis.

9. Using hydraulic stand support the

transmission assembly.
6. By using 15 mm socket spanner, remove
the transfer case front & rear brackets
mounting bolts & remove the brackets.

10. Using a 16 mm socket spanner remove

the cross member mounting bolts and then
remove the cross member.
7. Disconnect transfer case motor
connectors and vehicle speed sensor
connector.

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 915
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Disconnect the breather hose from the

nipple.

12. Using a 14 mm socket spanner remove

the transfer case mounting nuts.

13. Remove the transfer case assembly

with care.

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
916 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.3 Inspection:
1. Check for any external oil leakage. Rectify if found.

11.5.1.4 Installation:

1. Lift and attach the transmission 3. Install the transmission rear mounting
assembly with transfer case using hydraulic bolts on bed, torque tighten the bolts to
stand. specified value.

2. Refit the cross member with the help of 4. Refit the transfer case mounting nuts on
mounting bolts, torque tighten the bolts to transmission assembly, torque tighten the
specified value. bolts to specified value.

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 917
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the transfer case front & rear 8. Refit the propeller shaft on transfer case
supporting brackets and mounting bolts and with the help of mounting bolt + nut
torque tighten the bolts to specified value. combination, torque tighten the bolts to
specified torque value.

6. Connect transfer case motor & vehicle

speed sensor electrical connectors. 9. Refit the propeller shaft centre bearing
with the help of mounting bolt + nut
combination, torque tighten the bolts to
specified torque value.

7. Mount front propeller shaft on transfer

case by inserting the U-Clips and fasten the
U-Clips with the help of mounting nuts.
Torque tighten the nuts to specified value. 10. Connect the battery negative terminal.

11. Check Transfer case oil level & top up if

required.

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
918 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1 Transfer Case Motor - R&R

11.5.1.1.2 Component Location Index

11.5.1.1.3 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Connect the electrical connector.
• Disconnect the electrical connector. • Check & confirm the neutral selection
through iSmart.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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 919
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1.4 Removal

1. Disconnect the transfer case motor

electrical connector.

2. Using a 10 mm socket spanner remove

the motor mounting bolts.

3. Remove the motor wiring pigtail and

remove the transfer case motor.

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
920 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1.5 Inspection
1. Check for the operation and any external damage, if found please replace.

11.5.1.1.6 Installation

1. Refit the transfer case motor, torque 3. Connect the motor electrical connection
tighten the mounting bolts to specified value. to transfer case wiring harness.

2. Refit the motor wiring pigtail on transfer

case.

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 921
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1 Transfer Case Controller R&R

11.5.1.1.2 Component Location Index

11.5.1.1.3 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/4 post lift. • Refit the Driver Seat .
• Remove the Driver Seat . • Connect the electrical connector.
• Disconnect the electrical connector.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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
922 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1.4 Removal

1. Remove the Driver Seat. For additional 4. Press the lock and disconnect the
information refer to Driver Seat R&R section. electrical connector from controller.

2. Remove the scuff plate mounting screws

and partially remove the front floor mat to
access the controller.

3. Using a 10 mm socket spanner remove

the mounting bolt and remove the Transfer
case controller.

11.5.1.1.5 Inspection
1. Check for any external damage & operation, if found please replace.

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 923
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.5.1.1.6 Installation

1. Connect the electrical connector.

2. Install the Transfer case controller and

mount with the help of mounting bolt torque
tighten the bolt to specified value.

3. Refit the front floor mat.

4. Refit the Driver Seat. For additional

information refer to Driver Seat R&R section.

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
924 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.6 Disassembly and Assembly

11.6.1 Transfer Case

11.6.1.1 Dis-assembly and Assembly Summary

Pre Removal Post Installation

• Drain the Transfer case Oil. • Refit the Transfer case .
• Remove the Transfer case from the • Refill the Transfer case Oil.
vehicle.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

10 mm Ring spanner 1

- Circlip plier 1

- Flat end screw driver 1

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 925
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.6.1.2 Dis-assembly

1. Drain the Transfer case fluid. For 4. Separate the oil seal and nut from the
additional information refer to Transfer case yoke flange.
fluid Drain Section.

2. Position the transfer case on the repair

fixture.

Dropping of heavy/large objects will

damage the part and cause personal
injury.

Ensure the oil is drained prior to

disassembly of the transfer case. 5. Remove the mounting bolts from the
bracket and take out the speedo body .

3. By holding the transfer case rear yoke

flange with a flange holder, remove the lock 6. Separate the speedo driven gear shaft
nut and washer and pull out the yoke with a and speedo body.
puller.

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
926 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using a suitable flat screw driver, remove 10. Gently pull and detach the sensor from
the oil seal from the rear casing. the rear casing. .

To avoid damage of the metal surface,

apply limited force to the bosses on the
cover and the transfer case while
breaking the sealant bond.

8. Remove the speedo drive gear from the

rear case.

11. Using a 16 mm socket spanner remove

the nine mounting bolts and remove the
identification tag

9. Using a 10 mm socket spanner, remove

the mounting bolts and remove the speed
sensor bracket and the motor.

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 927
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Separate the front case assembly, and 15. Remove the clutch coil wiring (single
the rear case assembly pin), from the connector .

13. Separate the return spring from the rear 16. Detach the clutch coil separately from
casing by pulling them outwards . the rear casing cover.

14. Using a 10 mm ring spanner, remove 17. Using suitable flat screw drivers,
the clutch coil mounting nuts. remove the snap ring

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
928 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18. Remove the ball bearing from the rear 21. Using a circlip plier , remove the circlip
casing. . from the output shaft.

19. Using a MST, pull out the needle 22. Remove the 2W - 4W lock up assembly,
bearing from the rear casing cover. lock up fork with sprocket and drive chain
from the output shaft.

Care must be taken not to damage the

metal surface while removing the needle
bearing

23. Detach the 2W - 4W shifting fork.

20. Remove the shifting fork and clutch

housing from the output shaft.

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 929
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24. Separate the drive chain. 27. Separate the gear rotor pump and
strainer assembly from the output shaft.

25. Separate the clutch plate and the 2W

sprocket . 28. Unlock the clip , and separate the
output shaft, gear rotor pump, the hose and
the strainer.

26. Remove the output shaft and the gear

rotor pump.
29. Remove the magnet from the front
casing.

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
930 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30. Remove the shaft assembly from front 33. Remove the input shaft from the front
side of the transfer case. casing.

31. Remove the cam and shaft assembly 34. Unlock the snap ring and remove the
bearing.

32. Separate the reduction hub and the

reduction fork from the case. 35. Using a yoke holder and a socket
spanner, remove the lock nut, washer and oil
seal then pull out the front yoke assembly.

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 931
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

36. Using a 16 mm socket spanner, remove 39. Remove the bush from the input shaft
the adapter input shaft and carrier assembly carrier assembly.
bolt.

40. Remove the needle bearing from the

37. Remove the carrier adapter front oil input shaft carrier assembly.
seal.

41. Separate the carrier assembly.

38. Remove the snap ring and pull out the
input shaft and the sun gear from the carrier.

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
932 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

42. Remove the input shaft assembly from 44. Using an outer circlip plier, unlock the
the carrier assembly. bearing lock circlip and remove the bearing.

43. Remove the sun gear thrust plate from

the input shaft.
Do not remove the ring gear shown in the
below figure from the case.

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 933
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.6.1.3 Assembly

1. Insert dowel pins to the ring gear casing. 3. Refit the input shaft on the front casing.

Check the oil seal prior to installation. In

case of any external damages are
observed, then replace the oil seal.

Dropping of heavy/large objects will

damage the part and cause personal
injury.

2. Press the ball bearing and install the 4. Using a suitable MST, refit an oil seal
retainer ring to the front casing. from the carrier assembly body.

Check the ball bearing for functionality

prior to installation.

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
934 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Using a circlip plier expand the snap ring 8. Refit the input shaft to the carrier
and press the ball bearing with bearing assembly by matching the splines.
installer and lock it in correct position.

9. Refit the thrust plate to the input shaft.

Using a circlip plier expand the snap ring

and press the ball bearing with bearing
installer and lock it in correct position.

6. Refit the needle bearing into the carrier

assembly input shaft.

10. Using a circlip plier expand the snap

ring and insert the carrier assembly with input
shaft to the adapter case.

7. Refit the bush into the carrier assembly

input shaft.

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 935
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Apply a 1.6 mm bead of sealant on the 14. Position the output shaft in transfer
mounting face for the transfer case and case, and install the end yoke assembly,
tighten the mounting bolts seal, washer and the lock nut.

12. Refit the adapter input shaft and carrier 15. Using a suitable MST yoke holder,
assembly to the case, and using a 16 mm socket spanner and torque wrench, tighten
socket spanner, tighten the mounting nuts to the front flange mounting lock nut to specified
specified torque. torque.

13. Refit the breather nipple. 16. Refit the reduction hub and reduction
shift fork into the front casing.

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
936 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17. Refit the electric shift cam . 20. Assemble the strainer and hose to the
gear rotor pump.

21. Align the gear rotor pump with the

Position the cam on the spring and rotate output shaft.
it in anti- clockwise direction, push the
spring towards left along with cam and
fix it on the drive tang.

18. Refit the fork shaft in the reduction hub

housing.

Align the guide pin of the shaft to the slot

on the pump body and slide the pump
assembly onto the output shaft over
pump pin.
19. Refit the magnet into body.

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 937
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22. Install the output shaft and gear rotor 25. Refit the drive chain from the sprocket .
pump assembly into the reduction hub
housing by matching the splines.

23. Position the drive sprocket on the rear Holding each sprocket with the drive
output shaft end. chain tight and parallel with the transfer
case, install the drive chain assembly to
the output shaft. Rotate the driven
sprocket slightly to engage splines on
the front output shaft.

26. Install the snap ring into the groove of

the front output shaft.

24. Refit the driven sprocket on the front

output shaft end.

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
938 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27. Refit the 2W - 4W lock up fork the 29. Using circlip plier install the bearing
clutch plate and the clutch housing to the lock.
output shaft.

30. Refit the return spring over rail shaft in

the transfer case.

Check the ball bearing prior to

installation. In case of any external
damages are observed, then replace the
ball bearing.

28. Using a suitable MST press the ball

bearing from the rear casing.

31. Using a suitable MST, install the needle

bearing in correct position and press it into
the cover.

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 939
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

32. Insert the clutch coil assembly inside of 34. Apply the loctite to the transfer case
the cover. mounting surface.

Insert the clutch coil wire into the hole in Align both the cover holes with the
the transfer case and pull it out. transfer case dowel pins. Align the cover
bearings with the output shaft and the
33. Tighten the coil mounting nut and shift shaft with the cover boss.
torque tighten the nut to specified value.

Align the cover blind hole with rail shaft

and make sure that the return spring is
not cocked.

35. Refit the front and rear housing and

bolts and torque tighten the nut to specified
value.

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
940 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

36. Install the speedo gear output shaft 39. Refit speed sensor.
spline in the cover assembly.

40. Apply the loctite at the motor and

37. Using a suitable MST, install a new oil transfer case mating surface.
seal into the cover assembly.

41. Refit the motor and the speed sensor

38. Install the flange and washer and lock bracket and mounting bolts and torque
nut to the output shaft. tighten the nut to specified value.

Do not fully tighten the bolts at this

stage.

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 941
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

42. Refit the speedo driven gear shaft and 45. Remove the transfer case from the
speedo body. repair fixture.

43. Refit the speedo sensor assembly and 46. Refill the Transfer case fluid. For
mounting bolts and torque tighten the bolts to additional information refer to Transfer case
specified value. fluid Drain & Filling Section.

44. Using a suitable MST tighten the rear

flange lock nut and torque tighten the nut to
specified value.

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
942 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.7 Technical Specifications

General Specification

Transfer Case Type Part time, Single Offset

Rear output configuration Circular flange

Front output configuration Fixed yoke

Input configuration Female spline

Offset hand Right hand

Lubrication System Force lubrication by Gear rotor pump

Transfer Case Fluid — DEXRON III ATF MEETING THE SPEC. OF DEXTRON III

Housing Material Aluminum

Dry weight in kgs 30 Kgs. Aprox.

Fluid Capacity in liters 1.2

Shift Pattern 2H - 4H - 4L

4WH shift on the fly Optional

Shift Control Selector switch

11.8 Sealant Specification

Location Sealants
Transfer Case Cover Loctite RTV598

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 943
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11.9 Torque Specification

Description Torque (NM)

DRAIN PLUG 34±6

REAR FLANGE NUT 355±15

FRONT YOKE NUT 224±20

CASE BOLTS 34±6

MOTOR BOLTS AND COIL NUTS 10±1

SPEEDO BODY BOLT 10±1

11.10 Mahindra Special Tools (MST)

Sl No. Special Tool Description Mahindra Special Tool

Driver Transfer Case O/P shaft Front & MST 217

1
Rear Seal

2 Wedge Transfer case O/P shaft front MST 225

bearing cone removing

3 Ring transfer case O/P shaft bearing MST 223

cup removing

4 Puller transfer case shift rod oil seal MST 224

5 Puller transfer case output shaft oil seal MST 226

6 Thimble & Driver T/F case Shift rail oil MST 227
seal installing

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
944 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12 PROPELLER SHAFT

12.1 Description and Operation

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 to operate 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 sealing at the transmission end is achieved using an oil seal. When the propeller shaft is
removed from the transmission end some amount of transmission oil is expected to come out.
This is normal.

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 945
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.2 Component Location Index

12.2.1 Refer below illustration for rear propeller shaft layout (2WD)–

A. Centre Bearing and Socket.

B. Front Shaft Tube.
C. Front Universal Joint.
D. Front Sleeve Yoke.
E. Rear Universal Joint.
F. Rear Flange Yoke.
G. Rear Shaft Tube.
H. Centre Universal Joint.
I. Centre Sleeve Yoke.

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
946 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.2.2 Refer below illustration for propeller shafts layout (4WD)–

A. Centre Bearing and Socket.

B. Front Shaft Tube.
C. Front Universal Joint.
D. Front Flange Yoke.
E. Rear Universal Joint.
F. Rear Flange Yoke.
G. Rear Shaft Tube.
H. Centre Universal Joint.
I. Centre Sleeve Yoke.

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 947
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.3 Trouble Shooting

• Tyres that are out of round or wheels that are out of balance causes a low frequency
vibration.
• Brake drums that are unbalanced cause a harsh low frequency vibration.
• Drive line 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.
Refer below chart for various symptoms, causes and their remedial actions –

Symptom Causes Remedial Action

1. Undercoating or other ● Clean exterior of shaft &

foreign particle on the shaft. wash with solvent.

2. Worn-out yoke/slip joint. ● Replace the joint/yoke.

● Check run out, Replace

3. Excessive run out.
shaft if limit exceeded.

4. Incorrect drive line

● Correct angularity.
angularity.

Propeller Shaft Vibration 5. Worn universal joint

● Replace the universal joint.
bearings.

6. Propeller shaft damaged ● Replace the propeller

or bent. shaft.

● Re-index the propeller

7. Excessive run out or shaft by 180°, test and
unbalanced condition. correct as required.

8. Excessive pinion shaft run ● Check and rectify

out.

Universal Joint Noise UJ worn out ● Replace the UJ

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
948 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.3.1 Component Inspection and Testing Table

Component Inspection Action

Propeller shaft 1. Check the propeller shaft ● Replace the propeller

for any external damage or shaft.
bend.
● Replace the propeller
2. Check the propeller shaft shaft.
for any flyweights missing.

Universal Joint Check the joint for any ● Replace the universal joint
damage, worn or excessive
play.

Centre bearing Check the centre bearing for ● Replace the centre
play or noise. bearing.

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 949
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.4 Standard Checking Procedure

12.4.1 Propeller Shaft Imbalance - Check
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.

1. Clean all the foreign material from 8. Install a screw clamp at position “1”.
propeller shaft and the universal joint.

2. Ensure that the propeller shaft is not

worn, are properly installed and are correctly
aligned with the propeller shaft

3. Check the companion flange mounting

bolts.

4. Raise the vehicle and remove rear

wheels & tyres.

5. Install the wheel nuts to lock the brake

drum.
9. Start the engine and recheck for
6. Mark & number the shaft 6 inches from vibrations. If there is little vibration or no
pinion end at four positions 90° apart. change in vibrations then move the clamp to
the other 3 positions.

10. If there is no difference in vibration at

the other position then the vibration is not
due to the propeller shaft imbalance.

11. If the vibration decreases, install a

second clamp and repeat the test.

7. Run and accelerate the engine until

vibration occurs. Note the intensity & the
speed at which the vibration occurs.

12. If the clamps cause an additional

imbalance, separate the clamp (¼ inch
above & below the mark). Repeat the
vibration test.

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
950 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Increase the distance between the

clamps until the vibration is at the lowest
level.

14. At this position bend the slack end of

the clamp so that it does not loosen.

15. Install the wheel & tyres. Lower the

vehicle.

16. If the amount of the vibration remains

unacceptable then repeat the exercise at the
gearbox end.

• After completing above procedure, if vibration is reduced, which indicates there is

some imbalance in the propeller shaft.
• Replace the propeller shaft.

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 951
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.4.2 Propeller Shaft Run out – Check

1. Remove the propeller shaft from vehicle.

2. Remove dirt, rust, paint & undercoating

from the propeller shaft surface

3. Keep the propeller shaft on surface plate

along with ‘V’ block at both ends.

4. Assemble dial indicator.

5. The dial indicator must be installed

perpendicular to the shaft surface.

6. Measure the run out at the center and at

the ends by rotating propeller shaft assembly
by hand – away from the weld.

7. Replace the propeller shaft if the run out

is beyond the specified limit.

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
952 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.4.3 Propeller Shaft Greasing

1. 1. Clean the propeller shaft (front &

Rear) sliding yoke lubrication nipple and
surrounding area (Dirt, rust, paint & anti rust
coating etc.,).

2. Apply greasing on sliding yoke

lubrication nipple by using greasing gun.

3. Clean the propeller shaft sliding yoke

lubrication nipple and surrounding area to
avoid dust accumulation after greasing.

• Propeller Shaft Sliding Yoke Assembly greasing to be done first at 10,000 kms / 6
months and then every regular service.
• For Non –ABS vehicles, 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 the correct LSPV setting height.
• Recommend to use only LITHIUM COMPLEX GREASE (NLGI 3 (Mineral) : Upto -10̊ C
/ NLGI 2 (Synthetic) :-10̊ C & below)

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 953
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5 In Car Repairs

12.5.1 Propeller Shaft (2WD) R&R

12.5.1.1 Component Location Index

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
954 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post / 4 post • Check and ensure proper functioning of
lift. propeller shaft.
• Transmission should be in neutral
position.

Removal steps:
1. Remove the centre bearing mounting bolts.
2. Remove propeller shaft rear flange mounting bolts on companion flange.
3. Remove rear propeller shaft.
Tools Required

Size Type Quantity

14 mm Ring Spanner 01

14 mm Open end spanner 01

18 mm Socket Spanner 01

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 955
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.1.3 Removal:

Put aligning marks on the flange, UJ and propeller shaft before removal.

1. Remove the centre bearing mounting 3. Carefully pull-out and remove the
bolts using 18 mm socket spanner. propeller shaft assembly.

• When the propeller shaft is removed

from the transmission end some
amount of transmission oil is expected
to come out. This is normal.

2. Remove rear propeller shaft mounting

bolts on companion flange with the help of 14
mm ring spanner.

While loosening the bolt, hold the nut

using 14 mm open end spanner.

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
956 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.1.4 Inspection:
1. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if found
replace the propeller shaft assembly.
2. Clean the propeller shaft if any foreign materials like dirt found.
3. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found.

12.5.1.5 Installation:

1. Position the propeller shaft assembly. 5. While assembling the propeller shaft on
to the vehicle, first keep the centre bearing
2. Mount the rear flange yoke using loose, tighten at the axle end, after that
mounting bolts and nuts. Torque tighten the tighten the centre bearing mounting bolts
bolts to specified value.

3. Fasten the centre bearing using

mounting bolts. Torque tighten the bolts to
specified value.

4. Check and top up transmission fluid if

required.

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 957
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.2 Rear Propeller Shaft (4WD) R&R

12.5.2.1 Component Location Index

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
958 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post / 4 post • Check and ensure proper functioning of
lift. propeller shaft.
• Transmission should be in neutral
position.

Removal steps:
1. Remove the centre bearing mounting nuts.
2. Remove propeller shaft front flange mounting bolts on transfer case.
3. Remove propeller shaft rear flange mounting bolts on companion flange.
4. Remove rear propeller shaft assembly.
Tools Required

Size Type Quantity

14 mm Ring Spanner 01

14 mm Open end spanner 01

16 mm Ring Spanner 01

18 mm Socket Spanner 01

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 959
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.2.3 Removal:

Put aligning marks on the flange, UJ and propeller shaft before removal.

1. Remove the centre bearing mounting 3. Remove rear propeller shaft mounting
nuts using 18 mm socket spanner. bolts on transfer case with the help of 14 mm
ring spanner.

While loosening the nut, hold the bolt

using 16 mm ring spanner. While loosening the bolt, hold the nut
using 14 mm open end spanner.

2. Remove rear propeller shaft mounting

bolts on companion flange with the help of 14 4. Remove the rear propeller shaft
mm ring spanner. assembly from vehicle.

While loosening the bolt, hold the nut

using 14 mm open end spanner.

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
960 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.2.4 Inspection:
1. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if found
replace the propeller shaft assembly.
2. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found.
3. Clean the propeller shaft if any foreign materials like dirt found.

12.5.2.5 Installation:

1. Position the propeller shaft assembly. 4. Fasten the centre bearing using
mounting bolts. Torque tighten the bolts to
2. Mount the rear flange yoke using specified value.
mounting bolts and nuts. Torque tighten the
bolts to specified value.

5. While assembling the propeller shaft on

to the vehicle, first keep the centre bearing
3. Refit the propeller shaft on transfer case loose, tighten at the axle end, after that
with the help of mounting bolt + nut tighten the centre bearing mounting bolts
combination, torque tighten the bolts to
specified torque value.

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 961
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.3 Front Propeller Shaft (4WD) R&R

12.5.3.1 Component Location Index

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
962 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post / 4 post • Check and ensure proper functioning of
lift. propeller shaft.
• Transmission should be in neutral
position.

Removal steps:
1. Remove propeller shaft U - Clamps from transfer case.
2. Remove propeller shaft clips on front axle side.
3. Remove front propeller shaft.
Tools Required

Size Type Quantity

13 mm Combination spanner 01

- Flat end screw driver 01

8 mm Socket spanner 01

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 963
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.3.3 Removal:

1. Remove front propeller shaft U- clamp 4. Remove front propeller shaft assembly.
mounting nuts on transfer case using 13 mm
combination spanner.

2. With the help of flat screw driver and

mallet, tap slightly and remove the U-Clips of
front propeller shaft on transfer case side.

3. Using 8 mm socket spanner, remove

front propeller shaft mounting bolts of front
axle and detach the clips.

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
964 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.3.4 Inspection:
1. Inspect the propeller shaft for any bend, crack, twisting, and stone penetration, if found
replace the propeller shaft assembly.
2. Clean the propeller shaft if any foreign materials like dirt found.

12.5.3.5 Installation:

1. Position the propeller shaft.

2. Mount front propeller shaft on front axle

with the help of clips and mounting bolts,
Torque tighten the bolts to specified torque
value.

3. Mount front propeller shaft on transfer

case by inserting the U-Clips and fasten the
U-Clips with the help of mounting nuts.
Torque tighten the nuts to specified value.

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 965
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.4 Universal Joint (UJ) R&R

12.5.4.1 Component Location Index

Tools Required

Size Type Quantity

— Snap ring plier 01

32 mm Socket wrench 01

- Push rod- O.D 25 mm x 50 mm Length 01

Bearing cup spacer – O.D 50 mm x I.D 32 mm x

— 01
Height 30 mm

— Round fine toothed file 01

— Marker pen 01

— Alignment mandrel dia 30.125 01

— Soft Hammer 01

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
966 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.4.2 Removal:

1. Remove the propeller shaft assembly.For 4. Grip the partially removed bearing cup in
additional information refer to propeller shaft an Bench vice, Tap the yoke with soft
R&R section. hammer so that the Bearing cup is
completely dismantled from the yoke.
2. Using snap ring plier remove all the snap
rings of the universal joint kit. Mark position
of the Flange yoke & Stub yoke so that it is
fitted in the same position on the shaft after
kit replacement.

U3A100011

5. Repeat Step 2 & 3 to remove the other

Bearing cup from the yoke.
U3A100010
6. Inspect the dismantled stub yoke &
flange yoke for any dent or damages in the
3. To remove U.J Kit, Place bearing spacer cross hole area, Deburr the area near the
onto the base of the arbor press or Hydraulic face with soft toothed file. Verify the
press & under the Flange yoke Cross hole alignment of Yokes with Alignment mandrel,
diameter. Press down the upper bearing cup If the alignment does not pass thru the two
assembly until the shoulder of the cross cross holes simultaneously, The cross holes
make contact with inside of the flange yoke are misaligned & the distorted yoke (s) need
ear (Do not over press the Bearing cup to be replaced, Use fresh yokes in the
subassembly, This may damage the inside of assembly.
the Yoke ear.

U3A100012
W1A130022

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 967
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.4.3 Installation:

1. Insert the universal joint cross inside the

cross hole of the yoke, Place the yoke onto
the base of Arbor or Hydraulic press. Locate
one bearing cup in the upper cross hole of
the yoke & press down the bearing cup
assembly with push rod so that groove
diameter of the yoke is completely exposed,
ensure that the cross is properly located into
the bearing cup assembly.

U3A100013

2. Insert the snap ring with the help of plier

into the cross hole groove.

3. Repeat the above procedure for the

other end of the yoke.

4. Check & ensure that joint movement is

smooth without any jerks & stickiness.

5. Grease the U. J kit with recommended

grease.

6. Refit the propeller shaft assembly. For

additional information refer to propeller shaft
R&R section.

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
968 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.5 Centre Bearing — Dismantling

12.5.5.1 Component Location Index

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 969
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.5.2 Removal:

1. Remove the propeller shaft assembly 4. Remove the centre bearing assembly by
from vehicle. For additional information refer striking with a soft hammer or hydraulic
to propeller shaft R&R section. press.

2. Remove the centre universal joint and

detach rear shaft tube.
Place the Mid ship shaft on flat portion
and tap it, so that Centre bearing come
out from mid ship shaft.

U3A100008

3. Support the shaft on ‘V’ block and

remove the lock nut, steel washer and
remove the end yoke.

U3A100014

U3A100016

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
970 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.5.5.3 Installation:

1. Slip the new centre bearing assembly

onto the shaft.

U3A100015

2. If the centre bearing cannot be pushed

into place, use a tube which fits over the
spline and contacts the bearing inner race to
press or drive the bearing into place.

U3A100016

3. Refit the end yoke in the correct position

and mount using nut. Torque tighten the nut
to specified value.

4. Refit the propeller shaft assembly from

vehicle. For additional information refer to
propeller shaft R&R section.

5. While assembling the propeller shaft on

to the vehicle, first keep the centre bearing
loose, tighten at the axle end, after that
tighten the centre bearing mounting bolts

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 971
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12.6 Tightening Specifications & Sequence

Location Torque Nm

Front axle propeller shaft front mounting U clamp 4WD 19 ± 3

Front axle propeller rear mounting U clamp 4WD 25 ± 5

Propeller shaft front end demo 52.5 ± 10

Propeller shaft rear end 52.5 ± 10

Split propeller clamp 88.5 ± 16.5

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
972 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13 FRONT AXLE

13.1 Description and Operation

The front axle is a hypoid independent front suspension (IFS) type and utilizes shim
adjustment to obtain bearing pre-loads. The differential case with the crown wheel and drive
pinion are mounted in the opposed taper roller bearing in single- piece rear axle carrier. The
differential bearing preload and ring gear backlash are adjusted by using shims (select
thickness). The shims are located between the differential bearing cups and the axle housing.
The pinion bearing preload is maintained by using a collapsible spacer.
The Constant Velocity (CV) joints are held in the housing by the bearings and the retainers at
the outer end of the housing.
The axle for a 4WD vehicle receives power from the transfer case through the front propeller
shaft. The propeller shaft in turn transfers the power to the differential. The power is now
transmitted to the axle shafts through the pinion mate and side gears. The side gears are
splined to the axle shafts. This is done through two constant velocity (CV) drive shafts.

13.1.1 Automatic Locking Hub

Automatic Locking Hub locks the axle shaft to the wheel hub when 4-wheel drive is selected.
This occurs when the vehicle is driven in either forward or reverse direction. The hub unlocks
when 2- wheel drive is selected, and the vehicle is driven in the opposite direction for a few
feet.

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 973
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.2 Component Location Index

A. Half Shaft Assembly.

B. Rubber Boot.
C. Breather Nipple.
D. Differential Housing.
E. Front Axle mounting Bracket.
F. Companion Flange.

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
974 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.3 Trouble Shooting

13.3.1 Inspection and Verification
1. Verify the customers concern.
2. Visually inspect the front axle for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to
the next step.
4. If the cause is not found visually during the inspection, refer to the troubleshooting chart.
5. Check for oil level and condition.

13.3.2 Mechanical
1. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal.
2. Check for any noise in the bearing, pinion gear, crown wheel, sun and planet gears.

13.3.3 Refer below chart for various symptoms, causes and there
remedial actions of system

Symptom Causes Remedial Action

1. Axle shaft lock looseness • Inspect the axle shaft lock,

or broken. and replace it if necessary.

2. Bent axle shaft. • Replace the axle shaft.

3. End play in drive pinion • Refer to pinion pre- load

bearings. information and correct it if
necessary.

4. Excessive or very low gear • Correct the adjustment of

backlash between the ring the ring gear and the pinion
gear and pinion. backlash.

Axle Noise 5. Improper adjustment of the • Adjust pre-load of the pinion

pinion bearings. bearings.

6. Loose pinion yoke nut. • Tighten the pinion yoke nut

to specified torque.

7. Scuffed gear tooth contact • Inspect and replace the

surfaces. gear tooth if necessary.

8. Insufficient axle oil. • Replace the axle oil and

maintain correct level.

9. Deteriorated or poor grade • Replace the oil with

oil. recommended oil.

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 975
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial Action

10. Loose differential side • Adjust differential side

bearing. bearing.

11. Worn differential side • Replace differential side

bearing. bearing.

12. Ring gear thrust bolt lock • Reapply the liquid gasket
nut loose. and tighten the lock nut to
specified torque.

13. Drive pinion and/ or ring • Replace the drive pinion

gear damage. and the ring gear as a set.

14. NG excessive ring gear • Replace the drive pinion

run-out. and the ring gear as a set.

15. Worn drive pinion and • Replace the drive pinion

ring gear. and the ring gear as a set.

1. Overloaded vehicle. • Replace the broken shaft.

Avoid loading excessive
Axle Shaft Broken weight on the vehicle.

2. Axle bearing seized. • Replace the axle bearing.

1. Improper adjustment of the • Inspect the gears and

differential bearings. bearings for further damage.
Adjust differential bearing
preload. Replace the case.

2. Excessive ring gear • Inspect gears and bearings

Differential Cracked backlash. for further damage. Adjust
ring gear backlash. Replace
the case.

3. Vehicle overloaded. • Inspect gears and bearings

for further damage. Replace
the case. Avoid excessive
load on the vehicle.

1. Insufficient lubrication. • Fill the differential with

recommended quantity of
fluid.
Differential Gears Scored
2. Improper grade of • Replace the scored gears.
lubricant. Fill the differential with the
correct grade and quantity
fluid.

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
976 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial Action

3. Excessive spinning of one • Replace scored gears.

wheel/tyre. Inspect all gears, pinion
bores, and shaft for damage.
Service if necessary.

1. Lubricant level is too high. • Drain and adjust the

lubricant to correct level.

2. Worn axle shaft seals. • Replace the seals.

3. Cracked differential • Replace the differential

housing. housing.
Loss of Lubricant
4. Worn pinion seal. • Replace the seal.

5. Worn/scored yoke. • Replace the yoke.

6. Axle cover is not properly • Remove, clean, and re-seal

sealed. the cover.

1. Lubricant level is low. • Fill the differential with the

lubricant in correct level.

2. Improper grade of • Fill the differential with the

lubricant. correct grade fluid.
Axle Overheating
3. Pre-loads of the bearing is • Adjust the pre- loads of the
too high. bearing.

4. Insufficient ring gear • Adjust the ring gear

backlash. backlash.

1. Overloading. • Replace the gears.

Gear Teeth Broken
2. Improper backlash • Replace gears. Correct the
adjustments. ring gear backlash.

13.3.4 Noise when the vehicle is coasting

Check point Causes Remedial Action

Drive pinion and ring gear Insufficient backlash. • Adjust the back lash.
backlash.

Ring gear. Ring gear damaged. • Replace the ring gear and
the pinion as a set.

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 977
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.3.5 Intermittent Noise

Check point Causes Remedial Action

Half shaft. Too much spline play. • Replace the shaft.

Ring gear. Warped ring gear. • Replace the drive pinion

and the ring gear as a set.

Differential cage. Loose differential cage bolts. • Tighten the differential cage
bolts.

Axle case inside. Foreign material in the axle • Remove the foreign
case. material.

13.3.6 Noise when the vehicle is turning

Check point Causes Remedial Action

Half shaft. Worn rear Half shaft splines. • Replace the Half axle shaft.

Side gear. Worn side gear. • Replace the side gear.

Differential pinion. Worn differential pinion. • Replace the differential

pinion.

Differential cross pin. Worn differential cross pin. • Replace the differential
cross pin.

13.3.7 Constant Noise

Check point Causes Remedial Action

Half shaft Bent Half shaft. • Replace the Half shaft.

Drive pinion Flat spot on the drive pinion • Replace the drive pinion
gear teeth. and the ring gear as a set.

Worn pinion splines oil seal. • Replace the drive pinion

and the ring gear as a set.

Ring gear Flat spot on the gear teeth • Replace the drive pinion
pilot bearing wear. and the ring gear as a set.

Bearing 1. Flat spot on the drive • Replace the drive pinion

pinion. bearing.

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
978 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Check point Causes Remedial Action

2. Flat spot on the side • Replace the side bearing.

bearing oil seal.

13.3.8 Vibration

Check point Causes Remedial Action

Hub bearing Worn hub bearing. • Replace the hub bearing.

Half shaft Half axle shaft. • Replace the Half shaft.

13.3.9 Oil leakage from Differential carrier leakage

Check point Causes Remedial Action

Gear oil level Too much gear oil. • Correct the oil level.

Oil seal Worn or defective oil seal. • Replace the oil seal.

Air breather Clogged air breather. • Clean the air breather.

1. Loose bolts. • Tighten the bolts to the

specified torque.
Differential carrier
2. Liquid gasket seal bed. • Reapply the liquid gasket

Ring gear thrust bolt Loose lock nut and/or liquid. • Reapply the liquid gasket
and / or tighten the locknut to
the specified torque.

13.3.10 Axle case oil leakage

Check point Causes Remedial Action

Oil filler and drain plug Loose drain plug. • Tighten the drain plus.

Air breather Clogged air breather. • Clean the air breather.

Axle Cracked axle bolts. • Replace the axle case.

1. Loose bolts. • Tighten the bolts to

Differential carrier specified torque.

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 979
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Check point Causes Remedial Action

2. Liquid gasket seal bed. • Reapply the liquid gasket.

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
980 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.4 Standard Checking Procedure

13.4.1 Ring Gear & Pinion Assembly Theory:
Ring gear and pinion is supplied as a set. They are matched with each other during
manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer
illustration shown below for more clarity.

Illustration 1 Illustration 2

If a new gear set is used, verify numbers on pinion and ring for matching before proceeding
with assembly.
Standard mounting distance from centre line of ring gear to back face of pinion is controlled by
selecting shims, which are positioned between the inner pinion bearing cone and pinion gear.
Best running position of gear set is achieved by proper shim selection.
This dimension for front live axle will be different. On the bottom face of pinion, a number is
etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim
selection is achieved with help of this number. If alphabet "m" appears on pinion face shim,
selection has to be done in mm (Metric). If alphabet "m" does not appear on pinion face, shim
selection has to be done in inches (English).
Shims with different thicknesses are available for selection.

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 981
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.4.2 Shim Selection Procedure:

Use tables shown below for selecting correct thickness of shims either for addition or for
subtraction from old shim pack.
Illustration 1 shows ring and pinion etched with inch identification. Refer Table A.
Illustration 2 shows ring and pinion etched with metric identification. Refer Table B.
Example 1

In metric In inches

No punched on removed +8m +3

pinion.

No punch on new pinion. -5m -2

Value derived from table. +0.13 +0.005

Thickness of shim in OE x y
assembly.

Thickness of shims to be X+ 0.13 Y+0.005

selected for new ring/pinion.

Example 2

In metric In inches

No punched on removed -5m -3

pinion.

No punch on new pinion. +5m +4

Value derived from table. -0.1 -0.007

Thickness of shim in OE x y
assembly.

Thickness of shims to be X-0.1 Y-0.007

selected for new ring/pinion.

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
982 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

TABLE A

Old New Pinon Marking (English)

Pinion
Mark- -4 -3 -2 -1 0 +1 +2 +3 +4
ing
(Eng-
lish)

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 - 0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 - 0.001 - 0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 - 0.001 - 0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 - 0.001 - 0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 - 0.001 - 0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 - 0.001 - 0.002 -0.003 -0.004 -0.005 -0.006

-3 +0.001 0 - 0.001 - 0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 - 0.001 - 0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

TABLE B

Old New Pinon Marking (Metric)

Pinion
Mark- -10 -8 -5 -3 0 +3 +5 +8 +10
ing
(Met-
ric)

+10 +.20 +.18 +.15 +.13 +.10 +.07 +.05 +.02 0

+8 +.18 +.16 +.13 +.11 +.08 +.05 +.03 0 -.02

+5 +.15 +.13 +.10 +.08 +.05 +.02 0 -.03 -.05

+3 +.13 +.11 +.08 +.06 +.03 0 -.02 -.05 -.07

0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10

-3 +.07 +.05 +.02 0 -.03 -.06 -.08 -.11 -.13

-5 +.05 +.03 0 -.02 -.05 -.08 -.10 -.13 -.15

-8 +.02 0 -.03 -.05 -.08 -.11 -.13 -.16 -.18

-10 0 -.02 -.05 -.07 -.10 -.13 -.15 -.18 -.20

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 983
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Observe the marking on pinion. If ‘m’ is found etched on the face, refer table B. If not
refer table A.

13.4.3 Measuring Pinion & Gear Depth Using Service Tools & Gauges
“Pinion Shim Selection: (If Old Shim Not Available)
Pinion position shim selection can be done using a special tool, in the absence of removed
ring/pinion gear.
1. Fix the pinion height set master block on the pinion inner bearing setting area.
2. Fix the dial gauge on to O (zero), on the surface plate. Install dial gauge on pinion height
gauge by setting the pre load.

3. (Say ‘X’ mm for example) which is again a part of tool.

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
984 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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 985
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.4.4 Interpretation of Contact Pattern

The TOE of the gear is the portion of the

tooth surface at the end towards the centre.
The HEEL of the gear tooth is the portion of
the tooth surface at the outer end. The TOP
LAND of a gear tooth is the surface of the top
of the tooth. Every gear has a characteristic
pattern.

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
986 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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 987
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.5 Care of the System

13.5.1 Front Differential Oil Replace - Procedure

Tools Required

Size Type Quantity

½ Inch Square bit 01

Preliminary Activities/Conditions
1. Position the vehicle on 2 post lift/ 4 post lift.
Front Differential Oil –API GL-5, Meeting LS specification (Upto -10°C - 80W-90 and -10°C &
below - 80W-90)
Capacity – 1.25 Litres.

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
988 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.5.1.1 Front Differential Oil Draining & Filling Procedure:

1. Remove front differential filler plug using 3. Refit the drain plug and torque tighten to
1/2 inch square bit. specified value.

2. Remove front differential drain plug using 4. Fill recommended front differential fluid
1/2 inch square bit. with the help of a mechanical pump through
filler plug.

• Ensure that the oil level is up to lower

most point of the filler plug.

• Place a tray beneath the drain plug for

collecting the oil while draining.

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 989
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the filler plug and torque tighten to

specified value.

• Recommend to use only API GL-5, Meeting LS specification

• Front Differential oil to be inspected first at 5,000 kms/3 Months, 20,000 kms/12
months (Distance Covered in kms / Months in service whichever is earlier) and then
every service exclude oil replacement Interval.
• Front Differential oil to be replaced first at 10,000 kms/6 months and then every
30,000 kms/18 months (Distance Covered in kms / Months in service whichever is
earlier).
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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
990 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.5.2 Front Wheel Bearings Inspection

13.5.2.1 Component Location Index

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 991
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.5.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the wheel and tighten the wheel nut
sequentially with the specified torque.
• Remove the respective front wheel.
• Check for any grease leakage or
seepage.

Tools Required

Size Type Quantity

6 mm Allen key 1

21 mm Wheel Spanner 1

12 mm / 17 mm / 19 mm Socket Spanner 1

MST 571 Special Socket for hub nut 1

— Circlip plier 1

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
992 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.5.2.3 Removal

1. Using 21 mm wheel spanner remove 4. Lift the caliper upwards as shown in

mounting nuts and remove the front wheel. illustration.

2. Using a 6 mm allen key, loosen the allen 5. Remove the brake pads and anti-rattle
bolts and remove the auto lock assembly. clips.

3. Remove front caliper lower mounting bolt

using 12 mm socket spanner.

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 993
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Using 19 mm socket spanner remove the 9. Using a MST 571(Special Socket for hub
caliper assembly mounting bolts, remove the nut), remove the half shaft secondary lock
caliper and hank on the coil spring without nut.
remove the brake hose.

10. Using a blunt prick punch, remove the

7. Using a circlip plier, remove the circlip lock washer from the half shaft.
from the half shaft.

11. Using a MST 571 (Special Socket for

8. Remove the spacer from the half shaft. hub nut), remove the half shaft primary lock
nut.

Never remove the lock nut without using

a special tool. Lock nut edges are prone
to damage when general tools are used.

Slippage/dropping of heavy/large objects

will cause personal injury.

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
994 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Remove the wheel hub assembly along

with brake disc unit from the knuckle.

13. Using screw driver remove the oil seal

from hub and remove the inner wheel
bearing.

13.5.2.4 Inspection
1. Check front wheel bearings for any damage, wear & tear.

• Clean bearing with metal cleaning solvent before Inspection.

• Bearing should not be ‘Spin dried’ with compressed air. Air should be directed so
that it goes through the bearing.
• Inspect the bearing seating area or the oil seal seating area.

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 995
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.5.2.5 Installation

1. Apply sufficient quantity of grease on 4. Refit the caliper assembly mounting bolt,
inner wheel bearing and place the bearing on torque tighten the bolts to specified value.
bearing outer race.

2. Press the new oil seal by using oil seal

installation special tool.

The lip of the oil seal

should be coated with grease. Also fill
grease in the cavity where the oil seal
spring is present.

5. Fix both the anti-rattle clips back in its

position and refit the brake pads.

3. Align and refit the wheel hub along with

disc, inner wheel bearing on knuckle
assembly.

• Apply sufficient quantity of grease on

inner and outer wheel bearing and
place the bearing on bearing outer
race.

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
996 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Move the caliper downwards and bring 8. Refit the primary lock nut on the half
back to its original position. shaft, torque tighten the nut to specified
value.

• 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.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

9. Refit the intermediate lock nut on half

shaft, torque tighten the nut to specified
value.

7. Refit the caliper bottom mounting bolt

and torque tighten the bolt to specified torque
value.

10. Refit the secondary lock nut on the half

shaft, torque tighten the nut to specified
value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

11. Refit the spacer on the half shaft.

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 997
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Refit the circlip on the half shaft.

13. Refit the auto lock assembly, torque

tighten the mounting bolts to specified value.

14. Refit the front wheel, torque tighten the

mounting wheel nuts to specified value.

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
998 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Recommend to use only LITHIUM COMPLEX GREASE (NLGI 3 (Mineral) : Upto -10̊ C
/ NLGI 2 (Synthetic) :-10̊ C & below)
• Check and Repack Front Axle 4WD wheel bearing grease & replace seals & also
check for smooth rotation first at 50,000 kms or 30Months , and 1,00,000 kms or
60Months (Distance Covered in km / Months in service whichever is earlier).
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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 999
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6 In Car Repairs

13.6.1 Half Shaft Assembly R&R

13.6.1.1 Component Location Index

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
1000 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and ensure proper functioning.
• Check for any oil leakage or seepage.

Tools Required

Size Type Quantity

6 mm Allen key 1

21 mm Wheel Spanner 1

12 mm / mm / 19 mm Socket Spanner 1

MST 571 Special Socket for hub nut 1

— Circlip plier 1

14 mm Socket spanner 01

36 mm Socket spanner 01

22 mm Socket spanner 01

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 1001
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.1.3 Removal:

1. Drain the front differential oil. For 5. Lift the caliper upwards as shown in
additional information refer to Front illustration.
differential oil draining and filling procedure.

2. Using 21 mm wheel spanner remove

mounting nuts and remove the front wheel.

6. Remove the brake pads and anti-rattle

clips.

3. Using a 6 mm allen key, loosen the allen

bolts and remove the auto lock assembly.

4. Remove front caliper lower mounting bolt

using 12 mm socket spanner.

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
1002 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using 19 mm socket spanner remove the 10. Using a MST 571 (Special Socket for
caliper assembly mounting bolts, remove the hub nut), remove the half shaft secondary
caliper and hank on the coil spring without lock nut.
remove the brake hose.

11. Using a blunt prick punch, remove the

8. Using a circlip plier, remove the circlip lock washer from the half shaft.
from the half shaft.

12. Using a MST 571 (Special Socket for

9. Remove the spacer from the half shaft. hub nut), remove the half shaft primary lock
nut.

Never remove the lock nut without using

a special tool. Lock nut edges are prone
to damage when general tools are used.

Slippage/dropping of heavy/large objects

will cause personal injury.

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 1003
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Using 10 mm socket spanner loosen 16. Using a 24 mm ring spanner, remove
and remove the wheel speed sensor the lower mounting lock nut from the lower
mounting bolt. arm ball joint.

14. Using 17 mm ring spanner loosen and 17. Using a MST-562 (Lower arm ball Joint
remove the steering tie rod mounting nut for Puller), detach the lower arm ball joint from
the respective side. the knuckle.

15. Using a nose plier remove the split pin 18. Detach the Knuckle assembly, Gently
from the lower arm ball joint lower mounting pull and take out the drive shaft from the axle.
lock nut.

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
1004 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.1.4 Inspection
1. Move the joint up, down, left, right, and in axial direction. Check for any rough movement
or significant looseness.
2. Check the drive shaft boot for cracks or other damage, and for grease leakage.
3. If damaged, disassemble the drive shaft to verify the damage, repair or replace if
necessary.
4. Check the splines for wear and tear.

13.6.1.5 Installation

1. Align and insert the half shaft assembly 4. Refit the split pin on the lower arm ball
in its position. joint mounting lock nut.

2. Position and refit the knuckle assembly. 5. Refit the steering tie rod end on the
knuckle, Tighten the nut.
3. Refit the lower arm ball joint on knuckle
assembly, Tighten the nut.

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 1005
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit the wheel speed sensor, torque 8. Fix both the anti-rattle clips back in its
tighten the mounting bolt to specified value. position and refit the brake pads.

Take sufficient care not to damage the

sensor.

7. Refit the caliper assembly mounting bolt,

torque tighten the bolts to specified value.

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
1006 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Move the caliper downwards and bring 11. Refit the primary lock nut on the half
back to its original position. shaft, torque tighten the nut to specified
value.

• 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.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

12. Refit the intermediate lock nut on half

shaft, torque tighten the nut to specified
value.

10. Refit the caliper bottom mounting bolt

and torque tighten the bolt to specified torque
value.

13. Refit the secondary lock nut on the half

shaft, torque tighten the nut to specified
value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

14. Refit the spacer on the half shaft.

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 1007
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15. Refit the circlip on the half shaft. 18. Refit the front wheel, torque tighten the
mounting wheel nuts to specified value.

16. Refit the auto lock assembly, torque

tighten the mounting bolts to specified value. 19. Refill the front differential oil. For
additional information refer to Front
differential oil draining and filling procedure.

17. Torque tighten the knuckle mounting

nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

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
1008 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.2 Front Axle R&R

13.6.2.1 Component Location Index

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 1009
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and ensure proper functioning of
front differential.
• Check oil level and top up if required.

Tools Required

Size Type Quantity

8 mm Socket spanner 01

14 mm Socket spanner 01

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
1010 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.2.3 Removal:

1. Drain the front differential oil. For 6. Lower the front axle assembly from the
additional information refer to Front vehicle.
differential oil filling and draining procedure.

2. Remove the front either side drive shafts.

For additional information refer to Half drive
shaft R&R section.

3. Loosen the front axle pinion flange bolts

and detach the front propeller shaft from the
front axle.

7. Support front axle using hydraulic lift and

remove front axle assembly.

4. Using a lift jack, support the front axle

assembly.

5. Using a 14 mm socket spanner loosen

and remove the front axle mounting bolts on
both sides of the chassis.

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 1011
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.2.4 Inspection:
1. Check the axle shaft for straightness, cracks, damage, wear or distortion, replace if
necessary.
2. Check axle case for yield, deformation or cracks, replace if necessary.
3. Inspect oil seals for any damages.

13.6.2.5 Installation:

1. Position the front axle on the vehicle. 5. Refill the front differential oil. For
additional information refer to Front
2. Refit the front axle mountings on either differential oil filling and draining procedure.
side of frame, torque tighten the bolts to
specified value.

3. Refit the propeller shaft on front axle,

torque tighten the pinion flange bolts to
specified value.

4. Refit the either side drive shafts. For

additional information refer to Half drive shaft
R&R section.

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
1012 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.3 Auto Locking Hub R&R

13.6.3.1 Component Location Index

13.6.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning.

Tools Required

Size Type Quantity

6 mm Allen key 1

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 1013
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.3.3 Removal:

1. Remove the respective side front wheel

assembly. For additional information refer to
Wheel R&R section.

2. Using a 6 mm allen key, loosen the allen

bolts and remove the auto lock assembly.

3. Pull out the auto lock hub from the wheel

hub.

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
1014 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.3.4 Installation

1. Align and insert the auto lock hub on

wheel hub assembly.

• Make sure that the snap ring and

spacer is installed on the axle shaft.
• Make sure that the slots on the Drag
Sleeve are engaging with the 4- tanged
washer. Install the Hub Lock in the
wheel hub.
• Rotate the Hub Lock to match the
threaded holes of the wheel hub. Put 6
nos. bolts face to face.

2. Refit the auto lock hub assembly, torque

tighten the mounting bolts to specified value.

3. Refit the respective side front wheel

assembly. For additional information refer to
Wheel R&R section.

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 1015
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.4 Rubber Boot R&R

13.6.4.1 Component Location Index

Tools Required

Size Type Quantity

- Marker 01

- Knife 01

- Clamp plier 01

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
1016 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.4.2 Removal:

1. Mark the position of small end of the boot

on shaft. It has been fitted back in the same
position during reassembly.

2. Cut boot clamps & discard.

3. Cut boots and discard.

• Boot clamps and boots are not to be

reused.

4. Wipe away grease, to make snap ring of

inner race visible.

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 1017
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.6.4.3 Installation

• Clean CV joint components and boot area on shafts using approved solvents. Do
not use gasoline.
• Apply tape to shaft splines to protect boot during installation.

1. Slide new boot from shaft having one 5. Position the boot and clamp over CV joint
circlip groove (of DOJ Side) in reverse (large end) and secure with appropriate
orientation. clamp.

2. Slide new small clamps (two no’s) and 6. Align boot marks on shaft.
rzeppa side boot in correct orientation.
7. Install and tighten small clamp.
3. Lightly coat inner and outer race with
approved Lithium grease. Pack CV joint only
with specified grease. If there is any
remaining grease, place it inside the boot.

4. Align CV joint splines with shaft splines.

Gently rock CV joint while pushing onto shaft,
until click is heard. Now Install the circlip pull
firmly on CV joint to make sure circlip is
seated.

• If necessary, tap CV joint shaft with

brass or soft face mallet.

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
1018 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.7 Disassembly and Assembly

Tools Required

Size Type Quantity

14 mm Socket spanner 01

- Flat end screw driver 01

MST205 01

- Dial gauge & Magnetic holder 01each

- Tommy bars 02

- Drift 01

- Hammer 01

- Punch 01

30 mm Socket spanner 01

- Mallet 01

10 mm Socket spanner 01

- Pinion height setting gauge 01

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 1019
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.7.1 Removal:

1. Drain the front axle oil. For additional 5. Using a screwdriver, remove the RHS
information refer to Front differential oil filling axle shaft clip from the inner end of the
and draining procedure. differential assembly.

2. Remove the front axle from vehicle.

3. Using a 14 mm socket and wrench set,

remove the differential assembly cover bolts
and remove the cover.

6. Remove the snap ring and pull out the

axle shaft assembly from the differential
housing.

4. Remove bearing caps by removing

bearing cap bolts with the help of 14 mm
socket spanner.

• Liquid Gasket is used for seal carrier

section with banjo beam. Scrap this
sealant & clear it.
• Identification marks are punched on
bearing cap; this is to ensure correct
bearing cap is installed on correct
side. Ensure correct bearing caps
used while reassembly.

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
1020 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Position the MST205 into the differential 10. Pry out differential case from carrier
locating holes. Attach the magnetic dial with help of tommy bars (Qty. 2 No's) as
indicator on the differential, load indicator shown in the illustration.
plunger against the opposite side of the
housing, and reset the indicator value to
zero.

• Remove the shims from the differential

8. Using a suitable double end spanner, case and record the thickness for
rotate the MST205 to expand the differential assembly reference.
housing.
11. Remove the MST205 from the housing.

• Do not spread carrier more than 0.58

mm.

9. Remove the dial indicator once the

differential housing expands.

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 1021
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Using the MST, remove the differential 14. Remove ring gear. If required tap ring
case bearing. gear with a mallet to free it from case.

• Identify shims and side bearings on • Discard ring gear screws and replace
both sides, they are not to be with new ones.
interchanged during assembly.
• If shims are damaged, replace with 15. Clamp anyone (LH/RH) of axle shaft in
new shims during assembly. vice firmly.
• This step is to be carried out only if the
bearing needs to be replaced or there
is a concern with the crown backlash.
If any of the above is not present then
it is advisable not to tamper with the
crown wheel assembly.

13. Clamp the differential in a bench vise

equipped with soft jaws.

Vice jaws should not locate on axle

splines or any machined surfaces.

16. Install differential case on axle shaft.

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
1022 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17. Use a suitable drift to remove the roll 21. Lift outside gears and thrust washers.
pin retaining the cross shaft.

18. Use hammer and punch as shown to

remove the cross pin from case.

• Inspect all parts, including the

machined surfaces of the case itself,
19. To remove side gears and pinion mate where necessary, replace all worn
gears, rotate the side gears, this will allow the parts.
pinion mate gears to turn to opening of the • If excessive wear is noticed on all
case. parts, it is recommended that the
complete differential assembly to be
20. Remove pinion mate gears and replaced.
spherical washers behind the gears.
• If any gears are to be replaced, they
must be replaced as sets.

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 1023
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22. Using the MST, remove the axle shaft 25. Using the MST, hold the companion
oil seal from the differential housing. flange and remove the pinion nut using 30
mm socket spanner from the differential
housing.

23. Using the MST, remove the side

bearing from the differential housing.

If yoke or flange shows wear in the area

of seal contact, it should be replaced.

26. Using a suitable universal puller,

remove the companion flange along with dust
cover.

24. Remove the needle bearing from the

axle shaft tube.

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
1024 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27. Pull-out pinion oil seal with puller slide 29. Remove the collapsible spacer, and by
hammer as shown in the illustration. using the MST, remove the pinion inner
bearing from the pinion shaft.

30. Using the MST, remove the pinion

Discard oil seal. bearing cone from the differential housing.

28. Using a mallet, tap the pinion assembly

and remove the pinion assembly from the
differential housing.

To avoid damage to the pinion shaft,

make a centre punch and tap at top of the
pinion assembly by using a mallet.

31. Remove the oil seal with help of oil seal

puller from the disconnect housing.

• Discard oil seal when removed from

disconnect housing.

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 1025
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

32. Move the shifter sleeve towards 34. Pull out the axle shaft from wheel end
differential side as shown in illustration. side of the disconnect housing.

33. Remove the circlip with the help of

circlip plier or any other suitable too which
locks the axle shaft in the disconnect
• The shaft is loaded with thrust washer.
housing.
Remember the sequence of their
fitting. Also replace the bush pressed
on side with new one while assembly.

35. Remove the shifter sleeve & thrust

washer from disconnect housing.

Tool should not damage the splines on

the axle shaft this affects disconnect
operation.

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
1026 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

36. Slide out the intermediate shaft from

wheel end side of the disconnect housing.

37. . Remove the bearing with help of

bearing puller through disconnect housing
wheel end side bore.

• Discard the bearing if damaged or

worn out.

13.7.2 Inspection
1. Inspect all bearings and races for pitting or uneven wear.
2. The inner carrier bearing races should not spin on the carrier journals. The carrier races
should fit snugly in the differential housing.
3. Inspect the carrier race bores for grooves from spinning races. The side gear bores
inside the carrier should not have any abnormal wear.
4. Inspect all gear teeth for pitting, chips, breaks, and for signs of uneven wear and
overheating.
5. Inspect the axles for pitted, grooved or dull and rough bearing surfaces.
6. Inspect gear teeth of side gears and pinion mate gears for wear and cracks.
7. Inspect external teeth of side gears for wear & cracks.

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 1027
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Inspect cross pin for excessive wear. Replace if necessary.

• If replacement of one gear is required, then both side gears, pinion mate gears and
washers have to be replaced.
• Always replace gears as a complete set, do not mix new gears with old gears, as this
may cause uneven wear and short gear life.

13.7.3 Installation

1. Install the disconnect housing bearing on 3. Install the shifter sleeve on the
bearing pressing dolly & press the same intermediate shaft through disconnect
while locating through the oil seal bore in the housing window while aligning with the
disconnect housing. splines on it.

• Ensure that the bearing is pressed in • Shaft splines & shifter sleeve must be
by a distance of 35.3 mm from free from foreign particles & burr.
disconnect housing face.

2. Clean the intermediate shaft. Insert &

push shaft in same way & direction, used
while removal.

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
1028 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Install the synthetic bush in the bore of 6. Install the circlip on the axle shaft with
axle shaft with the help of light nylon mallet. the help of circlip pressing tool.

• Press force must not so high which • Ensure there should not be excessive
may damage the bush during play between two shafts. This affects
pressing. the disconnect operation.

5. Insert the thrust washers in the 7. Insert the spring & shift fork through the
sequence opposite to removal in the disconnect cover window while aligning the
disconnect housing & insert the axle shaft spring into bore in the cover & sitting in the
through the bearing from wheel end side of slit of shift fork.
the disconnect housing.

• Ensure cleanliness of Disconnect

housing cover, Shift fork, Shaft shift
fork & spring.
• Ensure Old Spring is discarded & new
one is used.

• Orientation of the shift fork is

important & it should be in same way,
while was removing.

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 1029
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Insert the shaft shift fork in the opposite 11. Using the MST, install the outer bearing
way of removal ensuring that it passing cone of the pinion into the differential
through shift fork as well as spring. housing.

9. Press the shaft shift fork in the bore by

hand.

12. Using the MST, install the inner bearing

cone of the pinion into the differential
housing.
10. Install the new cover gasket while
locating in the dowel on the disconnect
housing.

13. Using the pinion height setting gauge,

measure and select the pinion depth
adjustment shims.

• Do not bent or wrap the gasket while

installing, the gasket orientation is
fixed by dowel on the disconnect
housing hence it will fit in one
direction only.
• Bent or wrapped cover gasket may
lead to leak during running.

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
1030 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14. In case of replacing the pinion, using a 17. Install the new collapsible spacer into
MST, assemble the inner bearing on to the the differential housing.
pinion shaft assembly.

• Collapsible spacer should rest on

• Take care to avoid damaging the bearing inner race & Pinion Shoulder,
pinion teeth while installing the and it can be fitted in any one
bearing. direction.

15. Install the pinion shaft assembly in the 18. Using the MST, install the pinion oil seal
differential housing. into the differential housing.

16. Install the outer bearing of the pinion

into the housing.
• Apply loctite 638 in the companion
flange splines to avoid the loosening
of the companion flange.

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 1031
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19. Assemble end yoke, washer and new 21. Place differential case in vise as shown.
pinion nut. Tighten pinion nut using torque Apply grease to new side gear thrust
wrench by holding companion flange with washers and hubs of side gears. Assemble
help of special tool tighten nut to specified both side gears. Apply grease to new pinion
torque or until all end play is removed. mate spherical washers, and the pinion mate
Continue to tighten in small increments until gears. Assemble pinion mate gears.
specified rotating torque is achieved.

• Always replace gears as a complete

set. Do not mix new gears with old
gears, as this may cause uneven wear
and shorter gear life.

• Excessive care must be taken during

bearing preload torque adjustment. Do
not over tighten, loosen and then
retighten nut. Do not exceed specified
bearing preload torque. 22. Use a drift to line holes of the gears up
with case. Assemble shaft, drive on shaft to
20. If preload torque is exceeded, a new remove drift. Be sure vertical lock pin hole is
collapsible spacer must be installed and lined up with that of the case, and that pinion
torque sequence as above to be repeated. mate washers are in place and lined up with
Check for rotating torque of pinion. gear and case.

• If only oil seal needs to be changed,

measure rotating torque of pinion with
the help special tool. In this case use
new collapsible spacer and keep same
rotational torque of pinion as before.

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
1032 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23. Assemble roll pin with a small drift. 25. Assemble master differential dummy
When roll pin bottoms out, stake (peen) bearings as shown in the illustration.
metal of case over pin in two places, 180
degrees apart.

26. Position the MST205 into the differential

locating holes. Attach the magnetic dial
indicator on the differential, load indicator
plunger against the opposite side of the
• An easy way to assemble the side housing, and reset the indicator value to
gears and pinion mate gears is to have zero.
all parts lubricated before assembly.

24. Adjust the backlash of the side gears

and pinion gears by setting a dial gauge to
the pinion gear as shown in the illustration.

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 1033
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27. Using a suitable double end spanner, 30. With force still applied, set indicator to
rotate the MST205 to expand the differential 0.00. Force differential assembly to the
housing. extreme end in opposite direction.

31. Detach the carrier assembly from the

differential housing.
• Never expand the differential housing
over 0.022” (0.58 mm) to avoid 32. Using a socket and wrench set, tighten
distortion. the ring gear bolts on the differential case to
the specified torque.
28. Install the crown assembly with the
dummy bearings in the carrier.

29. Install the bearing cap bolts as per the

marking made during removal and tighten to
the specified torque.

• Remove the dummy bearing from the

carrier assembly after checking the
backlash.

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
1034 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

33. Remove dial indicator. Install differential 35. Check ring gear and pinion backlash at
case assembly into carrier with the help of three equally spaced points with dial
mallet, ensure differential case shim (spacer indicator. Backlash tolerance is 0.13 to 0.20
bearing preload is behind the bearing cap). mm and should not vary more than 0.08 mm
between the three points checked.

36. Remove the MST 205 from the housing.

• Carelessness while installing
differential case assembly may result 37. Using the MST, install the axle shaft oil
in injury. seal into the differential housing.

• Mark the number of shims on each

side of the differential case while the
backlash adjustment is done, the
same number of shims have to added
during the bearing installation. If this
is not followed, the backlash would
exceed its specification and affect the
performance of the differential
thereby possibly leading to damage.

34. Install the bearing caps and tighten the

38. Using the MST, install the side bearing
bolts to the specified torque.
into the differential housing.

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 1035
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

39. Using the MST, install the needle 42. Using a screwdriver, install the RHS
bearing in the axle shaft tube. axle shaft clip into the differential and lock the
inner end of the shaft.

40. Install the axle shaft assembly and fit

the snap ring. 43. Apply sealant evenly across the exterior
surface of the differential and install the
differential cover into the differential housing
and tighten mounting bolts to the specified
torque.

41. Using the MST, install the inboard oil

seal on the differential housing.

44. Install the front axle into the vehicle.

45. Refill the front axle oil. For additional

information refer to Front differential oil filling
and draining procedure.

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
1036 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.8 Specifications & Wear Data

Description Specification

Type Dana Model 186, Independent suspension,

Electric disconnect

Pinion torque to rotate (PTTR) 17-34 Kgf-cm

Total torque to rotate (TTTR) 28 - 51 Kgf-cm

Backlash 0.13 - 0.20 mm

13.9 Lubricants & Sealants

Front Differential Oil –API GL-5, Meeting LS specification (Upto -10°C - 80W-90 and -10°C &
below - 80W-90)
Capacity – 1.25 Litres.

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 1037
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13.10 Torque Specification

Location Torque Nm

FILLER PLUG 34±7

DRAIN PLUG 34±7

RING GEAR BOLT TORQUE 108.5±13.5

PINION NUT TORQUE 447.5 ± 230.5

BEARING CAP BOLT TORQUE 57.5±10.5

COVER PLATE BOLT TORQUE 41.5±3.5

DISCONNECT HOUSING COVER SCREW 17±2

TORQUE

DISCONNECT HOUSING MOTOR 12.5±3.5

MOUNTING SCREW TORQUE

FRONT AXLE MTG. ON CHASSIS 4WD 63 ± 4

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
1038 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14 REAR AXLE

14.1 Description and Operation

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.
The rear axle pinion receives its power from the engine through the transmission and propeller
shaft. 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.

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 1039
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.2 Component Location Index

A. Brake Drum. E. Back Plate.

B. Rear Wheel Bearing. F. Axle Shaft Rear.

C. Bearing Lock nut. G. Companion Flange Axle.

D. Tonner Wheel. H. Rear Axle Shaft Tube.

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
1040 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.3 Trouble Shooting

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.

14.3.1 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 tend to peak or be more pronounced at particular speeds and
the noise is in no 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.

14.3.1.1 Axle noise fall into two basic categories: gear noise and/ or
bearing noise.

14.3.1.1.2 Gear 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: -
1. Whine from an engine component; this will always occur at the same engine speed
irrespective of which transmission gear is used.
2. 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.
3. 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).

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 1041
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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.).

14.3.1.1.3 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 vice
versa.
1. 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.
2. Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not
affected by the swerve check referred to previously.
3. 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.

14.3.1.1.4 Other Noise

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 end play
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 disappears 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.

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
1042 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.3.1.1.5 Trouble Shooting Chart

Symptom Causes Remedial Action

Abnormal Rear Axle Noise 1. Insufficient rear axle oil. • Replace the oil and
maintain correct oil level.

2. Degraded or non- • Replace the recommended

recommended rear axle oil. oil.

3. Improper drive pinion to • Adjust the backlash as per

gear backlash. recommendation.

4. Loose drive pinion • Adjust the drive pinion

bearing. bearing preload.

5. Worn drive pinion bearing. • Replace the drive pinion

bearing.

6. Loose differential side • Adjust the differential side

bearing. bearing.

7. Worn differential side • Replace the differential side

bearing. bearing.

8. Drive pinion or ring gear • Replace the drive pinion

damage. and the ring gear as a set.

9. Worn drive pinion and ring • Replace the drive pinion

gear. and the ring gear as a set.

Noise when the vehicle is 1. Drive pinion and ring gear • Adjust the backlash as
coasting backlash is insufficient. recommended.

2. Ring gear damaged. • Replace the ring gear and

the pinion as a set.

Intermittent Noise 1. Axle shaft spline play too • Replace the axle shaft.
high.

2. Warped ring gear. • Replace the drive pinion

and the ring gear as a set.

3. Loose differential cage • Tighten the differential cage

bolts. bolts to recommended torque
value.

4. Foreign material in the • Remove the foreign

axle case. material and replace the
differential oil.

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 1043
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial Action

Noise when the vehicle is 1. Worn rear axle shaft • Replace the rear axle shaft.
turning splines.

2. Worn side gear. • Replace the side gear.

3. Worn differential pinion. • Replace the differential

pinion.

4. Worn differential cross pin. • Replace the differential

cross pin.

Constant Noise 1. Bent rear axle shaft. • Replace the rear axle shaft.

2. Flat spot on the drive • Replace the drive pinion

pinion gear teeth. and ring gear as a set.

3. Worn drive pinion splines • Replace the drive pinion

oil seal. and ring gear as a set.

4. Ring gear wear. • Replace the drive pinion

and ring gear as a set.

5. Flat spot on the drive • Replace the drive pinion

pinion. bearing.

6. Flat spot on the bearing oil • Replace the side bearing.

seal.

Vibration 1. Worn rear hub bearing. • Replace the rear hub

bearing.

2. Bend rear axle shaft. • Replace the rear axle shaft.

Oil Leakage 1. Differential oil too high. • Correct the oil level.

2. Worn or defective oil seal. • Replace the oil seal.

3. Clogged air breather. • Clean the air breather.

4. Differential carrier bolts • Tighten the bolts to

loose. specified torque values.

5. Liquid gasket not proper. • Reapply the liquid gasket.

6. Ring gear thrust bolt lock • Reapply the liquid gasket

nut loose. and tighten the lock nut to
specified value.

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
1044 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial Action

Axle Case Leakage 1. Loose drain/filler plug. • Tighten to specified torque

value.

2. Clogged air breather. • Clean the air breather.

3. Cracked axle bolts. • Replace the axle case.

4. Differential carrier bolts • Tighten the bolts to

loose. specified value.

5. Improper liquid gasket. • Reapply the liquid gasket.

Axle Case to Inside Brake Worn or defective oil seal. • Replace the oil seal.
Drum Leakage

Power not being 1. Broken rear axle shaft. • Replace the rear axle shaft.
transmitted to the wheels.
(propeller shaft operation 2. Broken drive pinion or ring • Replace the drive pinion
is normal). gear. and the ring gear as a set.

3. Broken differential cage • Replace the differential

gears or spider. gears or the spider.

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 1045
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.4 Care of the System

14.4.1 Differential Oil Replace

Tools Required

Size Type Quantity

10 mm Allen key/ Allen socket 01

- Mechanical hand pump 01

Rear Axle Oil –API GL-5, Meeting LS specification (Upto -10°C - 80W-90 and -10°C & below -
80W-90)
Capacity – 1.8 Litres.

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
1046 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.4.1.1 Rear Axle Oil Draining Procedure:

1. Position the vehicle on a 2 post lift/ 4

post lift.

2. Remove rear axle filler plug using 10 mm

allen key.

3. Remove rear axle drain plug using 10

mm allen key and drain the entire oil
completely.

• Ensure entire oil is drained before

filling the new oil.

• Wait till the entire oil get drained.

• Place a tray beneath the rear axle for collecting the oil while draining.

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 1047
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.4.1.2 Rear Axle Oil Filling Procedure:

1. Refit the drain plug and torque tighten to 3. Check the oil level.
specified value.

• Clean the drain plug and differential

housing with a clean cloth before
refitting.

• Ensure that the oil level is up to lower

most point of the filler plug.

4. Refit the filler plug back and torque

tighten to specified value.
2. Refill specified quantity of recommended
differential oil into differential assembly.

• Never reuse drained oil.

• Always use recommended oil only.
• Never mix different types of oil and
use.
• Clean filler plug area properly using a
cloth before filling the oil.

• Clean the filler plug with a clean cloth

before refitting.

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
1048 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Recommend to use only API GL-5, Meeting LS specification

• Rear Differential oil to be inspected first at 5,000 kms/3 Months, 20,000 kms/12
months (Distance Covered in kms / Months in service whichever is earlier) and then
every service exclude oil replacement Interval.
• Rear differential oil to be checked at every regular service.
• Rear differential oil to be replaced first at 10,000 kms/6 months and then every
30,000 kms/18 months (Distance Covered in kms / Months in service whichever is
earlier).
• For Non –ABS vehicles, if the activity is done on a 2 post lift, ensure that the LSPV
spring is disconnected before lifting the vehicle. After lowering, reconnect the LSPV
spring and ensure the correct LSPV setting height.

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 1049
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5 In Car Repairs

14.5.1 Axle Shaft R&R

14.5.1.1 Component Location Index

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
1050 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check differential oil, top up the oil if
required.

Tools Required

Size Type Quantity

21 mm Deep socket spanner 01

- Star screw driver 01

11 mm Open end spanner 01

MST 576 & MST 577 Rear axle shaft puller 01

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 1051
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.1.3 Removal:

1. Remove rear brake drum. For additional 3. Using Axle Shaft Puller (MST 576 & 577)
information refer to rear Brake drum R&R pull-out and remove the axle shaft.
section.

2. Using 17 mm socket spanner remove the

back plate mounting nuts. To avoid the back plate falling down,
using a plastic tag tie it with any other
fixed member before the shaft is pulled
out.

14.5.1.4 Inspection:
1. Check axle shaft for any damage, crack or bend.
2. Check toner ring for any damage.
3. Check rear wheel bearing for any damage.
4. Check back plate for any damage.

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
1052 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.1.5 Installation:

1. Insert the drive axle shaft into the rear

axle shaft tube.

2. Refit the axle shaft by mounting the back

plate on brake flange, torque tighten the
mounting nuts to specified value.

3. Refit rear brake drum. For additional

information refer to rear Brake drum R&R
section.

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 1053
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.2 Axle Shaft Inner Oil Seal R&R

14.5.2.1 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check differential oil, top up the oil if
required.

Tools Required

Size Type Quantity

Leg puller for Carrier Oil Seal

0502CAA0022ST 01
Removal

Inboard Oil Seal Pressing

0502AAA0018ST dolly 01

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
1054 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.2.2 Removal:

1. Remove the Axle shaft. For additional

information refer to Axle shaft R&R section.

2. Using (MST 0502CAA0022ST/ Leg

puller for Carrier Oil Seal Removal) remove
the inboard oil seal.

14.5.2.3 Installation:

1. Refit the inboard oil seal using

(0502AAA0018ST — Inboard Oil Seal
Pressing dolly) and hammer.

2. Refit the Axle shaft. For additional

information refer to Axle shaft R&R section.

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 1055
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.3 Axle Shaft Wheel Bearing R&R

14.5.3.1 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check differential oil, top up the oil if
required.

Tools Required

Size Type Quantity

— Circlip plier 01

— Hydraulic press 01

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
1056 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.3.2 Removal:

1. Remove the axle shaft. For additional 5. Remove the outboard oil seal from hub
information refer to Axle shaft R&R section. assembly.

2. Remove toner ring using an hydraulic

press.

6. By using circlip plier, remove axle shaft

bearing circlip from hub assembly.

3. Using suitable MST, remove the Bearing

lock washer, locking nut and remove the
washer.

7. Remove axle shaft bearing from hub

assembly using an suitable tool.

4. Remove hub assembly from axle shaft

using an hydraulic press.

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 1057
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.3.3 Installation:

1. Refit the axle shaft bearing on hub 3. Refit the outboard oil seal on hub
assembly using an suitable tool. assembly.

Replace the outboard oil seal once

removed.

2. Refit the axle shaft bearing circlip on hub

assembly.

4. Refit the hub assembly on axle shaft

using an hydraulic press.

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
1058 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the washer on bearing & refit the

Bearing locking nut, lock washer by using
suitable tool.

6. Refit the toner ring using an hydraulic

press.

Replace the toner ring and bearing

assembly once removed.

7. Refit the axle shaft. For additional

information refer to Axle shaft R&R section.

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 1059
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.4 Rear Axle R&R

14.5.4.1 Component Location Index

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
1060 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit both the Rear Wheel Speed Sensor.
• Remove both rear wheels. • Refit both the Bundy Tube Rear Flexible
Hose to Wheel Cylinder.
• Drain the differential oil.
• Remove the rear stabilizer bar assembly. • Refit both the Rear Leaf Springs.
• Refit the rear stabilizer bar assembly.
• Remove both the Rear Leaf Springs.
• Remove both the Bundy Tube Rear • Refill the differential oil.
Flexible Hose to Wheel Cylinder. • Refit both rear wheels.
• Remove both the Rear Wheel Speed
Sensor.

Tools Required

Size Type Quantity

13 mm Socket spanner 01

14 mm Ring spanner 01

- Flat screw driver/Nose plier Each 01

- Hydraulic jack 01

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 1061
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.4.3 Removal:

1. Remove both rear wheel. For additional 8. Using a nose plier remove the parking
information refer to Rear Wheel R&R section. brake cable lock clip on both the side.

2. Drain the differential oil. For additional

information refer to Differential oil draining
procedure.

3. Remove the rear stabilizer bar assembly.

For additional information refer to Stabilizer
Bar R&R section.

4. Remove both the Rear Leaf Springs. For

additional information refer to Rear Leaf
Springs R&R section.

5. Remove both the Bundy Tube Rear

Flexible Hose to Wheel Cylinder. For 9. Remove the LSPV spring washer and
additional information refer to Bundy Tube disconnect the LSPV spring.
Rear Flexible Hose to Wheel Cylinder R&R
section.

6. Remove both the Rear Wheel Speed

Sensor. For additional information refer to
Rear Wheel Speed Sensor R&R section.

7. Using a flat screw driver slide the hand

brake lever & using a nose plier disconnect
the hand brake cable on both the side.

10. Using a 13 mm ring spanner and the

open end spanner loosen and remove the
shock absorber bottom mounting bolt and
nut.

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
1062 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Remove rear propeller shaft mounting

bolts on companion flange with the help of 14
mm ring spanner.

While loosening the bolt, hold the nut

using 14 mm open end spanner.

12. Support rear axle from bottom with the

help of an hydraulic jack.

13. Remove rear axle assembly from

vehicle.

14.5.4.4 Inspection:
1. Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if
necessary.
2. Check the axle case for yield, deformation or cracks, replace if necessary.

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 1063
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.5.4.5 Installation:

1. Align and reposition the rear axle 4. Refit the washer & reconnect the LSPV
assembly with the help of a hydraulic jack. spring.

2. Mount the rear flange yoke using 5. Using a flat screw driver slide the hand
mounting bolts and nuts. Torque tighten the brake lever & using a nose plier install the
bolts to specified value. hand brake cable.

3. Refit the shock absorber bottom 6. Install the hand brake cable locking clip.
mounting bolt, torque tighten the bolt to
specified value.

7. Refit both the Rear Wheel Speed

Sensor. For additional information refer to
Rear Wheel Speed Sensor R&R section.

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
1064 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Refit both the Bundy Tube Rear Flexible

Hose to Wheel Cylinder. For additional
information refer to Bundy Tube Rear
Flexible Hose to Wheel Cylinder R&R
section.

9. Refit both the Rear Leaf Springs. For

additional information refer to Rear Leaf
Springs R&R section.

10. Refit the stabilizer bar assembly. For

additional information refer to Stabilizer Bar
R&R section.

11. Refit both rear wheel. For additional

information refer to Rear Wheel R&R section.

12. Do LSPV height setting. For additional

information refer to LSPV height setting
section.

13. Refill the differential oil. For additional

information refer to Differential oil refilling
procedure.

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 1065
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6 Disassembly and Assembly

14.6.1 Rear Axle Assembly
Tools Required:

Size Type Quantity

13 mm/ 14 mm Socket spanner 01

- Flat end screw driver 01

Spreader differential carrier

MST 205 housing 01

- Dial gauge & Magnetic holder 01 each

- Tommy bars 02

- Drift 01

- Hammer 01

- Punch 01

30 mm Socket spanner 01

- Mallet 01

- Pinion height setting gauge 01

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
1066 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6.1.1 Dismantling Procedure

1. Drain the differential oil. For additional 5. Remove bearing caps by removing
information refer to Rear axle oil draining bearing cap bolts with the help of 14 mm
procedure. socket spanner.

2. Remove the rear axle from the vehicle.

For additional information refer to Rear Axle
R&R section. • Liquid Gasket is used for seal carrier
section with banjo beam. Scrap this
3. Remove the Rear axle shafts. For sealant & clear it.
additional information refer to Rear axle • Identification marks are punched on
shafts R&R section. bearing cap; this is to ensure correct
bearing cap is installed on correct side.
4. Using a 13 mm socket spanner, remove Ensure correct bearing caps used while
the differential assembly cover bolts and take reassembly.
out the cover.

6. Position the MST 205 into the differential

locating holes. Attach the magnetic dial
indicator on the differential, load indicator
plunger against the opposite side of the
housing, and reset the indicator value to
zero.

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 1067
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using a suitable double end spanner, 11. Using the MST, remove the differential
rotate the MST205 to expand the differential case bearing.
housing.

• Remove the shims from the differential

Do not spread carrier more than 0.58 mm. case and record the thickness for
assembly reference.
8. Remove the dial indicator once the • If shims are damaged, replace with new
differential housing expands. shims during assembly.
• There is no identification provided on
9. Pry out differential case from carrier with the shim, Needs to be measured by micro
help of tommy bars (Qty. 2 No's) as shown in meter.
the illustration. • This step is to be carried out only if the
bearing needs to be replaced or there is a
concern with the crown backlash. If any
of the above is not present then it is
advisable not to tamper with the crown
wheel assembly.

12. Clamp the differential in a bench vise

equipped with soft jaws.

10. Remove the MST 205 from the housing.

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
1068 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Remove ring gear. If required tap ring 16. Use a suitable drift to remove the roll
gear with a mallet to free it from case. pin retaining the cross shaft.

17. Use hammer and punch as shown to

remove the cross pin from case.
• Discard ring gear screws and replace
with new ones.

14. Clamp anyone (LH/RH) of axle shaft in

vice firmly.

18. To remove side gears and pinion mate

gears, rotate the side gears, this will allow the
pinion mate gears to turn to opening of the
case.

19. Remove pinion mate gears and

spherical washers behind the gears.
• Vice jaws should not locate on axle
splines or any machined surfaces.

15. Install differential case on axle shaft.

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 1069
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20. Lift outside gears and thrust washers. 21. Using the MST, hold the companion
flange and remove the pinion nut using 30
mm socket spanner from the differential
housing.

• If yoke or flange shows wear in the area

of seal contact, it should be replaced.

22. Using a suitable universal puller,

remove the companion flange along with dust
cover.

• Check the differential gear condition,

any damage replaces it.
• Inspect cross pin for excessive wear,
replace it if necessary.
• Always replace differential pinion gears
and side gear both along with washer as
a complete set.
• Do not mix new gears with old gears, as
this may cause uneven wear and short
gear life.

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
1070 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23. Pull-out pinion oil seal with puller slide 25. Remove the collapsible spacer, and by
hammer as shown in the illustration. using the MST, remove the pinion inner
bearing from the pinion shaft.

26. Using the MST, remove the pinion

• Discard oil seal. bearing outer race from the differential
housing.
24. Using a mallet, tap the pinion assembly
and remove the pinion assembly from the
differential housing.

• Fit a nut of pinion before tapping to

avoid tread damage.
• Hold the pinion with hand to avoid
falling.
• Gear teeth have sharp edges. Handle
gears carefully to avoid injury.
• Collect shims and keep them together.
27. Using the MST, remove the pinion inner
• Replace shims if found damaged. cone from the differential housing.

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 1071
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6.1.2 Inspection
1. Inspect all bearings and races for pitting or uneven wear.
2. The inner carrier bearing races should not spin on the carrier journals. The carrier races
should fit snugly in the differential housing.
3. Inspect the carrier race bores for grooves from spinning races. The side gear bores
inside the carrier should not have any abnormal wear.
4. Inspect all gear teeth for pitting, chips, breaks, and for signs of uneven wear and
overheating.
5. Inspect the axles for pitted, grooved or dull and rough bearing surfaces.
6. Inspect gear teeth of side gears and pinion mate gears for wear and cracks.
7. Inspect external teeth of side gears for wear & cracks.
8. Inspect cross pin for excessive wear. Replace if necessary.

• If replacement of one gear is required, then both side gears, pinion mate gears and
washers have to be replaced.
• Always replace gears as a complete set, do not mix new gears with old gears, as this
may cause uneven wear and short gear life.

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
1072 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6.1.1 Assembly Procedure

14.6.1.1.2 Ring Gear & Pinion Assembly Theory:

Ring gear and pinion is supplied as a set. They are matched with each other during
manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer
illustration shown below for more clarity.

Illustration 1 Illustration 2

If a new gear set is used, verify numbers on pinion and ring for matching before proceeding
with assembly.
Standard mounting distance from centre line of ring gear to back face of pinion is controlled by
selecting shims, which are positioned between the inner pinion bearing cone and pinion gear.
Best running position of gear set is achieved by proper shim selection.
This dimension for front live axle will be different. On the bottom face of pinion, a number is
etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim
selection is achieved with help of this number. If alphabet "m" appears on pinion face shim,
selection has to be done in mm (Metric). If alphabet "m" does not appear on pinion face, shim
selection has to be done in inches (English).
Shims with different thicknesses are available for selection.

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 1073
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6.1.1.3 Shim Selection Procedure:

Use tables shown below for selecting correct thickness of shims either for addition or for
subtraction from old shim pack.
Illustration 1 shows ring and pinion etched with inch identification. Refer Table A.
Illustration 2 shows ring and pinion etched with metric identification. Refer Table B.
Example

In metric In inches

No punched on removed
pinion. +8m +3

No punch on new pinion. -5m -2

Value derived from table. +0.13 +0.005

Thickness of shim in OE y
x
assembly.

Thickness of shims to be
selected for new ring/pinion. X+ 0.13 Y+0.005

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
1074 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

TABLE A

Old New Pinon Marking (English)

Pinion
Mark- -4 -3 -2 -1 0 +1 +2 +3 +4
ing
(Eng-
lish)

+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0

+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 - 0.001

+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 - 0.001 - 0.002

+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 - 0.001 - 0.002 -0.003

0 +0.004 +0.003 +0.002 +0.001 0 - 0.001 - 0.002 -0.003 -0.004

-1 +0.003 +0.002 +0.001 0 - 0.001 - 0.002 -0.003 -0.004 -0.005

-2 +0.002 +0.001 0 - 0.001 - 0.002 -0.003 -0.004 -0.005 -0.006

-3 +0.001 0 - 0.001 - 0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 - 0.001 - 0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

TABLE B

Old New Pinon Marking (Metric)

Pinion
Mark- -10 -8 -5 -3 0 +3 +5 +8 +10
ing
(Met-
ric)

+10 +.20 +.18 +.15 +.13 +.10 +.07 +.05 +.02 0

+8 +.18 +.16 +.13 +.11 +.08 +.05 +.03 0 -.02

+5 +.15 +.13 +.10 +.08 +.05 +.02 0 -.03 -.05

+3 +.13 +.11 +.08 +.06 +.03 0 -.02 -.05 -.07

0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10

-3 +.07 +.05 +.02 0 -.03 -.06 -.08 -.11 -.13

-5 +.05 +.03 0 -.02 -.05 -.08 -.10 -.13 -.15

-8 +.02 0 -.03 -.05 -.08 -.11 -.13 -.16 -.18

-10 0 -.02 -.05 -.07 -.10 -.13 -.15 -.18 -.20

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 1075
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Observe the marking on pinion. If ‘m’ is found etched on the face, refer table B. If not
refer table A.

14.6.1.1.4 Measuring Pinion & Gear Depth Using Service Tools & Gauges
“Pinion Shim Selection: (If Old Shim Not Available)
Pinion position shim selection can be done using a special tool, in the absence of removed
ring/pinion gear.
1. Fix the pinion height set master block on the pinion inner bearing setting area.
2. Fix the dial gauge on to 0 (zero), on the surface plate. Install dial gauge on pinion height
gauge by setting the pre load.

3. (Say ‘X’ mm for example) which is again a part of tool.

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
1076 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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 1077
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6.1.1.5 Interpretation of Contact Pattern

The TOE of the gear is the portion of the

tooth surface at the end towards the centre.
The HEEL of the gear tooth is the portion of
the tooth surface at the outer end. The TOP
LAND of a gear tooth is the surface of the top
of the tooth. Every gear has a characteristic
pattern.

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
1078 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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 1079
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.6.1.6 Installation

1. Using the MST, install the outer bearing 4. In case of replacing the pinion, using a
cone of the pinion into the differential MST, assemble the inner bearing on to the
housing. pinion shaft assembly.

2. Using the MST, install the inner bearing

cone of the pinion into the differential
housing. • Take care to avoid damaging the pinion
teeth while installing the bearing.

5. Insert a new collapsible spacer.

3. Using the pinion height setting gauge,

measure and select the pinion depth
adjustment shims.

• Collapsible spacer should rest in

between pinion inner and outer
bearing and it can be fitted in any
direction.
• Always use new collapsible spacer,
never use old one.

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
1080 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Install the pinion shaft assembly in the 9. Using the MST, install the pinion oil seal
differential housing. into the differential housing.

7. Install the outer bearing of the pinion into

the housing.
• Apply loctite 638 in the companion
flange splines to avoid the loosening of
the companion flange.
• Apply a light coat of oil to the lip of oil
seal.

10. Assemble end yoke, washer and new

pinion nut. Tighten pinion nut using torque
wrench by holding companion flange with
help of special tool tighten nut to specified
torque or until all end play is removed.
Continue to tighten in small increments until
specified rotating torque is achieved.

8. Place oil slinger on bearing pinion outer

cone.

• Excessive care must be taken during

bearing preload torque adjustment. Do
not over tighten, loosen and then
retighten nut. Do not exceed specified
bearing preload torque.

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 1081
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. If preload torque is exceeded, a new 13. Use a drift to line holes of the gears up
collapsible spacer must be installed and with case. Assemble shaft, drive on shaft to
torque sequence as above to be repeated. remove drift. Be sure vertical lock pin hole is
Check for rotating torque of pinion. lined up with that of the case, and that pinion
mate washers are in place and lined up with
gear and case.

• If only oil seal needs to be changed,

measure rotating torque of pinion with
the help special tool. In this case use new
collapsible spacer and keep same
rotational torque of pinion as before.

12. Place differential case in vise as shown.

Apply grease to new side gear thrust
washers and hubs of side gears. Assemble
both side gears. Apply grease to new pinion
mate spherical washers, and the pinion mate
gears. Assemble pinion mate gears.

14. Assemble roll pin with a small drift.

When roll pin bottoms out, stake (peen) metal
• Always replace gears as a complete set. of case over pin in two places, 180 degrees
Do not mix new gears with old gears, as apart.
this may cause uneven wear and shorter
gear life.

• An easy way to assemble the side gears

and pinion mate gears is to have all parts
lubricated before assembly.

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
1082 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15. Assemble ring gear to the differential 17. Position the MST205 into the differential
case using mounting bolts. Torque tighten locating holes. Attach the magnetic dial
the bolts to specified value in recommended indicator on the differential, load indicator
sequence. plunger against the opposite side of the
housing, and reset the indicator value to
zero.

• Always use new ring gear bolts. 18. Using a suitable double end spanner,
• Ring gear mounting bolts have LH rotate the MST205 to expand the differential
threads. While removing torque in housing.
clockwise direction and during assembly
torque in anti-clocking direction.

16. Assemble master differential dummy

bearings as shown in the illustration.

• Never expand the differential housing

over 0.022” (0.58 mm) to avoid distortion.

19. Install the crown assembly with the

dummy bearings in the carrier.

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 1083
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20. Install the bearing cap bolts as per the 24. Remove dial indicator. Install differential
marking made during removal and tighten to case assembly into carrier with the help of
the specified torque. mallet, ensure differential case shim (spacer
bearing preload is behind the bearing cap).

21. With force still applied, set indicator to

0.00. Force differential assembly to the
extreme end in opposite direction and select
the shims pack based on Backlash tolerance. • Carelessness while installing
differential case assembly may result in
injury.

• Mark the number of shims on each side

of the differential case while the
backlash adjustment is done, the same
number of shims have to added during
the bearing installation. If this is not
followed, the backlash would exceed its
specification and affect the performance
of the differential thereby possibly
leading to damage.
22. Detach the carrier assembly from the
differential housing and remove the dummy 25. Install the bearing caps and tighten the
bearing from the carrier assembly. bolts to the specified torque.

23. Press Differential bearing along with

shim on Differential case assembly.

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
1084 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26. Check ring gear and pinion backlash at

three equally spaced points with dial
indicator. Backlash tolerance is 0.127 to
0.254 mm and should not vary more than
0.08 mm between the three points checked.

27. Remove the MST 205 from the housing.

28. Apply sealant evenly across the exterior

surface of the differential and install the
differential cover into the differential housing
and tighten mounting bolts to the specified
torque.

29. Refit the rear axle into the vehicle. For

additional information refer to Rear Axle R&R
section.

30. Check the oil level and correct if

necessary.

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 1085
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.7 Specifications, Wear Data & Tightening Specifications

Description Value

TYPE : Semi floating single reduction with Open, MLD,LSD differential

No of teeth on crown N1 41

No of teeth on pinion N2 9

Axle reduction ratio N1/N2 4.55

Preloading of differential bearings 0.075 mm

Crown-pinion backlash 0.127 to 0.254 mm

Maximum variation of backlash in a crown 0.0762 mm

Run out of the ring gear / crown wheel 0.150 mm

Hub /Axle shaft end play Zero

Check for correct tooth contact on both the Check on both the driving & reverse flank.
forward and reverse direction This contact is for checking without load.

Clearance between side( sun) gears and diff 0.350 mm

case

Oil grade/ Viscosity/ Quantity 1.8 liter / SAE 80W90GL5

Axle Housing Salisbury

Differential 4 Pinion Open Differential, MLD, LSD

Reduction gear type Hypoid

Reduction ratio 4.55

Final drive gear backlash 0.15 to 0.25 mm

Ring gear bolt torque 88–108 Nm

Pinion nut torque 203 — 407 Nm

Pinion torque to rotate (PTTR) 20 to 40 Kgs.cm. / 2 to 4 Nm

Bearing cap bolt torque 88–108 Nm

Carrier mounting bolt 34–47 Nm

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
1086 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Description Value

Drain plug torque 40-54 Nm

Filler plug torque 20-27 Nm

Breather 12-15 Nm

Cover Mounting Bolt 40-47 Nm

Half Shaft Lock Nut 350-450 Nm

14.8 Lubricants & Sealants

Lubricants Recommended –
• No Grease – Wheel bearings are sealed and filled with grease for life
Rear Axle Oil
• Rear Axle Oil –API GL-5, Meeting LS specification (Upto -10° C - 80W-90 and -10° C & below -
80W-90)
• Capacity – 1.8 Litres.

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 1087
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

14.9 Mahindra Special Tools (MST)

MST Part No MST Description

MST 576 PULLER REAR AXLE SHAFT

MST 577 SLIDDING HAMMER

MST 578 RING- REAR AXLE COLLAR SUPPORT

MST 579 TUBE- REAR AXLE COLLAR PRESSING

MST 580 INSTALLER INNER OIL REAR AXLE TUBE

REAR AXLE PINION HEIGHT SETTING

MST 581 GAUGE(1)

REAR AXLE PINION HEIGHT SETTING

MST 582 GAUGE(2)

DIFFERENTIAL SIDE BEARING SETTING

MST 583 GAUGE (DUMMY BEARING)

MST 526 PINION OIL SEAL INSTALLER

MST 203 COMPANION FLANGE HOLDING TOOL

MST 208 COMPANION FLANGE PULLER

LEG PULLER FOR CARRIER OIL SEAL

0502CAA0022ST
REMOVAL

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
1088 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15 WHEELS & TYRES

15.1 Description and Operation

15.1.1 Wheels & Tyres
The tyres fitted in this vehicle are radial tubeless tyres mounted on 16 inch diameter wheels.
The radial tubeless tyres play an important role in vehicle handling and riding characteristic of
the vehicle, and a change of tyre should be as per specification.
The air pressure maintained in the tyres has direct influence on the obtained fuel average,
braking and on riding characteristic, so it is essential to maintain tyre pressure as per
specification.
The tubeless tyres are comparatively less vulnerable to heat and friction generated between
the tyres and the road surface helps to increase the life of the tyres. It also improves
acceleration and fuel efficiency because these are lighter and have lower rolling resistance
than the tube tyres. In case of tyre puncture you can safely drive with the tubeless tyres to
certain distance before the tyre loses the air completely.

15.2 Structure of Tyre

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 1089
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.2.1 Tread
This thick layer of rubber provides the interface between the tyre and the road. Wear-resistant
rubber is used to protect the carcass and belt against fractures and impacts and to deliver a
long driving life.

15.2.2 Shoulder
Located between the tread and sidewall, the shoulder rubber is the thickest so that the design
must allow for the easy diffusion of heat generated within the tyre while driving.

15.2.3 Sidewall
The part between the shoulder and bead, the flexible sidewall protects the carcass and
enhances the ride. A tire’s type, size, structure, pattern, manufacturing company, product
name and various characters are indicated here.

15.2.4 Bead
The bead attaches the tyre to the rim and wraps the end of the cord fabric. Comprised of the
bead wire, core, flipper and other parts, the bead is generally designed to be slightly tight
around the rim so that in the case of a sudden drop in inflation pressure, the tyre will not fall off
the rim.

15.2.5 Carcass
As the most important framework of a tyre, the entire inner layer of cord fabric is called the
carcass. The carcass acts to support air pressure, vertical load and absorb shocks.

15.2.6 Belt
The belt is made by steel wire. This reduces the impact from the road and provides the wide
tread.

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
1090 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.3 Tyre Information

A Max Load Limit

B Tyre Size

Radial tyres or bias-ply tyre - A

radial tyre has “RADIAL/STEEL
C BELTED RADIAL” on the sidewall.
A tyre not marked with “RADIAL”
is a bias-ply tyre.

“TUBELESS” or “TUBE TYPE” - A

tubeless tyre does not have a
tube inside the tyre and air is
D directly filled in the tyre. A tube
type tyre has a tube inside the tyre
and the tube maintains the air
pressure.

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 1091
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.4 Tyre Rating

Tyre rating of Mahindra Pikup - P245/75

R16 111S
A 245 (Three-digit number): This number
gives the width in millimeters of the tyre from
sidewall edge to sidewall edge. This is called
‘Section Width’.
B:75 (Two-digit number):This number, known
as the aspect ratio, gives the tyres ratio of
height to section width.
C: R This is the tyre construction Code. The
‘R’ stands for Radial.
D:16 (Two-digit number): This number is the
wheel or rim diameter in inches.
E:111 (Two or three digit number): This
number is the tyres load index. It is a
measurement of how much weight each tyre
can support.
F: S Tyre speed rating or speed symbol.
Never drive the vehicle faster than the tyre
speed rating. The speed rating denotes the
speed at which a tyre is designed to be
driven for extended periods of time under a
standard condition of load and inflation
pressure.

15.5 Speed Rating

Speed Symbol Max Speed Speed Symbol Max Speed

Capability (KM/ Capability (KM/
HR) HR)

L 120 T 190

M 130 U 200

N 140 H 210

P 150 V 240

Q 160 W 270

R 170 Y 300

S 180 Z 240+

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
1092 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.6 Tyre Label (Vehicle Placard)

The tyre Label (Vehicle Placard) is located on the driver door B pillar inner edge/face. This
placard gives important information about the tyre size designed for the vehicle, and the tyre
inflation pressures for the front and rear tyres.

Tyre Size Tyre Pressure Bar (psi)

245/75 R16 Front Rear

Laden 36 44

Unladen 30 36

15.7 Tyre Pressure

Proper tyre inflation pressure is essential to the safe and satisfactory operation of the vehicle.
Three primary areas are affected by improper tyre pressure;
1. Safety.
2. Fuel economy.
3. Ride Comfort and Vehicle Stability.
Proper tyre inflation contributes to a comfortable and safe ride. Overinflating produces a jarring
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.

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 1093
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.8 Component Index

15.8.1 Wheels & Tyres View

A. Front Tyre.
B. Front Wheel Rim/Alloy.
C. Spare Wheel Rim/Alloy.
D. Spare Wheel Tyre.
E. Rear Tyre.
F. Rear Wheel Rim/Alloy.
G. Valve.
H. TPMS.
I. Wheel Nut.

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
1094 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.9 Trouble Shooting

15.9.1 Symptom Possible Causes

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 1095
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1096 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symp- Symptom Image Possible Remedy

tom Causes
Rapid Over inflation Adjust
wear at of the tyres. correct tyre
center pressure to
correct
value.

One edge 1. Excessive • Camber

wear camber. to be
checked
and adjust
to the
specifica-
tion.

2. Excessive • Check
cornering. and adjust
hub end
play.

Feathered 1. Incorrect • Check

edge wear toe and correct
adjustment. toe value.

2. Improper • Carry-out
tyre rotation tyre
intervals. rotation at
regular
intervals.

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 1097
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symp- Symptom Image Possible Remedy

tom Causes
Wavy or 1. Lack of • Carry-out
Scalloped tyre rotation. tyre
wear rotation.

2. Worn or • Check
misaligned and
suspension replace the
parts. suspension
compo-
nents.

Bald 1. •
spots Unbalanced Unbal-
tyre anced tyre

2. Faulty • Replace
wheel the wheel
bearings. bearing.

3. Sudden • Avoid
braking. driving with
sudden
brake
locking.

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
1098 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

Side wall circumferential Run Flat (It is more obvious • Replace the tyre.
tyre bulging from inside).

Side tyre wall Crack/ 1. Kerb damage. • Replace the tyre.

diagonal
2. Stone hit.

Vehicle vibration due to 1. Tyre pressure is high or • Adjust the tyre pressure.
wheels low.

2. Wheel imbalance. • Balance the wheel

assembly.

3. Bent wheel rim. • Replace the wheel rim.

4. The tyre bead is not fixed • Remove and refit the tyre
properly in the wheel rim. on the rim properly.

5. Uneven tyre wear. • Replace both tyre and

rectify the reason for uneven
tyre wear.

Wheel wobbling 1. Loosen wheel nuts. • Check and tighten the

wheel nuts to the specified
torque value.

2. Damaged and unbalanced • Inspect the wheel rim and

wheel. tyre. Balance the wheel. If
necessary replace the tyre
and rim.

3. Worn out bearing. • Check and replace the front

wheel bearing.

4. Uneven worn brake disc. • Check and replace brake

disc.

5. Brake grabbing. • Check the brake caliper

assembly and replace the
necessary parts.

Cracked treads Under inflation. • Maintain the correct tyre

pressure.

Rapid wear at shoulder 1. Under inflation of the tyre. • Adjust correct tyre
pressure.

2. Lack of tyre rotation and • Do the tyre rotation.

excessive cornering.

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 1099
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.10 Care of the system

15.10.1 Service Tips and Precautions
Observe the following precautions when disassembling or servicing the wheels and tyres.
• Before attempting to balance the wheel assembly, clean both inner & outer sides of the
rims. Also remove any existing balance weights.
• Repair punctures only in the tread area.
• Avoid repairing of a tyre with bulges or blisters, ply separation, broken and cracked beads.
If any of these symptoms exist, replace the tyres.
• Clean the wheel rim bead seats by using a non-abrasive cleaner to remove the mounting
lubricants and old rubber.
• Lubricate bead area with suitable tyre lubricant, before mounting or demounting the tyre.
• Use an accurate tyre gauge to check tyre pressure.
• Mounting and demounting of the tyre must be done only from the narrow ledge side of the
wheel. Care must be taken to avoid damaging the tyre beads.

Improper Jacking will lead to accident, which will to personal injury or death.

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
1100 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.10.2 Wheel Balancing

If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel
rotation produces vibration. As the centrifugal force is produced proportional to the square of
the rotating speed, the wheel weight should be balanced even at high speed. There are two
types of the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur
due to unbalanced rigidity or size of tyres.

Static Balance When the free rotation of the wheel is

allowed, the heavier part is stopped on the
bottom if the wheel weight is unbalanced and
this is called "Static Unbalance". Also, the
state at which tyre's stop position is not same
is called "Static Balance" when the wheel is
rotated again. If the part A is heavier as
shown in the figure, add the “balance
weight” corresponding to unbalanced weight
from B to A to maintain the static balance. If
the static balance is not maintained,
tramping, up and down vibration of the
wheels, occurs.

Dynamic Balance The static unbalance of the wheel creates

the vibration in the vertical direction, but the
dynamic unbalance creates the vibration in
the lateral direction. As shown in the figure
(A), if two parts, (2) and (3), are heavier
when the wheels are under the static balance
condition, dynamic unbalance is created,
resulting in shimmy, left and right vibration of
the wheels, and the torque Fxa is applied in
the axial direction. To correct the dynamic
unbalance, add the balance weight of a
same weight for two points of the
circumference of the rim, M1 and M2, as
shown in the figure (B), and apply the torque
in the opposite direction to the torque Fxa to
offset in order to ensure smooth rotation of
the wheel.

The wheel should always be balanced and aligned in order to provide:

1. Enhanced tyre life.
2. Driving safety and steering control.
3. Better performance of the vehicle.
4. Unbalanced tyre may lead to premature tyre wear and driver fatigue due to vibration.
Tyres should always be balanced when they are mounted on wheels for the first time
5. When they are remounted after repair.
6. When there are signs of shimmy or vibrations.

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 1101
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.10.2.1 Wheel Balancing Precautions

1. Deposits of mud, dust must be cleaned from inside of the rim.

2. Remove stones from tread, clean the tyre and rim before balancing to achieve
better results.
3. Each tyre should be inspected for any damage.
4. The type of balance weights, when used, must be in accordance with the profile of
the rim flange. Refer below recommendations for usage of balance weights.

For balancing a wheel, follow the manufacturer’s (of balancing machine) manual for
balancing instructions, recommendations and any other additional information.

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
1102 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.10.3 Tyre Inspection and Rotation

Preliminary Activities/Conditions
• Position the vehicle on 2 post lift.
Tyres on the front and rear axles of vehicles operate at different loads and perform different
steering, handling, and braking functions. For these reasons, they wear at unequal rates and
develop irregular wear patterns. Rotation will increase tread life, help to maintain mud, snow,
and wet traction levels, and contribute to a smooth, quiet ride. Follow the recommended tyre
rotation.
It is recommended to rotate the tyres as per "Maintenance Schedule".
Below illustration shows suggested tyre rotation method:

Nut/ Bolt Description Torque value - Nm

Wheel nut (steel rim) 120±10

Wheel nut (Alloy wheel) 120±10

• Tyre rotation need to be carried out at every Service.

• For Non–ABS vehicles, 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 the correct LSPV setting height.

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 1103
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11 In Car Repairs

15.11.1 Wheels R&R

15.11.1.1 Component Location Index

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
1104 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift or lift by a • Tighten the wheel nut sequentially with the
jack. specified torque.

Removal Steps:
1. Remove the wheel nut.
2. Remove the Wheel.
Tools Required

Size Type Quantity

- Wheel spanner 1

21 mm Deep socket spanner 1

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 1105
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.1.3 Removal

1. Using a wheel spanner or 21 mm deep

socket loosen the wheel nuts.

2. Lift the vehicle, remove the mounting

nuts and then the wheel.

15.11.1.4 Inspection
1. Check for any external damage in the tyre or the rim, if found replace.
2. Check for any foreign material on tyre or rim, remove if found.

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
1106 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.1.5 Installation

1. Refit the wheel assembly & the nuts.

2. Down the vehicle as wheel on flat

surface and Torque tighten the nuts to
specified value in sequence.

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 1107
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.2 Tyre & Valve R&R

15.11.2.1 Component Location Index

15.11.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift or lift by a • Refit the wheel

jack.
• Remove the wheel

Tools Required

Size Type Quantity

- Tyre valve opener 1

- Tyre changing machine 1

- Tyre tool 1

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
1108 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.2.3 Removal

1. Remove the wheel. For additional 4. Using a bed breaker deflate the tyre.
information refer to Wheel R&R section.

2. Using a tyre valve opener remove the pin

& release the air pressure.

The TPMS sensor can get damaged,

ensure the bed breaker is not used near
the valve.
3. Break down the tyre preferably by using
a bead breaker with nylon roller, on the tyre
changing machine. 5. Use the tyre lever lift the tyre outer bead
over the rim and then using machine rotate
the wheel and detach the outer bead of the
tyre from rim.

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 1109
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Use the tyre lever lift the inner bead over

the rim & using machine rotate the wheel and
detach the inner bead of the tyre from rim
and remove the tyre.

7. Using a screw driver remove the screw &

the TPMS sensor & later the valve.

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
1110 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.2.4 Inspection
1. Check for any external damage in the tyre or the rim, if found replace.
2. Check the tyre inner surface for cuts and punctures.

15.11.2.5 Installation

1. Place the rim on the rotating table and 3. Apply jelly soap solution to top and
clamp the rim by activating jaw clamp and bottom of the tyre beadings.
paddle.

4. Place the tyre on the wheel rim.

2. Install the valve & using a screw driver
install the TPMS sensor.

Inner side / Outer side marking should be

checked before tyre fitment into wheel
rims. Any wrong fitment will have an
adverse impact on tyre life.

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 1111
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Fix the lower beading by rotating the 7. Inflate the tyre.

wheel rim clockwise and push down on the
lower beading using a tyre lever as the
position shown in the illustration below.

8. Refit the wheel. For additional

information refer to Wheel R&R section.

Ensure that the valve core is not fitted as

this may cause debris to get in to the
valve stem.

6. Fit the top beading of the tyre by rotating

the wheel clockwise, and pushing down the
bead as shown in illustration.

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
1112 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.3 Spare Wheel & Winch R&R

15.11.3.1 Component Location Index

15.11.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/ 4 post lift. • Install the spare wheel.

• Remove the spare wheel.

Tools Required

Size Type Quantity

- Jack lever 1

13 mm Socket spanner 1

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 1113
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.3.3 Removal

1. Using a Jack lever, rotate the nut anti 4. Remove the winch assembly from the
clock wise direction to lower the spare wheel. vehicle.

2. Bring down the spare wheel & remove

from the winch holder.

3. Using a 13 mm socket spanner, remove

the winch mounting bolts.

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
1114 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.3.4 Inspection
• Check for rust & freeness, if found rusty or hard please replace.

15.11.3.5 Installation

1. Position the spare wheel winch. 3. Place the spare wheel on winch hub and
by using jack lever rotate the nut clock wise
direction for spare wheel move upwards and
position in its place.

2. Install the winch mounting bolts and

torque tighten the bolts to specified value.

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 1115
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.4 Wheel Hub (2WD) R&R

15.11.4.1 Component Location Index

15.11.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2/ 4 post lift. • Install the wheel tighten the wheel nut
sequentially with the specified torque.
• Remove the respective side front wheel.

Tools Required

Size Type Quantity

21 mm Wheel Spanner 1

12 mm / 17 mm / 19 mm Socket spanner 1

- Mallet / Screw Driver Each 1

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
1116 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.4.3 Removal

1. Using 21 mm wheel spanner remove 4. Remove front caliper lower mounting bolt
mounting nuts and remove the front wheel. using 12 mm socket spanner.

2. By using screw driver remove the hub 5. Lift the caliper upwards as shown in
cover. illustration.

3. Using suitable spanner remove the hub

locking nut.

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 1117
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Remove the brake pads and anti-rattle 8. Remove the wheel hub assembly along
clips. with brake disc unit from the knuckle.

9. Using 17 mm socket spanner, remove

the brake disc mounting bolts and detach it
from the wheel hub assembly.

7. Using 19 mm socket spanner remove the

caliper assembly mounting bolts, remove the
caliper and hank on the coil spring without
remove the brake hose.

15.11.4.4 Inspection
• Check the wheel hub for any crack, damage and deformation. Replace if necessary.
• Check the hub bearing, if noisy please replace.

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
1118 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.4.5 Installation

1. Refit the wheel hub with brake disc 4. Fix both the anti-rattle clips back in its
assembly, torque tighten the mounting bolts position and refit the brake pads.
to specified value.

2. Gently slide in the wheel hub with the

brake disc unit on knuckle assembly.

3. Refit the caliper assembly mounting bolt,

torque tighten the bolts to specified value.

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 1119
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Move the caliper downwards and bring 7. Refit the locking nut on the knuckle,
back to its original position. torque tighten the nut to specified value.

• 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.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

8. Refit the hub cover.

6. Refit the caliper bottom mounting bolt

and torque tighten the bolt to specified torque
value.
9. Refit the front wheel, torque tighten the
mounting wheel nuts to specified value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

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
1120 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.5 Wheel Hub (4WD) R&R

15.11.5.1 Component Location Index

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 1121
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.5.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the wheel and tighten the wheel nut
sequentially with the specified torque.
• Remove the respective front wheel.

Tools Required

Size Type Quantity

6 mm Allen key 1

21 mm Wheel Spanner 1

12 mm / 17 mm / 19 mm Socket Spanner 1

MST 571 Special Socket for hub nut 1

— Circlip plier 1

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
1122 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.5.3 Removal

1. Using 21 mm wheel spanner remove 4. Lift the caliper upwards as shown in

mounting nuts and remove the front wheel. illustration.

2. Using a 6 mm allen key, loosen the allen 5. Remove the brake pads and anti-rattle
bolts and remove the auto lock assembly. clips.

3. Remove front caliper lower mounting bolt

using 12 mm socket spanner.

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 1123
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Using 19 mm socket spanner remove the 9. Using a MST 571(Special Socket for hub
caliper assembly mounting bolts, remove the nut), remove the half shaft secondary lock
caliper and hank on the coil spring without nut.
remove the brake hose.

10. Using a blunt prick punch, remove the

7. Using a circlip plier, remove the circlip lock washer from the half shaft.
from the half shaft.

11. Using a MST 571 (Special Socket for

8. Remove the spacer from the half shaft. hub nut), remove the half shaft primary lock
nut.

Never remove the lock nut without using

a special tool. Lock nut edges are prone
to damage when general tools are used.

Slippage/dropping of heavy/large objects

will cause personal injury.

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
1124 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Remove the wheel hub assembly along

with brake disc unit from the knuckle.

13. Using 17 mm socket spanner, remove

the brake disc mounting bolts and detach it
from the wheel hub assembly.

15.11.5.4 Inspection
1. Check the wheel hub for any crack, damage and deformation. Replace if necessary.

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 1125
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.11.5.5 Installation

1. Refit the wheel hub with brake disc 4. Fix both the anti-rattle clips back in its
assembly, torque tighten the mounting bolts position and refit the brake pads.
to specified value.

2. Gently slide in the wheel hub with the

brake disc unit on knuckle assembly.

3. Refit the caliper assembly mounting bolt,

torque tighten the bolts to specified value.

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
1126 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Move the caliper downwards and bring 7. Refit the primary lock nut on the half
back to its original position. shaft, torque tighten the nut to specified
value.

• 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.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

8. Refit the intermediate lock nut on half

shaft, torque tighten the nut to specified
value.

6. Refit the caliper bottom mounting bolt

and torque tighten the bolt to specified torque
value.

9. Refit the secondary lock nut on the half

shaft, torque tighten the nut to specified
value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

10. Refit the spacer on the half shaft.

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 1127
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Refit the circlip on the half shaft.

12. Refit the auto lock assembly, torque

tighten the mounting bolts to specified value.

13. Refit the front wheel, torque tighten the

mounting wheel nuts to specified value.

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
1128 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.12 Technical Specification

15.12.1 Specification

Description Specification

Make CONTINENTAL

Wheel rim size 6.5J X 16” Regular (Alloy & Steel)

Tyre size designation including ply rating Tyre Size: P245 / 75R16 111S

Tyre Type Radial - Tubeless

Un-laden Tyre pressure (front & rear) (Psi) Front: 30

Rear: 36

Laden Tyre pressure (front & rear) (Psi) Front: 36

Rear: 44

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 1129
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

15.13 Torque Specification

15.13.1 Tightening Specification

Place of Application Torque in Nm

Wheels Fitment (Alloy) 120.0±10.0

Wheels Fitment (Steel) 120.0±10.0

Wheel Hub mounting bolt 52.5± 7.5

Winch to underbody 45.0±5.0

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
1130 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16 SUSPENSION

16.1 Description and Operation

16.1.1 Suspension System

Front suspension is Double wish-bone type IFS. Torsion bar for 4WD and 2WD with Double
acting Shock absorber (oil & gas filled) and stabilizer bar.
The front suspension is a double independent suspension which is designed to allow each
wheel to independently adapt different road surfaces. This type of suspension uses two
parallel arms. Each arm has two mounting positions to the chassis and one ball joint
attachment at the wheel knuckle. The shock absorber mounted on the lower arm that controls
the vertical movement of the vehicle. A stabilizer bar and links are included to control
suspension lean/sway during turns . The lower arm and upper arm are connected to each
other via the knuckle assembly via the respective joints. The rubber bush is between the two
rigid parts, and is elastically deformable. A double-arm design controls motion of the wheel
throughout suspension travel, controlling parameters such as camber angle, caster angle and
toe.
The rear suspension system is semi elliptical leaf spring mounted onto the rear axle tube at the
center and the chassis frame at the other two ends. It also consists of the shock absorbers and
stabilizer bar. Stabilizer bar is mounted on the rear axle with the help of rubber bush. It is
connected to the chassis frame on both ends through the link rods.

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 1131
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Leaf spring is attached directly to the frame at one end and the other through a shackle, a
short swinging arm. The shackle takes up the tendency of the leaf spring to elongate when
compressed and thus makes for softer springiness.
The stabilizer bar receives all the transverse loads experienced especially during cornering
controlling the axle movement in lateral direction. The stabilizer bars transfer the loads to the
outer wheel during turns. The shock absorber will absorb the road shocks due to terrain and
different load conditions. The shock absorbers dampen the oscillations of the springs. The
body mounts made of rubber fitted on the chassis reduces the impact loads onto the body.

16.1.2 Upper Arm

The upper arm is mounted to the frame and

the knuckle and it transmit the load from the
tyre to the knuckle.

16.1.3 Lower Arm

The lower arm is mounted to the knuckle, the

shock absorber and frame assembly. It
transmits and also absorb (slightly) the load
delivered from the tyre to the knuckle. It
absorbs the braking and acceleration
reactions.

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
1132 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.1.4 Front Stabilizer Bar Assembly

Stabilizer bar is known as anti-roll bar or

antisway bar. The main function of the
stabilizer bar is to keep the vehicle stable by
keeping the wheels of the vehicle on the
ground during vehicle roll around sharp
corners. The stabilizer bar operates on the
principle of Torsion/Twisting.
Stabilizer link is used to connect control arm
and stabilizer bar to provide articulation to
stabilizer bar.

16.1.5 Knuckle

The knuckle is connected to the end of the

steering system and allows the steering
movement. It also is connected to the LCA
and UCA and also its orientation decides
wheel alignment specifications like camber,
caster and toe. The other side of the knuckle
the hub assembly is connected.

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 1133
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.1.6 Ball Joint

Ball joint is used to provide articulation and

force transmission to suspension control
arms.

16.1.7 Front Suspension Shock Absorber

Shock absorber dampens and dissipates the

vibrations due to suspension movement
caused by external excitation. It is mounted
to the lower control arm and at the other end
is connected to vehicle chassis frame with
the help of securing bolts.

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
1134 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.1.8 Torsion Bar

Torsion bar is a cylindrical rod with serrated

ends and acts as a spring. This is made of
spring steel.
Two torsion bars are horizontally mounted
along the chassis frame on both sides; one
end connected to each side of the lower
control arm and the other end is connected to
chassis. The main function of the torsion bar
is to support the vehicle for comfortable ride.
It prevents the shocks generated by uneven
roads from being transferred to the
passenger block of the vehicle. Both the
torsion bars are different and are clearly
differentiated by the direction and the LH, RH
painted on the respective torsion bar. The
arrow painted on the torsion bar always
points to the front of the vehicle facilitating
easy mounting on the vehicle. Ride height of
the vehicle is also controlled by the torsion
bar.

16.1.9 Rear Suspension Stabilizer Bar Assembly

The rear stabilizer bar is also called as anti-

roll bar/anti-sway bar. During cornering the
outer wheel suspension is compressed by
the vehicle body. The vehicle chassis also
rolls and the outer end of the stabilizer bar
twists upwards. Through the pivot mountings
the stabilizer bar transmits part of the
torsional force to the opposite wheel, pulling
into its wheel housing. This causes the inner
wheel suspension to be compressed and
thereby reducing the body roll. The stabilizer
bar is mounted on to the rear axle through
two mounting brackets with bushes.
The rear stabilizer bar link rod connects the
rear stabilizer to the chassis. There are two
such links connected to the respective ends
of the stabilizer Bar. These facilitate the
twisting of the stabilizer bar during cornering
and roll.

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 1135
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.1.10 Rear Suspension Shock Absorber

The Shock absorber is gas filled telescopic

type. It is mounted on the rear axle and the
other end is connected to vehicle chassis
frame with the help of securing bolts.
The shock-absorber is also called as
damper. The shock-absorber smooth out or
damps shock impulses or vibrations induced
due to wheel travel over uneven road
surfaces. The shock-absorber slows down
and reduces magnitude of vibratory motions
by converting the kinetic energy of
suspension movement into heat energy that
is dissipated through gas or hydraulic fluid.

16.1.11 Leaf Spring Assembly

The leaf spring supports the vehicle and

offers a comfortable ride. It prevents the
shocks generated by the irregularities in road
from being transferred to the passenger
block of the vehicle. It also supports the rear
axle.
Leaf spring attached directly to the frame at
one end and the other end is attached
through a shackle, a short swinging arm. The
shackle takes up the tendency of the leaf
spring to elongate when compressed and
thus makes for softer elasticity of the spring.
The U-bolts fit around the rear axle and
secure to a metal plate that rests against the
leaf springs. The purpose of the U-bolts is to
keep the leaf springs flush against the axle
thus the springs will take the weight of the
vehicle and will not move around too much
during driving. The friction pads are provided
between the leaves to minimize the noise.
Semi elliptical spring is form of a slender arc
shaped length of spring steel of rectangular
cross section. The center of the arc provides
location for the rear axle, while tie holes are
provided at either end for attaching to the
vehicle body. The leaf spring has been made
from six leaves stacked on top of each other
from the layers, often with progressively
shorter leaves. Leaf springs serves locating
and to some extent damping as well as
springing functions.

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
1136 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.2 Component Location Index

16.2.1 Front Suspension

A. Upper control arm ball joint. G. Torsion bar.

B. Shock absorber. H. Upper control arm.

C. Bump stopper. I. Knuckle.

D. Lower control arm ball joint. J. Stabilizer bar link rod.

E. Stabilizer bar. K. Lower control arm.

F. Height control arm.

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 1137
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.2.2 Rear Suspension

A. Leaf Spring.
B. Stabilizer bar.
C. Shock absorber.
D. Stabilizer bar link rod.
E. Bump stopper.

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
1138 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.3 Trouble Shooting

16.3.1 Symptom possible causes remedy

Symptom Possible Causes Remedy

1. Front shock absorber 1. Check & tighten the nuts

mounting nut on body as per torque specification.
loosened

2. Front shock absorber top 2. Check & tighten strut

center nut on Piston rod piston center nut.
Thud Noise from the front loosened.
side
3. Play in front LCA ball joint. 3. Replace the Ball joint
assembly from LCA.

4. Play on Stabilizer bar 4. Replace stabilizer bar

mounting bushes on cradle. bushes.

1. Deformed torsion bars. 1. Check and replace the

torsion bars if necessary.

Front Ride height low 1. Front shock absorber 2. Replace front shock
deformation or deflection. absorber (use same
peripheral parts if not
damaged)

1. High tyre pressure. 1. Correct the tyre pressure

as per specifications.

Front ride too bouncy 2. Oil leakage from front 2. Replace shock absorber.
shock Absorber.

3. Bump stopper damage. 3. Replace bump stopper.

1. Torque loose of shock 1. Check & ensure proper

absorber bottom bolt / front torques as per specification
LCA mounting hardware/ of hardware.
Stab bar & stab links.

2. Front bump stopper 2. Replace bump stopper.

damaged.
Metallic Noise
3. Spring seat top / bottom 3. Replace the spring seat.
worn out.

4. LCA rubber bush failure. 4. Replace LCA bush.

And LCA bush sleeve is
touching to cradle.

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 1139
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

1. Incorrect tire pressure. 1. Reset the tire pressure or

else replace the tire, if
damaged. Replace the tire
valve, if found leaking.

2. Wheel alignment is out of 2. Adjust the alignment as

Specification. per the specification.

Vehicle drifts or pulls to one 3. Brake drag. 3. Inspect and correct the
side. brake. Refer brake system.

4. Damage of steering 4. Inspect the steering

components. components and replace if
necessary.

5. Front shock absorber is 5. Check the leakage or

weak on one side. damage of shock absorber,
replace if damaged.

1. Worn out front wheel 1. Replace the front wheel

bearings. bearing, if damaged.

2. Damage or bent front 2. Replace the front wheel

wheel Knuckle. knuckle, if damaged.

3. Damage or bent front 3. Replace the front lower

Front tires incorrect or lower Control arm. control arm, if necessary.
abnormal tire wear
4. Damage or bent steering 4. Replace the steering inner
Inner ball joint. ball joint, if necessary adjust
wheel Alignment.

5. Incorrect wheel alignment. 5. Adjust the wheel alignment

to the specification.

1. Loose wheel nuts. 1. Tighten the wheel nuts to

required specification.

2. Leakage in front shock 2. Inspect the shock

absorber. absorber. Renew if
necessary.
Sway or roll
3. Loose or worn stabilizer 3. Inspect the stabilizer bar
bar Links or bushings. assemblies. Tighten to
specification or renew
stabilizer bar components if
necessary.

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
1140 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

1. Antiroll bar bush crack or 1. Replace the anti-roll bar

Worn out. bush if necessary.

2. Worn or damaged lower 2. Replace the lower arm

Squeak noise from the front arm Bush. bush if necessary.
suspension. 3. Front shock absorber 3. Replace the defective
deformation or deflection. shock absorber, if damaged

4. Improper installation or 4. Check and adjust specified

loose suspension parts. torque if necessary.

1. Check if mud is between 1. Clean with pressurized

the leaf springs. water.

2. Check tip insert if broken/ 2. Replace the tip between

worn out. the leaves.

Noise from the Rear 3. Check bushes. 3. Replace the bushes.

suspension.
4. Check shock absorber 4. Tighten the shock
bush- worn out/ loose. absorber mounting bolt or
replace the bushes.

5. Check leaf breakage. 5. Replace the spring

assembly.

1. Stabilizer bar link is loose 1. Tighten the mounting bolts

from one end of in shock and nuts to the specified
absorber assembly to other torque.
end of the stabilizer bar.

2. Damaged threads in 2. Replace the stabilizer bar

stabilizer Bar link rod. link rod, if damaged

Rattling, knocking noise from 3. Damaged in stabilizer bar 3. Replace the stabilizer bar
the front side stopper. stopper, if damaged

4. Loose suspension mounts 4. Tighten the suspension

mounting to the specified
torque.

5. Lower arm ball joint worn 5. Replace lower arm ball

out. joint, if worn out.

1. Defective front shock 1. Replace the shock

absorbers. absorbers if necessary.
Rough/Harsh ride
2. Over inflated tires 2. Check and rectify the tire
pressure.

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 1141
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

1. Spring leaf bushes worn 1. Replace the bushes.

out.

2. Shock absorbers leaking/ 2. Check the shock absorber

Vehicle ride Jumpy/ Jerky weak. and replace if required.

3. Leaf spring sagging / 3. Check the bump clearance

broken. as per the specified
procedure. Replace springs.

1. Loose wheel nuts. 1. Tighten the nuts to

specification.

2. Loose front suspension 2. Tighten the fasteners to

fasteners. the specification.

3. Loose or worn front wheel 3. Inspect and replace the

Bearings. front wheel bearings, if
Wheel wobble necessary.

4. Tires worn or wheels out of 4. Replace the tires or

Balance. balance the wheels.

5. Incorrect wheel alignment. 5. Adjust the wheel alignment

to the specification.

6. Brake disc run out. 6. Replace the disc.

16.3.2 Components inspection and action table

Component Inspection Action

1. Check the control arm ball 1. Replace the ball joint.

joint stud for any damage or
wear.

2. Check for control arm ball 2. Replace the control arm.

joint jam.
Lower Control Arm 3. Check the control arm ball 3. Replace the control arm.
joint play in axial directions or
if end play is excessive.

4. Check the control arm ball 4. Replace the control arm.

joint dust cover for any
damage.

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
1142 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Component Inspection Action

5. Check the control arm 5. Replace the bush/ lower

bushes For wear. control arm assembly.

6. Check the lower control 6. Replace the lower control

arm for any bend, twist or arm assembly.
damage.

1. Check the control arm ball 1. Replace the ball joint.

joint stud for any damage or
wear.

2. Check for control arm ball 2. Replace the control arm.

joint jam.

3. Check the control arm ball 3. Replace the control arm.

joint play in axial directions or
if end play is excessive.
Upper Control Arm
4. Check the control arm ball 4. Replace the control arm.
joint dust cover for any
damage.

5. Check the control arm 5. Replace the bush/ lower

bushes For wear. control arm assembly.

6. Check the upper control 6. Replace the lower control

arm for any bend, twist or arm assembly.
damage.

1. Check the stabilizer bar for 1. Replace stabilizer bar if

twist or deformation. found.
Stabilizer Bar Assembly
2. Check the rubber bushing 2. Replace stabilizer bar
for cracks, wear or bushes if found.
deterioration.

1. Check for any damage and 1. Replace the knuckle

Knuckle Assembly
deformation. assembly.

1. Check the torsion bar for 1. Replace the torsion bar.

Torsion Bar
deformation or cracks.

1. Check the hub for any 1. Replace the hub.

damage or deformation.
Wheel Hub
2. Check wheel hub play. 2. Check and replace the hub
assembly.

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 1143
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.4 Standard Checking Procedure

16.4.1 Ball joint checking
1. Prior to testing inspect the ball joint for wear, inspect the wheel bearings for any play.
2. Raise and support the vehicle.
3. Inspect the ball joint and ball joint boot for damage.
4. If the ball joint or ball joint boot is found damaged, renew the ball joint.
5. Inspect the ball joint for relative movement by alternatively pulling the wheel downward
and pushing upward. Observe any relative movement between the wheel knuckle and
lower arm of the ball joint.
6. If relative movement is not observed the ball joint is in good condition.
7. If relative motion observed, check the ball joint.
8. Check the looseness of ball joints in LCA.

16.4.2 Steering Straight Ahead Setting Procedure:

Refer the procedure given below for SAP setting:
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.
• 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 aligning system manufacturer.

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
1144 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.5 Care of the System

16.5.1 Service Tips and Precautions
Observe the following precautions when servicing the front suspension components.
• Ensure a dust free environment before starting the work.
• Before disassembling or servicing, clean the outer surface of the components.
• Ensure that the component parts are free from foreign objects during disassembly and
assembly of the component parts.
• Carefully assemble the disassembled parts in the correct order. If work is interrupted, the
disassembled parts must be covered with clean cover/paper cloth.
Do’s and Don’ts
1. Do not jack the vehicle by putting the jack below any of the front suspension link
assembly or front LCA or Frame mounting location. Jacking on suspension link assembly
will damage the Link.
For additional information refer to Jacking and Lifting section.

• Oil may reduce life of the rubber bushings; wipe off any oil on rubber parts
immediately.
• When installing the rubber bushings, the final tightening should be done without load
and with the tires on level ground.

• Care should be taken while working with heavy parts, failure to follow this
instruction will lead to personal injury and damage to the parts.
2. Stabilizer bars Front have to be fitted in the correct orientation with RH marking located
on RH of the vehicle. Any assembly deviation on this results in the fouling of stabilizer
bar with surrounding parts
3. All rubber bushings should be frees from oil and do not require any lubrication. Grease or
mineral oil base lubricants will deteriorate the bushings.
4. Only flanged Bolts and Nuts as per specifications should be used. Usage of spring and
plain washer to be avoided.
5. The top center nut for front strut should be properly torque to the specifications.
6. All silent block with voided and flange bushes should be mounted as per the specified
orientation.

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 1145
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.5.2 Front suspension bushes inspect

1. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear,
cracks & shift. Replace if necessary.
2. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear,
cracks & shift. Replace if necessary.
3. Check the ball joint boots for damage, cracks, replace if necessary.
4. Check shock absorber bushes, shock absorber dust boot, stabilizer bar & link bushes for
wear & tear, cracks and shift, replace if necessary.

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
1146 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.5.3 Rear Suspension Bushes Inspection Procedure

1. Check the leaf spring front bushes, shackle joint bushes, stabilizer bar and stabilizer bar
links bushes for any damage/crack or deterioration. Replace the bushes if found any.
2. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift.

• While tightening & torquing the link ensure that the wheels are resting on the
ground/ 4 post lift. If it is not done, the ride quality will get adversely affected.
• The suspension bushes are to be inspected first at 20,000 kms/12 months and then
every 20,000 kms/12 months (Distance covered in kms/months in service whichever
is earlier).
•

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 1147
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.5.4 Suspension arms & Links inspect

1. Inspect front suspension lower control arm

for any bend, damage or crack.

2. Inspect front suspension upper control arm

for any bend, damage or crack.

3. Inspect front suspension stabilizer bar for

any bend, twisting, damage or crack.

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
1148 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Inspect torsion bar for any bend, twisting,

damage or crack.

4. Inspect rear suspension stabilizer bar for

any bend, twisting, damage or crack.

6. Inspect rear suspension leaf spring for any

bend, twisting, damage or crack.

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 1149
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Inspect front & rear suspension stabilizer

bar link for any bend, twisting, damage or
crack.

• While tightening the link & torquing ensure that wheels are resting on the ground/ 4
post lift. If it is not done, the ride quality will get adversely affected.
• Suspension arms and links need to be inspected first at 20,000 kms/12 months and
then every 20,000 kms/12 months (Distance covered in kms/months in service
whichever is earlier).

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
1150 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.6 Wheel Alignment procedure

Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile
maintenance that consists of adjusting the angles of the wheels so that they are set to the
specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that
vehicle travel is straight and true (without "pulling" to one side).
Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular
to the ground and parallel to each other. The purpose of these adjustments is maximum tyre
life and a vehicle that tracks straight and true when driving along a straight and level road. The
symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or
drifting away from a straight line, Wandering on a straight level road, Spokes of the steering
wheel off to one side while driving on a straight and level road.
Tools Required

Size Type Quantity

15 mm Socket spanner 01

14 mm / 17 mm / 19 mm Open end spanner 01

19 mm Ring spanner 01

Preliminary Activities/Conditions
• 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.
• Before doing wheel alignment, Check and adjust ride height as per specified value.
• 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 steering wheel for Straight Ahead Position (SAP) and lock the steering
column rotation.
• Refer the wheel alignment specification chart for the front Suspension.
• Refer below decision tree for wheel alignment:

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 1151
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1152 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Wheel Alignment Sequence:

• If above sequence is not followed, it will lead to incorrect wheel alignment even
though individual adjustments are done correctly.
Run Out Compensation
• Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation.
• Refer wheel alignment equipment manufacturer's guide lines while doing run-out
compensation.
Steering Straight Ahead Position Setting Procedure
Refer the procedure given below for SAP setting:
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.
• 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 aligning system manufacturer.

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 1153
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Wheel Alignment - Check & Adjust

Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to
each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and
true tracking along a straight and level road.
Specification for Wheel Alignment
Front Suspension:

Values in Degree-Minutes
Parameter
Nominal Min Max Remark
Camber 1° 0’ 0⁰ 30’ 1⁰ 30’ Adjustable

Cross Not adjustable

0⁰ 0’ to 1⁰ 0’
camber

Caster 2⁰ 45’ 1⁰ 45’ 3⁰ 45’ Not adjustable

Cross caster 0⁰0’ to 2⁰ 0’ Not adjustable

KPI /SAI 10° 45’ 9° 45’ 11° 45’ Not adjustable

Toe-In
(+) 0⁰ 10’ (+) 0° 5’ (+) 0° 15’ Adjustable
(Individual)

Toe-In (Total) (+) 0⁰ 10’ (+) 0° 5’ (+) 0° 15’ Adjustable

Values in Degree-Decimal
Parameter
Nominal Min Max Remark
Camber 1° 0.5⁰ 1.5⁰ Adjustable

Cross Not adjustable

0° to 1.0°
camber

Caster 2.75⁰ 1.75⁰ 3.75⁰ Not adjustable

Cross caster 0° to 2.0° Not adjustable

KPI /SAI 10.75° 9.75° 11.75° Not adjustable

Toe-In
(+) 0.17⁰ (+) 0.09⁰ (+) 0.25⁰ Adjustable
(Individual)

Toe-In (Total) (+) 0.17⁰ (+) 0.087⁰ (+) 0.253⁰ Adjustable

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
1154 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Steering setting angle :

Left Wheel Right Wheel

Left Lock 31.2° 29°

Right Lock 29° 31.2°

• 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.

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 1155
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.6.1 Camber Adjustment Procedure

Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front.

• While adjusting camber angle vehicle should be unladen and nobody should sit
inside.
• The camber values should be within: 0.5⁰ to 1.5⁰.
• The difference between two wheels should be within: 0° to 1.0°.

1. To adjust camber loosen both the bolts of 2. Remove the shims and insert new shims
the LH pivot shaft (on the upper control arm) of required thickness to adjust the camber as
using a 15 mm socket spanner. per the readings.

While loosening hold the bolt with the • Shims are available in three sizes, 0.8
help of a 19 mm ring spanner. mm, 1.6 mm and 3.2 mm. The camber
decreases if thicker shims are added.

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
1156 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Once the reading is achieved tighten the

bolts to the specified torque.

16.6.2 Caster Adjustment Procedure

The angle between the vertical line and king pin, which fixes the steering knuckle and front
axle, (steering column which connects the top and bottom ball joints in the independent axle
type) when viewed the tyres from the side is called caster angle.

• The Caster values should be within: (1.75⁰ to 3.75⁰).

• The difference between two wheels should be within: 0° to 2.0°.
• Castor on the vehicle cannot be adjusted as it is in-built.

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 1157
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.6.3 Toe-in Adjustment Procedure

Toe is the difference of measured distances between the front ends of the tyres (A) and the
rear ends of the tyres (B) along the same axle when viewed the wheels from the top.

1. Hold tie rod end using 17 mm open end 2. Toe-in is adjusted by varying the length
spanner first and then loosen tie rod end lock of tie rods with the help of 14 mm open end
nut with the help of 17 mm open end spanner.
spanner.

While adjusting toe-in, adjust the length

of both the tie rods by rotating them in
the same direction such that their
lengths remain equal at all times.

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
1158 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. After adjusting the length of tie rods,

recheck toe in and then hold tie rod end with
19 mm open end spanner and then
tightening locknut with 19 mm open end
spanner.

• Front Toe In to be adjusted

individually on LH and RH side tie rod
ends.
• The Front Individual Toe In values
should be within: (+)0.09⁰ to (+)0.25⁰.
• The Front Total Toe In values should
be within: (+)0.087⁰ to (+)0.253⁰.

4. Once the reading is achieved tighten the

nuts to the specified torque.

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 1159
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.6.4 Ride Height

1. Front Ride height is the distance between the lower control arm mounting bolt center to
the level ground in unladen and straight ahead position.

2. Rear Ride height is the distance between the Rear Leaf spring Pivot end Center bolt to
the level ground in unladen and straight ahead position and Ride height at rear end is not
adjustable.
Ride Heights values are given in the table below:

Model Front Ride Height Rear Ride Height

2WD m-HAWK 264 mm ± 10 mm 360 mm ± 10 mm

4WD m-HAWK 264 mm ± 10 mm 360 mm ± 10 mm

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
1160 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

If ride height is not within limits, then check (Measure ride heights only when the
vehicle is on plain ground.):
• Correct tyre pressure.
• Torsion bar damage.
• Loosened suspension mounting bolts.
• Rubber bushes of UCA and LCA.
• And do Front Ride Height adjustment by tightening / loosening nut on height control
arm if value not within limits. For additional information refer to Ride Height
adjustment Procedure in Torsion Bar R&R section.

Nut/ Bolt description Torque Value – Nm

Upper arm frame mounting nuts 130 ±20

Steering toe adjusting nut tightening 56 ± 6

• Wheel alignment to be carried if any abnormal conditions are noticed or at every

service , whichever is earlier.

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 1161
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7 In Car Repairs

16.7.1 Upper Control Arm R&R

16.7.1.1 Component Location Index

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
1162 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.1.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Perform wheel alignment.

Removal Steps:
1. Remove the upper control arm ball joint lock nut.
2. Remove the upper control arm pivot mounting bolts & nuts.
3. Remove the shock absorber bracket mounting bolts and nuts.
4. Remove the upper control arm assembly.
Tools Required

Size Type Quantity

15 mm / 19 mm / 21 mm Ring spanner 1

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 1163
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.1.3 Removal

1. Remove the upper arm ball joint. For 4. Remove the upper control arm assembly.
additional information refer to Upper control
arm ball joint R&R section.

2. Using a 15 mm ring spanner and 19 mm

ring spanner loosen and remove the shock
absorber bracket mounting bolts and nuts.

3. Using a 21 mm ring spanner loosen and

remove the upper control arm pivot shaft
mounting nuts.

16.7.1.4 Inspection
1. Check the upper arm for deformation or cracks. Replace if necessary.
2. Check the ball joint for distortion or damage. Replace if necessary.

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
1164 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.1.5 Installation

1. Position and refit the upper control arm 6. Perform wheel alignment. For additional
information refer wheel alignment section.
2. Refit the upper control arm pivot
mountings bolts and nuts, tighten the
mountings bolts and nuts.

3. Refit the shock absorber bracket

mounting bolts and nuts, tighten the
mountings bolts and nuts.

4. Refit the upper control arm ball joint. For

additional information refer to Upper control
arm ball joint R&R section.

5. Torque tighten the Upper control arm

mounting nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

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 1165
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.2 Upper Control Arm Ball Joint R&R

16.7.2.1 Component Location Index

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
1166 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.2.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the respective front wheel and
tighten the wheel nut sequentially with the
• Remove the wheel
specified torque.
• Perform wheel alignment.

Tools Required

Size Type Quantity

- Nose plier 1

17 mm Socket spanner 1

MST-561 Upper arm ball Joint Puller 1

24 mm Open end spanner 1

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 1167
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.2.3 Removal

1. Remove the respective side front wheel. 4. Using a MST-561 (Upper arm ball Joint
For additional information refer to front Wheel Puller), detach the upper arm ball joint from
R&R section.. the knuckle.

2. Using a nose plier remove the split pin

from the upper arm ball joint lower mounting
lock nut.

5. Using a 17 mm socket spanner loosen

and remove the upper arm ball joint mounting
bolts and detach the upper arm ball joint.

3. Using a 24 mm open end spanner,

remove the lower mounting lock nut from the
upper arm ball joint.

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
1168 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.2.4 Installation

1. Position & refit the ball joint mounting 3. Refit the upper arm ball joint lock nut split
bolts, Tighten the bolts. pin.

4. Refit the front wheel. For additional

information refer to front Wheel R&R section.
While installing, don’t hammer the ball
joint. It will damage the ball joint. 5. Torque tighten the Upper control arm ball
Joint mounting nut and bolts to specified
2. Refit the ball joint lock nut, Tighten the values.
nut.

Torque tightening should be done

without load and with the tyres on level
ground.

6. Perform wheel alignment. For additional

information refer wheel alignment section.

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 1169
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.3 Lower Control Arm R&R

16.7.3.1 Component Location Index

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
1170 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.3.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Perform wheel alignment.

Removal Steps:
1. Remove the lower control arm split pin and lock nut.
2. Remove the stabilizer bar link rod bottom mounting nut.
3. Remove the shock absorber bottom mounting nut and bolt.
4. Remove the lower control arm pivot mounting bolts and nuts.
5. Remove the lower control arm assembly.
Tools Required

Size Type Quantity

17 mm / 18 mm / 21 mm Socket spanner 1

18 mm Ring spanner 1

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 1171
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.3.3 Removal

1. Remove the Lower arm ball joint. For 5. Using a 21 mm socket spanner loosen
additional information refer to Lower control and remove the lower arm mounting bolt from
arm ball joint R&R section. the chassis cross member.

2. Using a 18 mm socket spanner loosen

and remove the stabilizer bar link rod bottom
mounting nut.

In case the lower arm bump stopper has

failed/damaged then it needs to be
unscrewed from its position by tapping
3. Using a 18 mm ring spanner hold the bolt in the anti-clock-wise direction.
and by using 17 mm socket spanner loosen
and remove the shock absorber bottom
mounting bolt and nut.

4. Remove the torsion bar assembly for the

respective side. For additional information
refer to Torsion bar R&R section.

16.7.3.4 Inspection
1. Inspect the lower control arm for any external damage or bent, if found replace
2. Inspect the lower control arm ball joint and bushes for any damage.

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
1172 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.3.5 Installation

1. Refit the lower arm pivot mountings, 5. Refit the Lower arm ball joint. For
tighten the mounting bolts and nuts. additional information refer to Lower control
arm ball joint R&R section.

6. Torque tighten the lower control arm

mounting nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

7. Perform wheel alignment. For additional

information refer wheel alignment section.

2. Refit the torsion bar assembly. For

additional information refer to Torsion bar
R&R section.

3. Refit the shock absorber bottom

mounting, tighten the mounting bolt and nut.

4. Refit the stabilizer bar link rod bottom

mounting nut, tighten the nut.

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 1173
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.4 Lower Control Arm Ball Joint R&R

16.7.4.1 Component Location Index

16.7.4.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the respective front wheel and
• Remove the wheel tighten the wheel nut sequentially with the
specified torque.
• Perform wheel alignment.

Tools Required

Size Type Quantity

- Nose plier 1

17 mm Socket spanner 1

24 mm Ring spanner 1

MST-562 Lower arm ball Joint Puller 1

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
1174 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.4.3 Removal

1. Remove the respective side front wheel. 4. Using a MST-562 (Lower arm ball Joint
For additional information refer to front wheel Puller), detach the upper arm ball joint from
R&R section. the knuckle.

2. Using a nose plier remove the split pin

from the lower arm ball joint lower mounting
lock nut.

5. Using a 17 mm socket spanner loosen

and remove the lower arm ball joint mounting
bolts and detach the lower arm ball joint.

3. Using a 24 mm ring spanner, remove the

lower mounting lock nut from the lower arm
ball joint.

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 1175
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.4.4 Installation

1. Position & refit the ball joint mounting 3. Refit the lower arm ball joint lock nut split
bolts, Tighten the bolts. pin.

4. Refit the front wheel. For additional

information refer to front wheel R&R section.
While installing, don’t hammer the ball
joint. It will damage the ball joint. 5. Torque tighten the lower control arm ball
joint mounting nut and bolts to specified
2. Refit the ball joint lock nut, Tighten the values.
nut.

Torque tightening should be done

without load and with the tyres on level
ground.

6. Perform wheel alignment. For additional

information refer wheel alignment section.

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
1176 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.5 Front Suspension Stabilizer Bar Links R&R

16.7.5.1 Component Location Index

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 1177
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.5.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the wheel and tighten the wheel nut
sequentially with the specified torque.
• Remove the front wheels.

Removal Steps:
1. Remove the stabilizer link top mounting nut.
2. Remove the stabilizer link bottom mounting nut.
3. Remove the stabilizer link assembly.
Tools Required

Size Type Quantity

18 mm Socket spanner 1

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
1178 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.5.3 Removal

1. Using a 18 mm socket spanner loosen

and remove the link rod top mounting nut
from the stabilizer bar.

2. Using a 18 mm socket spanner loosen

and remove the link rod bottom mounting nut
from the LCA bracket.

16.7.5.4 Inspection
• Check for any external damage or boot punched, if found replace.

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 1179
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.5.5 Installation

1. Refit the stabilizer link rod bottom

mounting nut, torque tighten the nut to
specified value.

2. Refit the stabilizer link rod top mounting

nut, torque tighten the nut to specified value.

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
1180 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.6 Front Stabilizer Bar and Bushes R&R

16.7.6.1 Component Location Index

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 1181
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.6.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2 post lift. • —

Removal Steps:
1. Remove stabilizer bar link rod top mounting nut LH & RH.
2. Remove the stabilizer bar mounting bracket bolts.
3. Remove the stabilizer bar mounting bracket.
4. Remove the stabilizer bar bushes LH & RH.
5. Remove the stabilizer bar.
Tools Required

Size Type Quantity

18 mm Ring spanner 1

16 mm Socket spanner 1

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
1182 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.6.3 Removal

1. Using a 18 mm ring spanner loosen and

remove stabilizer bar link rod top mounting
nut LH & RH.

2. Using a 16 mm socket spanner remove

the stabilizer bar mounting bracket bolts &
the bracket.

3. Remove the stabilizer bar along with

bushes & remove the bushes.

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 1183
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.6.4 Inspection
1. Inspect the stabilizer bar for any damage, crack or twisting. Replace if found.
2. Inspect the stabilizer bar bushes for any damage or deterioration. Replace if found.
3. Inspect the stabilizer bar mounting bracket for any damage.

16.7.6.5 Installation

1. Refit the stabilizer bar bushes and 3. Refit the stabilizer link on either sides
Position the stabilizer bar. with the help of mounting nut. Torque tighten
the nut to specified value.

2. Refit the stabilizer bar bracket mounting

bolts, torque tighten the bolts to specified
value.

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
1184 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.7 Knuckle R&R

16.7.7.1 Component Location Index

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 1185
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.7.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the wheel hub assembly.
• Remove the wheel hub assembly. • Perform wheel alignment.

Removal Steps:
1. Remove the steering tie rod mounting nut.
2. Remove the UCA ball joint split pin and lock nut.
3. Remove the LCA ball joint split pin and lock nut.
4. Remove the knuckle assembly.

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
1186 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

- Nose plier 1

24 mm Open end spanner 1

10 mm Socket spanner 1

MST-561 Upper arm ball Joint Puller 1

MST-562 Lower arm ball Joint Puller 1

17 mm/ 24 mm Ring spanner 1

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 1187
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.7.3 Removal

1. For 2WD, Remove the wheel hub 5. Using a nose plier remove the split pin
assembly. For additional information refer to from the upper arm ball joint lower mounting
wheel hub (2WD) R&R section. lock nut.

2. For 4WD, Remove the wheel hub

assembly. For additional information refer to
wheel hub (4WD) R&R section.

3. Using 10 mm socket spanner loosen and

remove the wheel speed sensor mounting
bolt.

6. Using a 24 mm open end spanner,

remove the lower mounting lock nut from the
upper arm ball joint.

4. Using 17 mm ring spanner loosen and

remove the steering tie rod mounting nut for
the respective side.

7. Using a MST-561 (Upper arm ball Joint

Puller), detach the upper arm ball joint from
the knuckle.

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
1188 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Using a nose plier remove the split pin 11. Remove the knuckle assembly.
from the lower arm ball joint lower mounting
lock nut.

Using hammer give a slight tap on the

knuckle assembly to remove it from the
vehicle.

9. Using a 24 mm ring spanner, remove the

lower mounting lock nut from the lower arm
ball joint.

10. Using a MST-562 (Lower arm ball Joint

Puller), detach the lower arm ball joint from
the knuckle.

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 1189
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.7.4 Inspection
1. Check knuckle for any cracks, damage and deformation. Renew if necessary.

16.7.7.5 Installation

1. Position and refit the knuckle assembly. 4. Refit the upper arm ball joint on knuckle
assembly, Tighten the nut.
2. Refit the lower arm ball joint on knuckle
assembly, Tighten the nut.

5. Refit the split pin on the upper arm ball

joint mounting lock nut.
3. Refit the split pin on the lower arm ball
joint mounting lock nut.

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
1190 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit the steering tie rod end on the 11. Perform wheel alignment.For additional
knuckle, Tighten the nut. information refer wheel alignment section.

7. Refit the wheel speed sensor, torque

tighten the mounting bolt to specified value.

Take sufficient care not to damage the

sensor.

8. For 2WD, Refit the wheel hub assembly.

For additional information refer to wheel hub
(2WD) R&R section.

9. For 4WD, Refit the wheel hub assembly.

For additional information refer to wheel hub
(4WD) R&R section.

10. Torque tighten the knuckle mounting

nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

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 1191
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.8 Front Shock Absorber R&R

16.7.8.1 Component Location Index

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
1192 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.8.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the wheel and tighten the wheel nut
sequentially with the specified torque.
• Remove the respective front wheel.

Removal Steps:
1. Remove the shock absorber top mounting nuts.
2. Remove the washer and bush from shock absorber.
3. Remove the shock absorber bottom mounting bolt and lock nut.
4. Remove the spring washer.
5. Remove the shock absorber assembly.
Tools Required

Size Type Quantity

14 mm / 17 mm Socket spanner 1

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 1193
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.8.3 Removal

1. Remove the respective front wheel 4. Using a 17 mm socket spanner loosen

assembly. For additional information refer to and remove the lower mounting lock nut,
front Wheel R&R section. washer spring of the shock absorber from the
lower control arm.
2. Using a 14 mm socket spanner loosen
and remove the shock absorber top
mounting nuts from the bracket.

5. Detach the shock absorber from the

vehicle.

3. Remove the washer and bush from the

top mounting bracket.

These are gas filled shock absorbers. Do

not heat any components nearby. The
gasses may heat up and expand and
there is danger of exploding. Failure to
follow this instruction may cause
personal injury and/or damage to
components.

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
1194 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.8.4 Inspection
1. Check the shock absorber for smooth operation through a full stroke, both compression
and extension.
2. Check the shock absorbers oil leakage, damage and deformation. Replace if necessary.

16.7.8.5 Installation

1. Align and position the shock absorber on 4. Refit the shock absorber top bracket
the vehicle. mounting nuts, tighten the nuts.

2. Refit the washer spring of the shock

absorber and tighten the mounting lock nut.

5. Refit the front wheel. For additional

information refer to front Wheel R&R section.

6. Torque tighten the shock absorber

mounting nuts and bolts to specified values.
Do not interchange upper and lower
washers of the shock absorber. The
lower washer should be installed with its
cup side facing downwards and for the Torque tightening should be done
upper washer the cup side is installed without load and with the tyres on level
facing upwards. ground.
3. Refit the shock absorber in the top
bracket and put the washer and bushes.

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 1195
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.9 Torsion Bar R&R

16.7.9.1 Component Location Index

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
1196 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.9.2 Removal and Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Adjust the ride height.

Removal Steps:
1. Remove the height control arm mounting bolt.
2. Remove the torsion bar mounting bolts.
3. Remove the torsion bar assembly.
Tools Required

Size Type Quantity

- Long flat screw driver 1

16 mm / 18 mm / 21 mm Socket spanner 1

21 mm Ring spanner 1

21 mm Open end spanner 1

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 1197
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.9.3 Removal

1. Remove the respective side of front 4. Using a 18 mm socket spanner loosen

wheel. For additional information refer to and remove the stabilizer bar link rod bottom
front Wheel R&R section. mounting nut.

2. Using a 21 mm ring spanner loosen the

upper control arm pivot shaft mounting nuts.

5. Using a 21 mm open end spanner,

remove the torsion bar height control arm
mounting guide bolt and seating nut from
3. Using a 21 mm socket spanner loosen chassis cross member.
the lower arm mounting bolt on chassis cross
member.

6. Using a 16 mm socket spanner, loosen

the torsion bar torque arm mounting bolts
from the lower arm assembly.

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
1198 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Slide the torsion bar horizontally towards

the rear end of the vehicle to separate it from
the lower arm of the wishbone.

8. Slide the torsion bar forward and take out

from the height control arm. Remove the
torsion bar and height control arm from the
vehicle.

16.7.9.4 Inspection
1. Check the torsion bar for deformation, twist or cracks. Replace if necessary.

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 1199
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.9.5 Installation

1. Remove the Front shock absorber 4. Insert torsion bar into torque arm and
assembly. For additional information refer to Insert Other end of bar on height control arm.
Front Shock absorber R&R section.

2. Fix the Ride Height Fixture in place of

shock absorber and insert the bolt.
• Ensure torsion bar arrow points
towards vehicle front side.
• Ensure Punch marking on torsion bar
coincides with punch mark on torque
arm.
• Also ensure Punch marking on torsion
bar coincides with punch mark on
height control arm.

• By this arrangement LCA will be

maintained in Unladen Condition.
• The ride Height fixture should properly
match at the top end and Ensure
tightness of nut on the threads of
gauge after installation.

3. Insert height control arm on torsion bar

mounting cross member.

• Ensure wheel center with respect to

chassis while Installing height control
arm.

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
1200 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the torque arm on LCA, tighten the

mounting bolts.

Actual Stand out distance to be

calculated based on the initial bolt
threads out of the Guide nut.
1. Case 1: If bolt thread are 5 mm
outside the guide nut as shown
below, then Actual Stand out
distance = 5 mm + Stand out
distance.

6. Tighten height control arm bolt till bolt

stand out distance as per specified stand out
distance value.

2. Case 2: If bolt thread are 5 mm

inside the guide nut as shown
below, then Actual Stand out
distance = Stand out distance -5
mm.

Front Ride Stand Out

Model Height Distance

264 mm ± 10
SC 2WD 22.3 mm
mm

264 mm ± 10
SC 4WD 25.7 mm
mm
7. Torque tighten the torsion bar mountings,
upper control arm joints, lower control arm
264 mm ± 10
DC 2WD 23.3 mm joint to frame and stabilizer bar link on lower
mm
control arm as per the specified value.
264 mm ± 10
DC 4WD 26.5 mm
mm

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 1201
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Remove the ride height setting gauge by

removing nut and bolt at both ends.

9. Refit the shock absorber assembly. For

additional information refer to Shock
absorber R&R section.

10. Check ride height at LCA mounting bolt

(front) from ground, in vehicle unladen
condition on flat surface.

If change in ride height is observed on the

vehicle, then adjust front vehicle height by
tightening / loosening nut on height control
arm.

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
1202 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.10 Rear Stabilizer Bar and Bushes R&R

16.7.10.1 Component Location Index

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 1203
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.10.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the rear wheels and tighten the
wheel nut sequentially with the specified
• Remove the rear wheels.
torque.

Removal Steps:
1. Remove the stabilizer link (LH & RH) bottom mounting nut and bolt.
2. Remove the stabilizer bar (LH & RH) bracket mounting bolts.
3. Remove the stabilizer bar (LH & RH) brackets.
4. Remove the stabilizer bar mounted bushes.
5. Remove the rear suspension stabilizer bar.
Tools Required

Size Type Quantity

12 mm Open end spanner 1

12 mm / 13 mm Socket spanner 1

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
1204 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.10.3 Removal

1. Using a 12 mm open end spanner and 3. Remove the bushes and take out the
socket spanner loosen and remove the stabilizer bar separately.
stabilizer bar link rod bottom mounting nut on
both sides.

2. Using a 13 mm socket spanner loosen Take care while removing the mounting
and remove the stabilizer bar bracket brackets of the rear stabilizer bar so as to
mounting bolts from the rear axle. avoid damage to the wheel speed sensor
cables.

16.7.10.4 Inspection
1. Check the stabilizer bar for twist or deformation. Replace if necessary.
2. Check the rubber bushing for cracks, wear or deterioration. Replace if necessary.
3. Check for loose link rod ball joint. Replace if necessary.

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 1205
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.10.5 Installation

1. Position and refit the stabilizer bar and 4. Torque tighten the stabilizer bar
the bushes. mounting nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

2. Refit the stabilizer bar mounting clamps,

tighten the bolts.

3. Refit the stabilizer bar link rod (LH & RH)

bottom mounting bolt & nuts, tighten the bolt
& nut.

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
1206 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.11 Rear Suspension Shock Absorber R&R

16.7.11.1 Component Location Index

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 1207
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.11.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the rear wheel.

• Remove the respective side rear wheel.

Removal Steps:
1. Remove the upper mounted nut and bolt.
2. Remove the lower mounted nut and bolt from rear axle.
3. Remove the rear suspension shock absorber assembly.
Tools Required

Size Type Quantity

Ring spanner/ Open end

13 mm Spanner Each 1

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
1208 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.11.3 Removal

1. Using a 13 mm ring spanner and the

open end spanner loosen and remove the
shock absorber bottom mounting bolt and
nut.

2. Using a 13 mm ring spanner and the

open end spanner loosen and remove the
shock absorber top mounted bolt & nut.

These are gas filled shock absorbers. Do

not heat any components nearby. The
gases may heat up and expand and there
is danger of exploding. Failure to follow
this instruction may cause personal
injury and/or damage to components.

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 1209
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.11.4 Inspection
1. Check the shock absorber for smooth operation by full stroke, compression and
extension.
2. Check the shock absorber for fluid leakage, damage or deformation. Replace if
necessary.

16.7.11.5 Installation

1. Refit the shock absorber top mounting

bolt and nut, tighten the bolt and nut.

2. Position and refit the shock absorber

bottom mounting bolt and nut, tighten the bolt
and nut.

3. Torque tighten the shock absorber

mounting nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

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
1210 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.12 Rear Suspension Leaf Spring R&R

16.7.12.1 Component Location Index

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 1211
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.12.2 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and confirm the proper functioning
of leaf spring.

Removal Steps:
1. Remove the U-bolt lock nuts.
2. Remove the leaf spring support plate.
3. Remove the pivot plate mounting nut.
4. Remove the pivot plate mounting bolt on chassis bracket.
5. Remove the pivot plate and pin assembly..
6. Remove the shackle plate mounting nuts.
7. Remove the shackle plate.
8. Remove the shackle plate and pin assembly.
Tools Required

Size Type Quantity

10 mm / 13 mm/ 17 mm Socket spanner 1

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
1212 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.12.3 Removal

1. Using a 17 mm socket spanner loosen 4. Using a 13 mm socket spanner loosen

and remove the U- bolt lock nuts from the the shackle plate mounting nuts and remove
rear axle. the shackle plate and shackle plate assembly
mounted on the chassis.

2. Remove the spring support plate.

5. Using a 13 mm socket spanner loosen
and remove the pivot plate pin mounted nut.

3. Gently take out the leaf spring U- bolts

and bump stopper from the rear axle.
6. Using a 10 mm socket spanner loosen
and remove the pivot plate mounting bolt.

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 1213
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Provide jack support to the leaf spring

assembly and carefully detach the leaf spring
assembly and bushes from the vehicle.

16.7.12.4 Inspection
1. Check the leaf spring broken or sagging, Replace if necessary.
2. To check for the spring sagging it is recommended that bump clearance in unladen
conditions is measured.
The bump clearance is (For 2WD - 79.5±10 mm & 4WD - 69.5±10 mm) and Ride height
variation between Left and right should not be more than 7 mm.

• The vehicle should be in level ground and unladen condition.

• 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.
• Re-cambering of the spring is not recommended.

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
1214 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.12.5 Installation

1. Position the leaf spring assembly. 5. Refit the bump stopper and U-bolts on
the rear axle.
2. Refit the pivot plate mounting bolt,
tighten the bolt.

6. Refit the leaf spring support plate.

3. Refit the leaf spring pivot plate mounting

nut, tighten the nut.

7. Refit the U- bolts mounting nuts, tighten

the nuts.

4. Refit the shackle plate assembly on

chassis bracket, tighten the mounting nuts.

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 1215
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Torque tighten the leaf spring mounting

nuts and bolts to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.

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
1216 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.13 Leaf Spring Pivot End Bush Replacement

16.7.13.1 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and confirm the proper functioning
of leaf spring.

Tools Required

Size Type Quantity

10 mm / 13 mm Socket spanner 1

16.7.13.2 Removal

1. Using a 13 mm socket spanner loosen 3. Provide jack support and carefully detach
and remove the pivot plate pin mounted nut. the pivot plate from leaf spring assembly and
remove the bush.

2. Using a 10 mm socket spanner loosen

and remove the pivot plate mounting bolt.

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 1217
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.13.3 Installation

1. Properly align the eyes in spring & pivot 3. Refit the leaf spring pivot plate mounting
and insert the bush. nut, tighten the nut.

• The rubber bushes are liberally coated

with soap water.
• The hole in the centre of the pivot and
the hanger bracket are clean and not
blocked by mud.

4. Torque tighten the Pivot mounting nut

and bolt to specified values.

Torque tightening should be done

without load and with the tyres on level
ground.
2. Refit the pivot plate mounting bolt,
tighten the bolt.

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
1218 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.14 Leaf Spring Shackle End Bush Replacement

16.7.14.1 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and confirm the proper functioning
of leaf spring.

Tools Required

Size Type Quantity

13 mm Socket spanner 1

16.7.14.2 Removal

1. Using a 13 mm socket spanner loosen

the shackle plate mounting nuts.

2. Provide jack support and carefully

detach the shackle plate assembly from leaf
spring assembly and remove the bushes .

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 1219
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.7.14.3 Installation

1. Properly align the eyes in spring & 3. Torque tighten the Pivot mounting nut
shackle and insert the bushes. and bolt to specified values.

• The rubber bushes are liberally coated Torque tightening should be done
with soap water. without load and with the tyres on level
ground.
• 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.

2. Refit the shackle plate assembly on

chassis bracket, tighten the mounting nuts.

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
1220 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.8 Technical Specification

16.8.1 Front Suspension

Description Specification

Type Double Wish-Bone type IFS (Independent

Front Suspension).

Shock absorber Double acting shock absorber (Oil & Gas

filled).

Torsion bar

Upper control arm with ball joint

Lower control arm with ball joint

Split knuckle

Stabilizer bar

Rubber Bump stop mounted on lower control arm

16.8.2 Rear Suspension

Description Specification

Type Semi Elliptical Leaf Spring

Shock absorber Double acting shock absorber (Oil & Gas

filled).

Stabilizer bar

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 1221
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

16.9 Torque Specification

16.9.1 Tightening Specification

Sl Place of Application Torque in NM

No
1. Knuckle assembly upper ball joint 135 ± 25

2. Wheel nuts 120±10

3. upper arm front mounting nut 90 ± 10

4. upper arm rear mounting nut 90 ± 10

5 upper arm frame mounting nuts 130 ± 20

6. Knuckle arm upper ball joint 140 ± 20

7. Knuckle assembly lower arm ball joint 70 ± 10

8. mounting bolts at LCA 0.63”(16mm) 40 ± 10

9 mounting bolts at LCA 0.71”(18mm) 80 ± 10

10. Lower control arm front mounting nut 97 ± 10

11. Lower control arm rear mounting nut 97 ± 10

12. Shock absorber bottom mounting bolt LCA 70 ± 10

13. Shock absorber upper mounting nut on chassis 19 ± 3

14. Stabilizer bar mounting bracket bolts on chassis 38 ± 7

15. Stabilizer bar link bolts lower control arm 70 ± 5

16 Bolt – Leaf spring pivot 60 ± 10

17 Bolt - Shackle 60 ± 10

18 U Bolt 90 ± 10

19 Shock Absorber Top 50 ± 10

20 Shock Absorber Bottom 50 ± 10

21 Assembly Plate End Pivot 25 ± 10

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
1222 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17 BRAKES

17.1 Description and Operation

17.1.1 Brake System

Braking at the wheel is done by disc brakes in front and drums at rear. The disc brake is
double pot and with ventilated disc. Parking brake is at rear which is mechanically actuated
through cable.
The double diaphragm vacuum booster helps in reducing the pedal effort. In case the vacuum
fails or the booster has failure. Then also the brakes will be applied manually due to push rod-
though at much higher pedal efforts.
To reduce pedal effort, a double diaphragm vacuum booster is fitted between brake pedal and
tandem master cylinder. when the servo unit fails, the push rod still acts mechanically to
provide non-assisted braking. The vacuum in the system is generated by the vacuum pump.
The parking brake is console mounted cable operated acting on rear wheels.
The braking system includes a Load sensing proportioning valve (LSPV) (for Non ABS only ).
It controls the brake fluid pressure going to the rear depending on the load on the vehicle.
ABS system allow efficient braking without wheel locking, thereby allowing the driver to retain
steer-ability and control of the vehicle during panic braking. Even if one circuit fails, the other
remains unaffected and the vehicle can be brought to a halt. The hydraulic pressure is applied

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 1223
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

from the tandem master cylinder to the front wheel calipers and rear wheel drum through
suitable bundy tubes/flexible hoses.
The vehicle is equipped with a 4 channel ABS system. Brake pressure to individual wheels are
controlled by ABS EHCU.
The main components of the ABS system are:
Electronic hydraulic control unit (EHCU) consists of Electronic control unit (ECU) and
Hydraulic control unit (HCU).
When the brake is applied, hydraulic fluid is routed from the tandem master cylinder to the
front & rear brakes through the ABS-EHCU. The Primary and Secondary outlet of the tandem
master cylinder is connected to the EHCU inlet. The EHCU outlet is connected to the front left,
front right, rear left and the rear right brake circuit. The electronic control unit (ECU) monitors
the front and the rear wheel speeds through the speed sensors. If a wheel is about to lock-up,
the ECU signals the concerned cartridge (Valve) in the EHCU. The valve modulates the
hydraulic brake pressure to the respective wheels to prevent wheel lock-up.

17.1.2 Hydraulic Control Unit

The hydraulic control unit consists of:

17.1.2.1 Isolation Valve

• One isolation valve for each hydraulic circuit.
• Normally open valve to allow the free passage of brake fluid.
• On energizing the coil, armature moves down, closing the normally open orifice.

17.1.2.2 Dump Valve

• One dump valve for each hydraulic circuit.
• Normally closed valve to prevent any brake fluid from entering the low pressure
accumulators until needed.
• On energizing, coil moves the armature up, which opens the normally closed orifice.

17.1.2.3 Pump Motor

• Actuates the hydraulic pumps.
• Uses an offset cam that pushes against the internal pump pistons.

17.1.2.4 Low Pressure Accumulator

• One LPA for each master cylinder circuit.
• Provides a reservoir for the brake fluid to be dumped during an ABS event.

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
1224 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.2.5 Attenuator
• Acts as a shock absorber to reduce pedal pulsation, duration and intensity of brake pedal
feedback from the ABS unit.

17.1.3 Electronic Control Unit

• Monitors brake switch input to determine whether or not to prepare for possible anti-lock
braking.
• Monitors WSS (Wheel Speed Sensor) data input to determine when a wheel is approaching
lock-up.
• Monitors input regarding drive mode status.
• Operates the HCU Assembly during anti-lock braking based on WSS information in
comparison to data programmed in the ECU’s memory.
• Detects system related problems and performs diagnostic processes, such as illuminating
the warning lamps in the cluster by sending signals & setting DTCs (Diagnostic Trouble
Codes).

17.1.4 Normal Braking

During non-antilock braking,
1. Pressure is applied through the brake pedal and fluid comes from the master cylinder
into the EHCU.
2. The fluid travels through the center of the normally open isolation cartridge, around the
normally closed dump cartridge and out into the brakes.
3. The pump does not turn on, and the LPA and attenuators are empty of residual pressure.
4. Even though the ABS is passive during normal braking, the EHCU constantly monitors
wheel sensor inputs for rapid deceleration.

17.1.5 Anti-lock Braking

17.1.5.1 Isolation Mode

1. If the information from the WSS indicate rapid wheel deceleration, the first step in the
antilock sequence is to isolate the brake pressure being applied by the driver.
2. The ECU sends a voltage to the isolation coil to energize and close the isolation valve.
3. This prevents any additional fluid pressure applied by the driver from reaching the wheel.
4. Thus, with the isolation valves closed, further unnecessary increases in the brake
pressure will be prohibited.

17.1.5.2 Dump Mode

1. To get the wheels rolling once again, the pressure in the wheel has to be reduced further.
This is accomplished by dumping a portion of the brake fluid pressure into the LPA.
2. The ECU energizes the dump valve thus allowing fluid from the wheels to be dumped
into the LPA.

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 1225
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. This is done with very short activation pulses opening and closing the dump cartridge
passageway.
4. Brake pressure is lowered at the wheel and allows the wheel to begin spinning again.
5. A portion of the fluid also primes the pump and the attenuators are ready to handle
pumped fluid.

17.1.5.3 Reapply Mode

1. The reapply sequence is initiated to obtain optimum braking. The isolation valve is
momentarily pulsed open to allow master cylinder and pump pressure to reach the
brakes.
2. If more pressure is required, more fluid is drawn from the master cylinder. The driver may
feel slight pedal pulsation, or pedal drop, this is normal and expected.
3. As fluid is reapplied to the wheels, they begin to slow down. If they approach imminent
lockup again, the module will isolate, dump and reapply again. This control cycle occurs
in millisecond intervals, allowing several cycles to occur each second. It is a much faster
and more controlled way of “pumping the pedal.”

17.1.5.4 Brake Release Mode

1. At the end of the antilock stop, when the driver releases the brake pedal, the motor will
remain running for a short time to help drain any fluid in the LPA.
2. While the fluid drains back into the system, the LPA springs help force the piston back to
their original position.
3. When the brake switch opens, the isolation valve is turned off and fluid may return to the
master cylinder.

17.1.6 Electronic Stability Program

This system enhances directional control and stability of the vehicle under various driving
conditions. The ESP corrects for over steering and under steering behavior of the vehicle by
applying the brake of the appropriate wheel automatically. Engine power may also be reduced
to assist in counteracting the condition of oversteer or understeer and help the vehicle
maintain the desired path. ESP uses steering angle sensors and YAW rate sensor to
determine the path that the driver intends to steer the vehicle and compares it to the actual
path of the vehicle. When the actual path does not match the intended path, the ESP applies
the brake of the appropriate wheel to assist in counteracting the condition of oversteer or
understeer.
• Oversteer - when the vehicle is turning more than appropriate for the steering wheel
position
• Understeer - when the vehicle is turning less than appropriate for the steering wheel
position.

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
1226 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.6.1 Hydraulic Schematics - ESP

Hydraulic Schematics - ESP The hydraulic circuit layout of the ESP system similar to ABS, i.
e., diagonally split. For details refer the Hydraulic System Layout in ABS Section.
The ESP system consists of a hydraulic modulator with integrated pressure sensor; electronic
control unit and four wheel speed sensors which it shares with the ABS system. In addition to
the individual wheel valves present for the ABS, the ESP hydraulic modulator has a pair of
internal switching valves on the primary and secondary brake circuits from the master cylinder.
These are used when brake pressure has to be increased at individual wheels. It has a yaw
rate sensor and steering angle sensor connected via the high speed CAN. There is information
lamp in the instrument cluster which is used to identify when the system is operating and when
a fault has been detected.

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 1227
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.7 ABS Hydraulic Schematic

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
1228 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.8 Non ABS Hydraulic Schematic

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the 1229
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.9 Brake Pad

Brake pads convert the kinetic energy of the

car to thermal energy by friction. Two brake
pads are contained in the brake caliper with
their friction surfaces facing the brake disc
which are pressed together against the
rotating disc to slow/stop the vehicle.

17.1.10 Brake Caliper

Brake calipers hydraulically operate the

brake pads to create enough friction either to
slow or to stop the vehicle. The role of the
caliper is to apply the pressure needed for
the brake pad to grip the rotating disc.

17.1.11 Brake Disc

The brake disc is mounted on the wheel hub

and this provides the friction surface against
which brake pads come in contact and slow
down the vehicle. The brake disc can
become very hot during braking. Do not
touch with bare hand on vehicles where
braking operation has just happened

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
1230 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.12 EHCU (Electronic Hydraulic Control Unit)

The EHCU is of Gen 9.1 type. It is mounted

in the engine compartment LH side.

17.1.13 Tandem Master Cylinder/ Brake Booster Assembly

The vehicle is equipped with Vacuum

assisted tandem type FSFS 8”+9” Double
diaphragm booster. Brake booster increases
the force the brake pedal exerts on the brake
master cylinder by using engine vacuum and
pressure. The brake booster contains a
diaphragm that separates its interior into two
parts, with both in a partial vacuum. As the
brake pedal is depressed, it causes a valve
inside the booster to open, which in turn
allows air into one side of the booster. This
difference in pressure on one side helps to
push the piston inside the brake master
cylinder forward in response to the brake
pedal, which in turn slows and stops your
vehicle.

17.1.14 Brake Pedal

It is connected to brakes booster push rod.

Brake pedal switch is mounted on the brake
pedal. When the brake pedal is depressed by
the driver based on brake pedal travel, brake
pedal ratio and vacuum assist booster ratio,
hydraulic pressure is generated in the master
cylinder. Also brake switch gets released to
activate brake lamps/stop lamps and high
mount stop lamp at the rear of the 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 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 1231
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.1.15 Brake Drum

Drum brakes are internal expanding shoe

type, here a set of brake liners expand
against a brake drum which is connected to
wheel leading to braking of the vehicle. The
brake liners are operated by a wheel cylinder
which receives hydraulic pressure form the
tandem master cylinder. Drum brakes are
normally fitted on rear brakes.
Automatic adjuster adjusts the clearance
between the brake shoe and the brake drum
automatically. Each time when the brakes
are applied, a screw in the adjuster turns.
This extends the length of the adjuster to
compensate the wear of the brake lining

17.1.16 LSPV ( Load Sensing Proportionating Valve)

During braking the load on the rear axle is

reduced as due to braking action the load
moves forward. With the existing brake line
pressure the wheels lock. The LSPV valve
senses the amount of the rear axle travel
and adjust the brake line pressure to avoid
wheel locking. The LSPV is mounted on
chassis. LSPV valve is connected through a
spring to rear axle.

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
1232 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.2 Component Index

17.2.1 Brake System Layout View 1 (ABS)

A. TMC I. Front Flexible Hose

B. EHCU Unit J. Brake Caliper

C. Wheel Speed Sensor K. Brake Disc

D. Brake Reservoir L. Parking Brake Lever Assembly

E. Brake Drum M. Parking Brake Cable

F. Brake Booster N. Rear Flexible Hose

G. Brake Bundy Tubes O. Brake Liner

H. Brake Pedal P. Wheel Cylinder

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 1233
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.2.2 Brake System Layout View 2 (Non ABS)

A. Brake Bundy Tube I. Brake caliper

B. Brake Booster J. Brake Disc

C. Brake Reservoir K. Brake Drum

D. Four Way Square Connector L. LSPV

E. Parking Brake Lever Assembly M. Wheel Cylinder

F. Brake Pedal N. Brake Liner

G. TMC O. Parking Brake Cable

H. Flexible hose

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
1234 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.3 Symptom Possible Causes Remedy

Symptom Possible Causes Remedy

1. Leakage in the hydraulic • Rectify the leakage. Top-up

system. the brake fluid and bleed the
system.

2. Air in the system. • Carry-out brake system air

bleeding.

3. Brake pads or disc are • Replace with new brake

worn out. pads.

4. Master cylinder piston • Install the new master

Brake pedal soft/ spongy scored or piston bore is worn cylinder.
out.

5. Soft or weak hoses. • Replace the hoses, and

bleed the system.

6. Brake pads or discs worn • Replace the disc and pads.

out.

7. Poor quality brake fluid. • Flush the system and refill

with recommended grade of
brake fluid.

1. Brake pad worn below • Replace the brake pads

recommended thickness. with new one.

2. Brake booster not working. • Perform the brake booster

functional test and replace if
required.

3. Vacuum leakage. • Check and rectify the

vacuum leakage.

4. Kinked, dented or clogged • Identify and replace.

Brake pedal hard bundy tubes, hoses or 'T'
connections.

5. Binding pedal linkage. • Lubricate and free up the

system.

6. Fading brake due to non- • Replace with recommended

recommended grade of grade of brake pads.
brake pads.

7. Brake lining soiled with • Replace the brake pads.

brake fluid, oil or grease.

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 1235
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

1. Air in the system. • Bleed the system.

2. Incorrect pedal play. • Adjust the pedal play.

Excessive pedal travel 3. Soft or bulging hoses. • Replace the hoses. Bleed
the brake system.

4. Leakage from caliper • Rectify the leakage and

assembly. carry-out brake bleeding.

1. Incorrect tyre pressure. • Inflate all the tyres to the

recommended pressure.

2. Wrong wheel alignment. • Check and adjust the wheel

alignment as per
specification.

3. Loose suspension parts. • Tighten suspension

Grabbing or Pulling brakes mountings to the specified
torque.

4. Loose caliper mountings • Tighten the caliper and disc

and disc. mounting bolts to the
specified torque.

5. One side brake pad soiled • Replace the brake pads and
with brake fluid, oil or grease. necessary parts.

1. Excessive lateral face out • Check and replace the

in disc or parallelism not brake disc.
within the specification.
Brake Chatter or Brake
2. Broken anti-rattle clip. • Replace the anti-rattle clips.
roughness
3. Incorrect parking brake • Check and adjust the
adjustment. parking brake as per
specification.

1. Worn out brake disc or • Check and replace the

pad. brake disc and pad.

2. Glazed brake pad lining. • Clean the brake pad lining

surface with sand paper.
Poor braking efficiency
3. Seized master cylinder or • Replace the master
plunger. cylinder.

4. Vacuum leak in the hose to • Check and replace the

servo. vacuum hose.

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
1236 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Possible Causes Remedy

1. Bent or warped backing • Replace or realign the

plate causing interference backing plate.
with disc.
Squealing noise when 2. Loose parts in the brake • Check and adjust the loose
brakes are not applied system. parts.

3. Improper positioning of • Correct the position of pads

pads in caliper. in caliper.

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 1237
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.4 Troubleshooting of Vacuum Booster Assembly

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
1238 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.5 Vacuum Leak Test

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 1239
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.6 Standard Checking Procedure

17.6.1 Brake switch adjustment

1. Press the lock and disconnect the 4. Adjust the brake switch till the gap
electrical connector from the brake switch. between the switch and the stopper on the
brake pedal is 2 mm.

2. Place the brake pedal in release

• Loosen the switch completely.
position.
• Keep 2 mm thick spacer on the stopper.
• Tight the switch till the switch face
touches the spacer surface.
Make sure weld nut is not disturbed
during brake pedal switch adjustment.

3. Loosen the lock nut using 14 mm open Ensure the plunger is in fully pressed
end spanner. condition.
• Lock the switch position by tightening the
lock nut.
• Remove the washer.

Ensure that the plunger is getting fully

pressed in brake pedal released
condition.

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
1240 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Connect brake switch connector.

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 1241
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7 Care of the System

17.7.1 Service Tips and Precautions

Do’s Don’ts
1. Inspect brake fluid level regularly and 1. Don’t use old brake pads.
top up if necessary. 2. Don’t use the disc with thickness below
2. Inspect brake pads/Lining as permissible limits.
scheduled and Change brake pads/ 3. Don’t over torque and under torque any
lining if necessary. joints including hydraulic joints.
3. Use only genuine Dot 4 brake fluid. 4. Don’t reuse the brake oil, always use
4. Extreme cleanliness is required when fresh oil from sealed container.
dealing with hydraulic system. 5. Do not allow the brake fluid to come
5. Use only brake fluid for cleaning below MIN level in reservoir.
internal parts of the hydraulic system. 6. Do not use kerosene / petrol / diesel for
6. To clean glazed brake pad/ liners. Do cleaning the cylinders.
use metal files. Do not use emery 7. Do not apply grease on anti rattle clips
paper. for front as well as rear brakes.
7. Disconnect the ABS EHCU's wiring 8. Do not expose any part of the ABS
harness connector, Before undertaking control system to excessive heat or
any electric arc welding work. flame.
8. Must remove the ABS EHCU's, during 9. Do not push the wheel speed sensor in
paint work operations or major repair with any hard material.
work, which are likely to subjected to
higher temperature (above 85° C). 10. Do not leave the wheel speed sensor
loose. It will lead to vibration issues and
9. The wheel speed sensor should not be lead to malfunction of the ABS system.
exposed to strong magnetic field.
11. Do not allow the brake fluid to come in
contact with eyes or skin. If it happens
by accident, thoroughly wash the
affected area with water and get
medical help.
12. Do not use any mineral oil or diesel or
kerosene to clean any brake system
part in touch with brake fluid. It will
contaminate and damage the seal as
well the fluid characteristic. Do not use
water or compressed air to clean either.

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
1242 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.2 Brake Fluid Level & Leak Test

17.7.2.1 Component location Index

17.7.2.2 Lubricant Specification & Quantity

Brake Fluid - Fluid Meeting SAE J 1703 FMVSS No.116; DOT 4 specifications
Capacity –0.9 Litres. (Excludes bleeding quantity).

1. Check Brake fluid reservoir fluid level, if

found less than MIN mark, top up to
MAX mark.
2. Check the reservoir for leakage and
check the level of fluid, if found less top
up till MAX mark.
3. Always maintain fluid level at MAX
mark on reservoir.

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 1243
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.2.3 Check for Brake Fluid leakages at (For ABS/ESP Vehicles) :

1. Check for brake fluid leakage at master 3. Check for brake fluid leakage or seepage
cylinder outlet. at bundy tube joints shown in illustration.

2. Check for brake fluid leakage at EHCU 4. Check for brake fluid leakage or seepage
unit inlet and outlet pipes. at bundy tube joints shown in illustration.

5. Check for brake fluid leakage at caliper

flexible hose end on bundy tube (Both RH &
LH).

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
1244 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Check for brake fluid leakage at front

caliper inlet and bleeding nipple (Both RH &
LH).

7. Check for brake fluid leakage at rear RH

& LH flexible hose.

8. Check for brake fluid leakage at rear

wheel cylinder inlet & bleeding nipple (Both
LH & RH side).

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 1245
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.2.4 Check for Brake Fluid leakages at (For Non-ABS Vehicles) :

1. Check for brake fluid leakage at master 4. Check for brake fluid leakage or seepage
cylinder outlet. at front LH tube 2 connector (applicable for
4WD).

2. Check for brake fluid leakage at bottom

four way square joints. 5. Check for brake fluid leakage at caliper
flexible hose end on bundy tube (Both RH &
LH).

3. Check for brake fluid leakage or seepage

at bottom secondary tube connector.

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
1246 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Check for brake fluid leakage at front 9. Check for brake fluid leakage at rear
caliper inlet and bleeding nipple (Both RH & wheel cylinder inlet & bleeding nipple (Both
LH). LH & RH side).

7. Check for brake fluid leakage at LSPV

inlet bundy, outlet flexible hose and bleeding
nipple.

8. Check for brake fluid leakage at rear 3

way Joints.

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 1247
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Use recommended fluid & do not mix different brand fluids.

• In case brake fluid reservoir replaced, then system needs bleeding.
• 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.
• Avoid direct water spray on reservoir while washing engine compartment.
• Brake Fluid level & Leak need to be inspected at every service.
• Always use brake oil specification for Fluid Meeting SAE J 1703 FMVSS No.116; DOT
4 specifications.
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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
1248 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.3 Brake Fluid Replace or Bleeding

17.7.3.1 Component Location Index

17.7.3.2 Lubricant Specification & Quantity

Brake Fluid - Fluid Meeting SAE J 1703 FMVSS No.116; DOT 4 specifications
Capacity –0.9 Litres. (Excludes bleeding quantity).

• Entire bleeding operation should be done with engine ON condition.

• In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is
required.

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 1249
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• 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.

17.7.3.3 Brake Fluid Draining Procedure :

1. Open brake fluid reservoir cap. 3. Pull-out the bleeding nipple dust cap
from both rear RH and LH bleeding nipple.

2. Pull-out the bleeding nipple dust cap

from both front RH and LH bleeding nipple.

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
1250 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Using 9 mm 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. For Non-ABS vehicle, Pull-out the

bleeding nipple dust cap from LSPV & loosen
the bleeding nipple on LSPV.

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 1251
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.3.4 Refilling Procedure

1. Hand tighten all the bleeding nipples. 4. Press and release brake pedal gently, so
that brake fluid will get circulated throughout
the circuit.

2. For Non-ABS vehicles, hand tighten the

bleeding nipple on LSPV also.
5. 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
fluently without air bubbles.

3. Fill recommended brake fluid up to

“MAX” mark on the brake fluid reservoir.

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
1252 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.3.1 Brake Fluid Air Bleeding Procedure (With ABS/ESP)

In vehicles equipped with ABS, brake circuit air bleeding needs to be carried out in 3 steps as
mentioned below:
1. Manual bleeding.
2. Bleeding the EHCU with the use of diagnostic Tool.
3. Final manual bleeding.

17.7.3.1.2 Mechanical Bleeding

• During the bleeding process, ensure that the fluid level in the reservoir does not
drop below minimum.
• Refer the below illustration for the bleeding sequence for vehicle with ABS/ESP -

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 1253
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Connect a transparent tube into rear LH 3. Open the rear LH bleeding screw, allow
bleeding nipple and insert the other end of the fluid to flow through the transparent pipe
tube in a transparent container with brake into the container.
fluid.

• Air bubbles will escape from brake

• Ensure other end of tube is circuit to container through
submerged in liquid, else chances for transparent pipe and the bubbles will
air entry is high. 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.

5. Continue procedure 2-4 till there is no air

bubbles visible in the transparent tube.

6. Remove the transparent tube.

7. Tighten the bleeding screw firmly.

2. Press and release the brake pedal 3- 4

times slowly to the full stroke and hold the
pedal in depressed condition.

• Ensure proper quantity of brake fluid

in the reservoir throughout the
bleeding procedure.
8. Follow steps from 1-7 for Rear RH side
brake.

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
1254 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Follow steps from 1-7 for Front LH side 12. Maintain recommended brake fluid up
brake. to MAX mark on the brake fluid reservoir.

10. Follow steps from 1-7 for Front RH side 13. Refit the brake fluid reservoir cap.
brake.

11. Refit the dust cap back on all the

bleeding nipples (both front and rear).

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 1255
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.3.1.3 Tool (i-SMART) Bleeding

• During the tool-bleeding process, ensure that the fluid level in the reservoir does not
drop below minimum.
1. Connect i-SMART and turn the ignition “ON”.
2. Select Mahindra Pikup from the list of vehicle models and Select the “required variant”
from the list of variants.
3. From the list of controllers shown, select “ABS ECU”. The following window appears.

W1A170151

Click on “WRITE DATA” button of left panel and the below shown screen appears.
4. Select “EOL ROUTINE”.

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
1256 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

W1A170152

The following window appears.

W1A170164

5. Click on “ROUTINE SELECTION” Drop down list and select “REPAIR BLEEDING”.

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 1257
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

W1A170153

6. Click on “START ROUTING” to initiate the tool bleeding.

Ensure the fluid level in brake fluid reservoir is at “MAX” mark.

W1A170154

The following pop up window appears.

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
1258 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

W1A170155

7. Connect a transparent tube into rear LH side bleeding nipple and insert the other end of
tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding
screw and then press “OK” button.

• Ensure other end of tube is submerged in liquid, else chances for air entry is
high.
The following pop up window appears.

W1A170156

Click on “YES” button to proceed for “Bleeding phase I”.

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 1259
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• After pressing “YES” button, Press and hold the brake pedal for 3 seconds and
then release for 0.5 seconds.
• Continue above procedure till “Bleeding phase I ” ends
The following pop up window appears once the “Bleeding phase I” ends.

W1A170157

Close the rear LH bleeding nipple once the above mentioned pop up window appears.
8. Connect a transparent tube into front LH side bleeding nipple and insert the other end of
tube in a transparent container with brake fluid. Loosen and open the front LH bleeding
screw and then press “OK” button.

• Ensure other end of tube is submerged in liquid, else chances for air entry is
high.
The following pop up window appears.

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
1260 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

W1A170158

Click on “YES” button to proceed for “Bleeding phase II”.

• After pressing “YES” button, Press and hold the brake pedal for 3 seconds and
then release for 0.5 seconds.
• Continue above procedure till “Bleeding phase II ” ends.
The following pop up window appears once the “Bleeding phase II” ends.

W1A170159

9. Close the front LH bleeding nipple once the above mentioned pop up window appears.
10. Connect a transparent tube into front RH side bleeding nipple and insert the other end of
tube in a transparent container with brake fluid. Loosen and open the Front RH bleeding
screw and then press “OK” button.

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 1261
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Ensure other end of tube is submerged in liquid, else chances for air entry is
high.
The following pop up window appears.

W1A170160

Click on “YES” button to proceed for “Bleeding phase III”.

• After pressing “YES” button, Press and hold the brake pedal for 3 seconds and
then release for 0.5 seconds.
• Continue above procedure till “Bleeding phase III” ends.
• In bleeding phase III, pump motor switches ON and OFF in a pre defined
intervals. While pump motor is ON, brake pedal pulsations can be felt along
with the motor operating sound.
The following pop up window appears once the “Bleeding phase III” ends.

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
1262 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

W1A170161

11. Connect a transparent tube into Rear RH side bleeding nipple and insert the other end of
tube in a transparent container with brake fluid. Loosen and open the Rear RH bleeding
screw and then press “OK” button.

• Ensure other end of tube is submerged in liquid, else chances for air entry is
high.
The following pop up window appears.

W1A170162

Click on “YES” button to proceed for “Bleeding phase IV”.

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 1263
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• After pressing “YES” button, Press and hold the brake pedal for 3 seconds and
then release for 0.5 seconds.
• Continue above procedure till “Bleeding phase IV” ends.
• In bleeding phase IV, pump motor switches ON and OFF in a pre defined
intervals. While pump motor is ON, brake pedal pulsations can be felt along
with the motor operating sound.
The following pop up window appears once the “Bleeding phase IV” ends.

W1A170163

Press “OK” button to complete brake bleeding through i-SMART.

17.7.3.1.4 MECHANICAL BLEEDING

1. Once again carry-out mechanical bleeding. For additional information refer to Manual
bleeding section (ABS).

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
1264 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.3.5 Brake Fluid Air Bleeding Procedure (Non ABS – LSPV Type):
Refer the below illustration for the bleeding sequence for Non ABS vehicle with LSPV-

1. For vehicles equipped with LSPV, only 3. Connect a transparent tube into LSPV
mechanical bleeding is required. bleeding nipple and insert the other end of
tube in a transparent container with brake
2. Carry-out manual bleeding as per fluid.
bleeding sequence mentioned in above
illustration.
• Rear left wheel.
• Ensure other end of tube is
• Rear right wheel. submerged in liquid, else chances for
• LSPV. air entry is high.
• Front left wheel. • Always use transparent tube for better
visibility of air bubbles.
• Front right wheel.

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 1265
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Carry-out manual bleeding for all wheels

as per bleeding sequence mentioned above.
For additional information refer to Manual
bleeding section.

• 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.
• Avoid direct water spray on reservoir while washing engine compartment.
• Always use brake oil specification for Fluid Meeting SAE J 1703 FMVSS No.116; DOT
4 specifications.
• 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/18 Months (Distance Covered in
km / Months in service whichever is earlier).
• For Non – ABS vehicles 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 the correct LSPV setting height.

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
1266 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.4 Brake Pad Inspect & Replace

17.7.4.1 Brake Pad Removal

1. Using 21 mm wheel spanner remove 5 4. Remove the brake pads.

mounting nuts and remove the front RH
wheel.

5. Remove the anti-rattle clips.

2. Remove front RH caliper lower mounting
bolt using 12 mm socket spanner.

3. Lift the caliper upwards as shown in

illustration.

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 1267
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.4.2 Brake Pad Inspection

Brake Pad Inspection:
Measure the pad lining thickness if it is found to be 1 mm or less, it has to be replaced.
Wear Limits:
• New pad thickness: 11 mm.
• Useful PAD Thickness: 10 mm.

Disc Thickness
Inspect the disc thickness before assembling the caliper back to the carrier.
• Actual thickness of disc= 26 mm.
• Wear limit = 2 mm.

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
1268 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.4.3 Brake Pad Installation

• While inserting the pads between the carrier and disc care should be taken that the
friction material should be towards the disc.
• Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and
rectify.
• Before inserting the pads ensure that caliper is returned fully to its position. (Push
the caliper inside if necessary.)
• Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard
particles of sandpaper will be deposited in lining and may damage disc. When pad
lining requires correction, replace it with a new one.
• While fitting the guide pin ensure that the straight portion of the pin matches with
the ear of the calliper body.
• The Pads in the Pad kit should be replace on the respective caliper i.e. assemble <
RH > marked pads on RH Caliper and < LH > marked pads on LH Caliper.
• Always ensure that the anti rattle pad clips are replaced whenever the pads are
replaced.
• Do not apply grease on anti rattle clips.
• If the pads are to be reused make sure they are assembled back in the same position
as they were when removed i.e., inboard pad on to the piston side and outboard pad
to the wheel side. This is possible only when at the time of removal these pads are
marked for their positions and kept aside. Never lubricate the pad seating areas as it
may lead to jamming.
• 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 200 kms of run or until the new pads are
performing satisfactorily.
• Never lubricate the pad seating areas as this may lead to jamming.

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 1269
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

1. Fix both the anti-rattle clips back in its 3. Move the caliper downwards and bring
position. back to its original position.

• Replace anti-rattle shims with a new • For easy movement, pull the caliper
one if found any damage or crack. outwards a bit and move it down.
• Chances for piston seal damage is
high, so take adequate precaution
while moving the caliper downwards.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

2. Refit the brake pads.

• Ensure both the brake pads are fitted

properly.
4. Refit the caliper bottom mounting bolt
and torque tighten the bolt to specified torque
value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

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
1270 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the front RH wheel, torque tighten

the mounting wheel nuts to specified value.

6. Follow the same procedure for front LH

brake pad and caliper inspection.

Nut/ Bolt description Torque Value – Nm

Wheel nuts 120±10

Caliper mounting bolt 90

• 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 service.
• DO NOT use grease to the pad shims/ anti-rattle shims.
• For Non –ABS vehicles, 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 the correct LSPV setting height.

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 1271
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.5 Brake Liner Inspect & Replace

17.7.5.1 Brake Drum Removal Procedure:

1. Remove the wheel assembly. For

additional information refer to Wheel R&R
section.

2. Using a star screw driver, remove drum

mounting screw and then slightly hammer
drum using a mallet and remove.

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
1272 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.5.2 Brake Drum/Lining Inspection Procedure:

1. Clean the brakes by blowing

compressed air.

2. Check the wheel cylinder for oil leakage.

(It is recommended to check the oil
seepage from wheel cylinder by lifting the
dust boots.)

3. Check the brake lining for wear/cracks.

4. The minimum usable thickness of the

rear brake liner is 1 mm.

• The brake shoe must be replaced

before the rib starts touching the
drum.
• Measure the wear of the brake lining at
the maximum worn out place.

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 1273
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.5.3 Brake Liner Removal Procedure:

1. Using a flat screw driver slide the parking 4. Gently expand and remove the liner
brake retaining lever and using a plier assembly carefully.
remove the parking brake cable.

5. Using a flat end screw driver detach the

2. Disconnect the parking brake cable top shoe return spring.
connection from the liner assembly.
6. Remove the auto-adjuster and adjuster
lever.

3. Using a plier remove the liner spring

holder.
7. Remove the bottom shoe return spring
and remove the liners.

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
1274 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.5.4 Brake liner Installation Procedure

1. Assemble the Liner kit. 4. Using a plier slide the parking brake
retainer lever & fix the parking cable.
• Align the shoes and fit bottom return
spring.
• Refit the auto-adjuster and auto-adjuster
lever.
• Refit the top shoe return spring.

5. Refit the brake drum with the help of

mounting screw.

2. Refit the liner kit assembly.

3. Refit the liner spring holder.

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 1275
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit the wheel. For additional

information refer to Wheel R&R section.

• Whenever the brake shoes are

replaced, replace both RH & LH
assemblies as a set to prevent car
from pulling to one side when braking.
• If there is significant difference in the
thickness of the liner on the left and
right sides, check parking brake
operation/ wheel cylinders piston for
free movement.
• Rear brake drum & liners to be
inspected atEvery regular service
• For Non – ABS vehicles, 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
the correct LSPV setting height.

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
1276 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.6 LSPV Height Setting Procedure

1. Using a screw driver remove the spring 4. Loosen the nut (use 12 ring spanner),
‘E clip ‘. during removal hold the other end with 14
mm open end spanner.

2. Remove the washer, slide the control

spring outwards and detach the spring from 5. Move the bolt in such a way that the bolt
the adjusting bolt. is aligned & enters in the slot on LSPV setting
tool.

6. Tighten the nut in such a way that the

bolt is in the correct position as indicated by
the tool.

7. Remove LSPV setting tool.

3. Insert the projection pin of the MST:

0606EB001ST (LSPV setting tool) in the eye
of the spring and allow the tool to hang freely.

8. Pull down the spring and locate the eye

in the bolt.

9. Ensure that the spring is sitting properly

in its position.

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 1277
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10. Insert the washer.

11. Secure the spring with ‘E’ clip.

Nut/ Bolt description Torque Value – Nm

LSPV mounting pin & spring & axle bracket 25±5

connection

• LSPV spring need to be disconnected before lifting the vehicle using a 2 post lift.
• The LSPV setting length is 92.5 mm at unladen condition.
• LSPV setting should be carried out with the vehicle on the ground or on a 4 - post
lift. The vehicle should not be lifted using a 2-post lift while doing this operation.

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
1278 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.6.1 Parking Brake adjustment

1. Apply and release the parking brake 5 3. Using 10 mm open end spanner, loosen
times to condition the cables for normal use. the lock nut located on back side of the
equalizer and then loosen the adjusting nut
fully.

Hold the cable while loosening the

adjusting nut.

2. Equalizer is located under the vehicle

next to the muffler.

4. Position the parking brake lever at 6th

notch position.

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 1279
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Tighten the adjusting nut till the rear

wheels can no longer be rotated using
hands, and tighten the lock nut.

6. Pull the parking brake lever up slightly,

press the release button on the lever tip and
lower the parking brake lever completely.

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.

• Parking brake adjustment needs to be done at every service.

• For Non –ABS vehicles, 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 the correct LSPV setting height.

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
1280 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.7.7 Inspection of Brake & Clutch Pedal for free play & operation

1. Press and release the clutch pedal and

Inspect the Clutch Pedal for free play &
operation.

2. Press and release the brake pedal and

Inspect the Brake Pedal for free play &
operation.

• Inspection of Brake & Clutch Pedal for free play & operation needs to be done first at
20,000 kms /12 months and then every 20,000 kms /12 months (Distance covered in
kms/months in service whichever is earlier)..

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 1281
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8 In Car Repair

17.8.1 Caliper Assembly R&R

17.8.1.1 Component Location Index

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
1282 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the wheel tighten the wheel nut
sequentially with the specified torque.
• Remove the respective front wheel.
• Carry-out brake bleeding.

Removal Steps:
1. Remove the flexible hose banjo bolt.
2. Remove the outer washer
3. Disconnect the flexible hose.
4. Remove the inner washer
5. Remove the caliper assembly mounting bolts.
6. Remove the caliper assembly.
Tools Required

Size Type Quantity

21 mm Deep socket spanner 1

14, 19 mm Socket spanner 1

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 1283
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.1.3 Removal

1. Using 21 mm wheel spanner, remove the 4. Disconnect the caliper hose connection
rear wheel. from the caliper.

2. Using a 14 mm socket spanner remove 5. Remove the caliper hose banjo inner
the caliper hose mounted banjo bolt. washer.

3. Remove the caliper hose banjo outer 6. Using 19 mm socket spanner remove the
washer. caliper assembly mounting bolt.

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
1284 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.1.4 Inspection
1. Check for the external damage & the caliper piston condition, if found replace.

17.8.1.5 Installation

1. Refit the caliper assembly mounting bolt, 3. Refit the front wheel, torque tighten the
torque tighten the bolts to specified value. mounting wheel nuts to specified value.

2. Refit the fluid flexible hose, torque 4. Carry-out brake bleeding procedure. For
tighten the mounting banjo bolt to specified additional information refer to Brake bleeding
value. procedure.

Always replace the washers with new

ones while installation, else brake fluid
leakage may happen.

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 1285
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2 Brake Disc (2WD) R&R

17.8.2.1 Component Location Index

17.8.2.2 Removal and Installation Summary

Pre Removal Post Installation –

• Place the vehicle on a 2/ 4 post lift. • Install the wheel tighten the wheel nut
sequentially with the specified torque.
• Remove the respective side front wheel.

Tools Required

Size Type Quantity

21 mm Wheel Spanner 1

12 mm / 17 mm / 19 mm Socket spanner 1

- Mallet / Screw Driver Each 1

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
1286 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2.3 Removal

1. Using 21 mm wheel spanner remove 4. Remove front caliper lower mounting bolt
mounting nuts and remove the front wheel. using 12 mm socket spanner.

2. By using screw driver remove the hub 5. Lift the caliper upwards as shown in
cover. illustration.

3. Using suitable spanner remove the hub

locking nut.

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 1287
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Remove the brake pads and anti-rattle 8. Remove the wheel hub assembly along
clips. with brake disc unit from the knuckle.

9. Using 17 mm socket spanner, remove

the brake disc mounting bolts and detach it
from the wheel hub assembly.

7. Using 19 mm socket spanner remove the

caliper assembly mounting bolts, remove the
caliper and hank on the coil spring without
remove the brake hose.

17.8.2.4 Inspection
1. Check the brake disc thickness, if required replace.

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
1288 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2.5 Installation

1. Refit the wheel hub with brake disc 4. Fix both the anti-rattle clips back in its
assembly, torque tighten the mounting bolts position and refit the brake pads.
to specified value.

2. Gently slide in the wheel hub with the

brake disc unit on knuckle assembly.

3. Refit the caliper assembly mounting bolt,

torque tighten the bolts to specified value.

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 1289
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Move the caliper downwards and bring 7. Refit the locking nut on the knuckle,
back to its original position. torque tighten the nut to specified value.

• 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.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

8. Refit the hub cover.

6. Refit the caliper bottom mounting bolt

and torque tighten the bolt to specified torque
value.
9. Refit the front wheel, torque tighten the
mounting wheel nuts to specified value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

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
1290 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2.1 Brake Disc (4WD) R&R

17.8.2.1.2 Component Location Index

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 1291
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2.1.3 Removal and Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Install the wheel and tighten the wheel nut
sequentially with the specified torque.
• Remove the respective front wheel.

Tools Required

Size Type Quantity

6 mm Allen key 1

21 mm Wheel Spanner 1

12 mm / 17 mm / 19 mm Socket Spanner 1

MST 571 Special Socket for hub nut 1

— Circlip plier 1

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
1292 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2.1.4 Removal

1. Using 21 mm wheel spanner remove 4. Lift the caliper upwards as shown in

mounting nuts and remove the front wheel. illustration.

2. Using a 6 mm allen key, loosen the allen 5. Remove the brake pads and anti-rattle
bolts and remove the auto lock assembly. clips.

3. Remove front caliper lower mounting bolt

using 12 mm socket spanner.

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 1293
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Using 19 mm socket spanner remove the 9. Using a MST 571(Special Socket for hub
caliper assembly mounting bolts, remove the nut), remove the half shaft secondary lock
caliper and hank on the coil spring without nut.
remove the brake hose.

10. Using a blunt prick punch, remove the

7. Using a circlip plier, remove the circlip lock washer from the half shaft.
from the half shaft.

11. Using a MST 571 (Special Socket for

8. Remove the spacer from the half shaft. hub nut), remove the half shaft primary lock
nut.

Never remove the lock nut without using

a special tool. Lock nut edges are prone
to damage when general tools are used.

Slippage/dropping of heavy/large objects

will cause personal injury.

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
1294 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Remove the wheel hub assembly along

with brake disc unit from the knuckle.

13. Using 17 mm socket spanner, remove

the brake disc mounting bolts and detach it
from the wheel hub assembly.

17.8.2.1.5 Inspection
1. Check the brake disc thickness, if required replace.

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 1295
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.2.1.6 Installation

1. Refit the wheel hub with brake disc 4. Fix both the anti-rattle clips back in its
assembly, torque tighten the mounting bolts position and refit the brake pads.
to specified value.

2. Gently slide in the wheel hub with the

brake disc unit on knuckle assembly.

3. Refit the caliper assembly mounting bolt,

torque tighten the bolts to specified value.

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
1296 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Move the caliper downwards and bring 7. Refit the primary lock nut on the half
back to its original position. shaft, torque tighten the nut to specified
value.

• 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.
• If the pads are changed with a new
one, push both the pistons inside
before moving the caliper downwards.

8. Refit the intermediate lock nut on half

shaft, torque tighten the nut to specified
value.

6. Refit the caliper bottom mounting bolt

and torque tighten the bolt to specified torque
value.

9. Refit the secondary lock nut on the half

shaft, torque tighten the nut to specified
value.

Ensure the sliding pins are greased well,

whenever removed or replaced.

10. Refit the spacer on the half shaft.

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 1297
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Refit the circlip on the half shaft.

12. Refit the auto lock assembly, torque

tighten the mounting bolts to specified value.

13. Refit the front wheel, torque tighten the

mounting wheel nuts to specified value.

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
1298 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.3 Tandem Master Cylinder (TMC) and Reservoir R&R

17.8.3.1 Component Location Index

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 1299
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Fill brake fluid and carry-out bleeding.

Removal Steps:
1. Remove the primary and secondary bundy tubes.
2. Remove the TMC and reservoir mounting nuts.
3. Remove the TMC and reservoir assembly.
Tools Required

Size Type Quantity

13 mm Open end spanner 1

12 mm Socket spanner 1

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
1300 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.3.3 Removal

1. Drain the brake fluid. For additional 4. Using a 12 mm socket spanner remove
information refer to Brake fluid draining the master cylinder mounting nuts.
procedure.

2. Press and disconnect the brake level

sensor connector.

5. Remove the master cylinder assembly.

3. Using a 13 mm open end spanner loosen

the mounting nut and detach master cylinder
Primary & Secondary outlet tubes.

17.8.3.4 Inspection
1. Check for oil leakage or external damage, if found replace.

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 1301
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.3.5 Installation

1. Position and refit the TMC and reservoir 4. Refill the brake fluid and Carry-out brake
assembly, torque tighten the mounting nuts bleeding procedure. For additional
to specified value. information refer to Brake bleeding
procedure.

2. Refit the brake primary & secondary

tubes, torque tighten the nuts to specified
value.

3. Connect the brake level sensor

connector.

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
1302 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.4 Brake Booster R&R

17.8.4.1 Component Location Index

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 1303
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Do the brake bleeding.

• Drain the brake fluid.

Removal Steps:
1. Remove the TMC primary & secondary tubes.
2. Disconnect brake booster vacuum hose.
3. Remove the brake pedal clevis pin by removing cotter pin.
4. Remove the brake booster and pedal mounting nuts.
5. Remove the brake booster assembly.

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
1304 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

- Cutting plier 1

7,10, 12, 13 mm Socket spanner 1

13 mm Open end spanner 1

10 inches Extension rod 1

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 1305
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.4.3 Removal

1. Drain the brake fluid. For additional 5. Using a plier remove the pin & remove
information refer to Brake fluid draining the carter pin.
procedure.

2. Using 13 mm open end spanner remove

the primary and secondary tubes from TMC.

6. Using a 12 mm socket spanner remove

the booster and brake pedal mounting nuts.

3. Disconnect the reservoir electrical

connector.

7. Using 12 mm socket spanner remove

fuel filter assembly mounting bolts and then
partially remove the fuel filter assembly.

4. Disconnect the vacuum hose from brake

booster assembly.

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
1306 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Using a 12 mm socket spanner remove

the master cylinder mounting nuts.

9. Remove the brake booster assembly.

17.8.4.4 Inspection
1. Check for oil seepage in the booster diaphragm if found check & replace the assembly or
the TMC.

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 1307
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.4.5 Installation

1. Position and refit the TMC and reservoir 4. Connect the vacuum hose with the brake
assembly on booster, torque tighten the booster assembly.
mounting nuts to specified value.

5. Refit the primary and secondary tubes on

2. Position and refit the booster assembly TMC, torque tighten the mounting nuts to
mounting nuts, torque tighten the mounting specified value.
nuts to specified value.

6. Connect the reservoir electrical

3. Refit the carter & the pin. connectors.

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
1308 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit the fuel filter assembly, torque

tighten the mounting bolts to specified value.

8. Refill the brake fluid and carry-out brake

bleeding procedure. For additional
information refer to Brake bleeding section.

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 1309
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.5 Brake Pedal R&R

17.8.5.1 Component Location Index

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
1310 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Adjust the brake switch if required.

Removal Steps:
1. Remove the brake pedal clevis pin by removing cotter pin.
2. Disconnect the brake switch electrical connector.
3. Remove the brake pedal mounting nuts & bolt.
4. Remove the brake pedal assembly.
Tools Required

Size Type Quantity

- Cutting plier 1

12 mm Socket spanner 1

13 mm Socket spanner 1

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 1311
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.5.3 Removal

1. Using a plier remove the cotter & the 4. Using 10 mm socket spanner loosen and
clevis pin. remove the MBFM bracket mounting bolts.

2. Using a 13 mm socket spanner remove 5. Using 12 mm socket spanner remove the

the brake pedal top mounting bolt. brake pedal mounting bolt.

3. Disconnect the brake switch electrical

coupler.

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
1312 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.5.4 Inspection
1. Inspect the brake pedal for any physical damage. Replace if found any.
2. Inspect the brake switch for any damage. Replace if found damaged.

17.8.5.5 Installation

1. Position and refit the brake pedal, torque 3. Refit the brake pedal top mounting bolt,
tighten the mounting nuts to specified value. torque tighten the bolt to specified value.

2. Connect the brake pedal using stud and 4. Connect the brake switch electrical
then refit the cotter pin. connector.

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 1313
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Align and refit the MBFM bracket

mounting bolts.

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
1314 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.6 EHCU Unit R&R

17.8.6.1 Component Location Index

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 1315
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.6.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Connect battery negative terminal.

• Disconnect the battery negative terminal. • Do brake bleeding.
• Check and ensure proper functioning of
ABS system.

Removal Steps:
1. Disconnect the EHCU electrical connector.
2. Disconnect EHCU inlet primary and secondary tubes.
3. Disconnect EHCU outlet tubes.
4. Remove the EHCU mounting bolts.
5. Remove the EHCU unit.

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
1316 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

11 mm / 13 mm Open spanner 1

13 mm Socket spanner 1

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 1317
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.6.3 Removal

1. Drain the brake fluid. For additional 4. Using 11 mm and 13 mm open end
information refer to Brake fluid draining spanner remove the brake bundy tubes from
procedure. EHCU to wheels.

2. Open the lock and then gently pull-out

and disconnect the EHCU electrical
connector.

5. Using 13 mm socket spanner remove the

EHCU bracket mounting bolts and then
gently pull-out and remove the EHCU unit.

3. Using 13 mm open end spanner remove

the primary & secondary tube from EHCU
unit.

17.8.6.4 Inspection
1. Check for any oil leakage or external damage, if found replace.

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
1318 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.6.5 Installation

1. Position and refit the EHCU unit, torque 3. Connect EHCU inlet bundy tubes, torque
tighten the mounting bolts to specified value. tighten the mounting nuts to specified values.

2. Connect EHCU outlet bundy tubes to 4. Connect EHCU electrical connector and
wheels, torque tighten the mounting nuts to engage the lock.
specified values.

Take sufficient care while installation and

ensure correct bundy is connected to the
specified outlet port. Use color code for
identification.

5. Fill the brake fluid and carry-out brake

bleeding. For additional information refer to
Brake bleeding procedure.

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 1319
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.7 Vacuum Reservoir and Hoses R&R

17.8.7.1 Component Location Index

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
1320 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.7.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Ensure the proper functioning of brake
pedal.

Removal Steps:
1. Disconnect the vacuum reservoir inlet and outlet hose.
2. Remove the vacuum reservoir mounting nuts
3. Remove the vacuum reservoir assembly.
Tools Required

Size Type Quantity

10 mm Socket spanner 1

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 1321
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.7.3 Removal

1. Disconnect the inlet & outlet vacuum

hose from reservoir by using Clip Plier.

2. Using a 10 mm socket spanner remove

the reservoir mounting nuts.

17.8.7.4 Inspection
1. Check for any external damage, if found please replace.

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
1322 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.7.5 Installation

1. Refit the vacuum reservoir assembly,

torque tighten the mounting nuts to specified
value.

2. Connect the vacuum reservoir inlet and

outlet hose.

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 1323
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.8 Rear Brake Drum R&R

17.8.8.1 Component Location Index

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
1324 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.8.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 / 4 post lift. • Tighten the wheel mounting bolts
sequentially with the specified torque.
• Remove the rear wheel.

Removal Steps:
1. Remove the wheel mounting nuts.
2. Remove the wheel assembly.
3. Remove the brake drum mounting screw.
4. Remove the brake drum assembly.
Tools Required

Size Type Quantity

- Star screw driver 1

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 1325
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.8.3 Removal

1. Remove the wheel assembly. For

additional information refer to Wheel R&R
section.

2. Using a star screw driver loosen and

remove the brake drum mounting screw.

3. Remove the brake drum assembly.

17.8.8.4 Inspection
1. Check for the run out, if deviated please replace.
2. Check the drum thickness, replace if required.

17.8.8.5 Installation

1. Refit the brake drum mounting screw.

2. Refit the wheel assembly. For additional

information refer to Wheel R&R section.

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
1326 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.9 Wheel Cylinder R&R

17.8.9.1 Component Location Index

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 1327
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.9.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do brake bleeding.

Removal Steps:
1. Remove the wheel nuts.
2. Remove the wheel & tyre assembly.
3. Remove the brake drum mounting screw.
4. Remove the brake drum.
5. Remove the wheel cylinder mounting bolts and disconnect the inlet bundy tube.
6. Remove the wheel cylinder assembly.

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
1328 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

10 mm Socket spanner 1

— Flat end screw driver 1

11 mm Open end spanner 1

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 1329
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.9.3 Removal

1. Remove the brake drum assembly. For 4. Using a flat end screw driver, detach the
additional information refer to rear Brake top shoe return spring and expand the liners
drum R&R section. and remove the wheel cylinder assembly.

2. Using 11 mm open end spanner remove

the brake fluid line from the wheel cylinder.

3. Using 10 mm socket spanner remove the

wheel cylinder mounting bolts.

17.8.9.4 Inspection
1. Check for the oil leakage in the boot, if found replace.

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
1330 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.9.5 Installation

1. Position and refit the wheel cylinder 4. Refit the brake drum. For additional
between the liners and refit the top shoe information refer to rear Brake drum R&R
return spring. section.

5. Do brake bleeding. For additional

information refer to Brake bleeding section.

2. Refit the wheel cylinder mounting bolts,

torque tighten the bolts to specified value.

3. Refit the wheel cylinder inlet bundy tube,

torque tighten the mounting nut to specified
value.

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 1331
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.10 Front Brake Flexible Hose R&R

17.8.10.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Do brake bleeding.

Tools Required

Size Type Quantity

11 mm Open end spanner 01

Flat end screw driver or

— 01
Cutting plier

14 mm Socket spanner 01

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
1332 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.10.2 Removal

Be careful not to twist flexible hose while loosening & tightening the bolt.

1. Using a 11 mm open end spanner loosen

the mounting nut and detach the bundy tube.

2. Using a 14 mm socket spanner remove

the banjo bolt and washer.

3. Remove the front brake flexible hose.

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 1333
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.10.3 Inspection
1. Inspect the flexible hose for any damage, crack or material deterioration. Replace if
found any.

17.8.10.4 Installation

1. Connect the flexible hose on caliper

using banjo bolt. Torque tighten the banjo
bolt to specified value.

Replace the banjo bolt washers with new

ones always while installation, else brake
fluid leakage may happen.

2. Connect the flexible hose to bundy tube,

torque tighten the bundy tube mounting nut
to recommended value.

3. Carry-out brake bleeding. For additional

information refer to Brake bleeding section.

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
1334 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.11 Rear Brake Flexible Hose (ABS) R&R

17.8.11.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2/4 post lift. • Do brake bleeding.

Tools Required

Size Type Quantity

11 mm Open end spanner 01

Flat end screw driver or

— 01
Cutting plier

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 1335
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.11.2 Removal

Be careful not to twist flexible hose while loosening & tightening the bolt.

1. Using a 11 mm open end spanner loosen

the nut and detach the bundy tubes from
flexible hose.

2. Using a flat end screw driver or plier

remove the locking clips and then detach and
remove the rear flexible hose.

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
1336 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.11.3 Inspection
1. Inspect the flexible hose for any damage, crack or material deterioration. Replace if
found any.

17.8.11.4 Installation

1. Position the flexible hose and insert the

locking clips.

2. Connect the flexible hose with the bundy

tubes.

3. Carry-out brake bleeding. For additional

information refer to Brake bleeding section.

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 1337
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.12 Front Brake Caliper Stem R&R

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do brake bleeding if required.
• Check and ensure proper functioning of
brake system.

Tools Required

Size Type Quantity

21 mm Deep socket spanner 1

12 mm Socket spanner 01

17.8.12.1 Removal

1. Using a wheel spanner or a 21 mm deep 2. Using a 12 mm socket spanner remove

socket spanner remove wheel mounting bolt the caliper mounting bolts, detach the caliper
& then the front wheel assembly. and position on lower control arm.

Fasten the caliper using a plastic tag

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
1338 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Pull-out and remove the stems along

with rubber boot.

Ensure the sliding pins are greased well,

whenever removed or replaced.
While fitting the guide pin ensure that the
straight portion of the pin matches with
the ear of the calliper body.
Stems are not interchangeable.

4. Remove the rubber boot.

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 1339
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.12.2 Installation

1. Insert the new rubber boot onto the 4. Refit the front wheel with the help of
stems. wheel nuts. Torque tighten the nuts to
specified value in recommended sequence.

2. Insert the stem into carrier assembly.

Stems are not interchangeable.

3. Refit the caliper assembly using

mounting bolts. Torque tighten the bolts to
specified value.

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
1340 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.13 Bundy Tube TMC to EHCU R&R

17.8.13.1 Component Location Index

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 1341
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.13.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on flat surface. • Do the brake bleeding.

Removal Steps:
1. Remove the primary & secondary bundy tubes from the TMC.
2. Remove the primary & secondary inlet bundy tube from EHCU unit.
3. Remove the primary & secondary bundy tubes form holding clamps and remove.
Tools Required

Size Type Quantity

13 mm Open end spanner 1

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
1342 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.13.3 Removal

1. Using 13 mm open end spanner remove

the primary & secondary brake bundy tube
from the TMC.

2. Using 13 mm open end spanner remove

the primary & secondary brake bundy tubes
from the EHCU unit.

3. Remove the brake bundy tubes from the

routings clamp.

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 1343
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.13.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

17.8.13.5 Installation

1. Refit the primary and secondary bundy 3. Refit the primary & secondary brake
tubes in the routing clamps. bundy tubes on TMC, torque tighten the
mounting nuts to specified value.

2. Refit the bundy tubes on EHCU unit,

torque tighten the mounting nuts to specified 4. Fill fresh brake fluid and carry-out
value. bleeding procedure. For additional
information refer to Brake bleeding section.

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
1344 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.14 Bundy Tube EHCU to Front LH Caliper R&R

17.8.14.1 Component Location Index

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 1345
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.14.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Disconnect the bundy tube from EHCU.
2. Disconnect the bundy tube part 1 & part 2.
3. Remove part 1 bundy tube from the holding clamps and remove.
4. Disconnect the part 2 bundy tube from the flexible hose.
5. Remove the part 2 bundy tube.

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
1346 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

11 mm Open end spanner 1

14 mm Combination spanner 1

- Flat screw driver 1

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 1347
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.14.3 Removal

1. Using 11 mm open end spanner remove 4. Remove the brake bundy tubes from the
the brake bundy tube on EHCU unit. routing & remove the assembly.

While removing the brake bundy tube the

tube should not be bent or twisted for
any reason, failure to comply would
result in brake tube damage.

2. Using 14 mm open end spanner hold the

part 1 & using 11 mm open end spanner
remove the part 2 brake bundy tube.

3. Using 11 mm open end spanner remove

the part 2 brake bundy tube from flexible
hose.

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
1348 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.14.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

17.8.14.5 Installation

1. Route the bundy tubes and refit the tube 4. Refit the brake bundy tube on EHCU
on holding clamps. unit, torque tighten the mounting nut to
specified value.
2. Refit the brake bundy tube part 2 on
brake flexible hose, torque tighten the
junction nut to specified value.

5. Do brake bleeding. For additional

information refer to Brake bleeding section.

3. Refit the brake bundy tube part 1 & 2,

torque tighten the junction nut to specified
value.

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 1349
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.15 Bundy Tube EHCU to Front RH Caliper R&R

17.8.15.1 Component Location Index

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
1350 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.15.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the bundy tube from EHCU unit.
2. Disconnect the brake bundy tube part 1 & part 2.
3. Remove the brake bundy tube part 1.
4. Disconnect the brake bundy tube from the flexible hose clip and remove it from the
routing clamps.
5. Remove the brake bundy tube part 2.

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 1351
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

11 mm Open end spanner 1

13 mm Open end spanner 1

14 mm Combination spanner 1

- Flat screw driver 1

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
1352 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.15.3 Removal

1. Using 13 mm open end spanner remove 4. Remove the brake bundy tubes from the
the brake bundy tube from the EHCU unit. routing & remove the assembly.

While removing the brake bundy tube the

tube should not be bent or twisted for
any reason, failure to comply would
result in brake tube damage.

2. Using 14 mm open end spanner hold the

brake bundy tube part 1 & using 11 mm open
end spanner remove the part 2 bundy tube.

3. Using 11 mm open end spanner remove

the brake bundy tube from the flexible hose.

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 1353
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.15.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

17.8.15.5 Installation

1. Route the bundy tubes and refit the tube 4. Refit the brake bundy tube connection on
on holding clamps. EHCU unit, torque tighten the mounting nut
to specified value.
2. Refit the brake bundy tube part 2 on
brake flexible hose, torque tighten the
mounting to specified value.

5. Do the brake bleeding. For additional

information refer to Brake bleeding section.

3. Refit the brake bundy tube part 1 & part

2, torque tighten the mounting to specified
value.

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
1354 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.16 Bundy Tube EHCU to Rear RH Wheel Cylinder R&R

17.8.16.1 Component Location Index

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 1355
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.16.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy tube from EHCU unit.
2. Disconnect the brake bundy tube part 1 & part 2.
3. Remove the brake bundy tube part 1.
4. Disconnect the brake bundy tube part 2 & part 3.
5. Disconnect from the routing clamps and remove the brake bundy part 2.
6. Disconnect the brake bundy tube from the rear flexible hose.
7. Disconnect from the routing clamps and remove the brake bundy tube part 3.
Tools Required

Size Type Quantity

11, 13, 14 mm Open end spanner 1

- Flat screw driver 1

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
1356 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.16.3 Removal

1. Using a 13 mm open end spanner 4. Remove the brake bundy tube part 3
remove the brake bundy tube from EHCU from the routing clamps
unit.

5. Using 11 mm open end spanner remove

2. Using 14 mm open end spanner hold the the brake bundy tube from the flexible hose.
brake bundy tube part 1 & using 11 mm open
end spanner remove the part 2 bundy tube.

3. Using a 14 mm open end spanner hold

the brake bundy tube part 2 & using 11 mm
open end spanner remove the part 3 bundy
tube.

17.8.16.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1357
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.16.5 Installation

1. Refit the part 3 brake bundy tube on the 4. Refit the brake bundy tube on EHCU
routing clamps. unit, torque tighten the mounting nut to
specified value.

2. Refit brake bundy tube part 3 on the

flexible hose, torque tighten the mounting nut 5. Do the brake bleeding. For additional
to specified value. information refer to Brake bleeding section.

3. Refit the brake bundy tube part 2 on the

routings, connect the part 3, part 2, part 1
bundy tubes, torque tighten the mounting
nuts to specified value.

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
1358 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.17 Bundy Tube EHCU to Rear LH Flexible hose R&R

17.8.17.1 Component Location Index

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 1359
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.17.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy tube from EHCU unit.
2. Disconnect the brake bundy tube part 1 & part 2.
3. Remove the brake bundy tube part 1.
4. Disconnect the brake bundy tube part 2 & part 3.
5. Disconnect the brake bundy tube from the routing clamps and remove the part 2 bundy
tube.
6. Disconnect the brake bundy tube part 3 & flexible hose junction.
7. Disconnect the bundy tubes from the routing clamps and remove the part 3 brake bundy
tube.

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
1360 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

11, 14 mm Open end spanner 1

- Flat screw driver 1

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 1361
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.17.3 Removal

1. Using 11 mm open end spanner remove 4. Remove the brake bundy tube part 3
the brake bundy tube from the EHCU unit. from the routing clamps.

2. Using 14 mm open end spanner hold the 5. Using 11 mm open end spanner remove
brake bundy tube part 1 & using 11 mm open the brake bundy tube from the flexible hose.
end spanner remove the part 2 bundy tube.

3. Using 14 mm open end spanner hold the

brake bundy tube part 2 & using 11 mm open
end spanner remove the part 3 bundy tube.

17.8.17.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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
1362 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.17.5 Installation

1. Refit the brake bundy tube on the routing 4. Refit the brake bundy tube on EHCU
clamps. unit, torque tighten the mounting nut to
specified value.

2. Refit the brake bundy tube part 3 on

flexible hose, torque tighten the mounting nut 5. Do the brake bleeding. For additional
to specified value. information refer to Brake bleeding section.

3. Refit the brake bundy tube on the routing

& connect the part3, part 2 & part 1 tubes,
torque tighten the mounting nuts to specified
value.

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 1363
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.18 Bundy Tube Rear Flexible Hose to Wheel Cylinder R&R

17.8.18.1 Component Location Index

17.8.18.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1364 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.18.3 Removal

1. Using 11 mm open end spanner remove

the brake bundy tube from the flexible hose.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from rear
RH wheel cylinder.

17.8.18.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1365
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.18.5 Installation

1. Refit the brake bundy tube on rear RH

wheel cylinder, torque tighten the tube to
specified value.

2. Refit the flexible hose clip & hose on the

chassis, torque tighten the mounting nut to
specified value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1366 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.19 Bundy Tube Primary TMC to Four Way Tee Part 1 (Non ABS) R&R

17.8.19.1 Component Location Index

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 1367
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.19.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy tube from TMC unit.
2. Disconnect the brake bundy tube from four way tee.
3. Remove the bundy tube primary TMC to four way tee.
Tools Required

Size Type Quantity

13 mm / 11 mm Open end spanner 1

- Flat screw driver 1

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
1368 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.19.3 Removal

1. Using 13 mm open end spanner remove

the brake bundy tube from TMC unit.

2. Using 11 mm open end spanner hold the

primary brake bundy tube part 2 (Four way
tee side) & using 14 mm open end spanner
remove the part 1 bundy tube (TMC side).

17.8.19.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1369
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.19.5 Installation

1. Refit the primary brake bundy tube part 1

and part 2. Torque tighten the tube to
specified value.

2. Refit the brake bundy tube TMC unit,

torque tighten the tube to specified value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1370 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.20 Bundy Tube Primary TMC to Four Way Tee Part 2 (Non ABS) R&R

17.8.20.1 Component Location Index

17.8.20.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on 2 post lift. • Do the brake bleeding.

Tools Required

Size Type Quantity

13 mm / 11 mm Open end spanner 1

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 1371
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.20.3 Removal

1. Using 14 mm open end spanner hold the

primary brake bundy tube part 1 (TMC side)
& using 11 mm open end spanner remove
the part 2 bundy tube (Four way tee side).

2. Using 11 mm open end spanner loosen

and remove the brake bundy tube from four
way tee.

17.8.20.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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
1372 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.20.5 Installation

1. Refit the bundy tube on four way tee,

torque tighten the tube to specified value.

2. Refit the primary brake bundy tube part

2. Torque tighten the tube to specified value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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 1373
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.21 Bundy Tube Secondary TMC to LSPV Part 1 (Non ABS) R&R

17.8.21.1 Component Location Index

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
1374 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.21.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy secondary TMC part 1 from TMC.
2. Disconnect the brake bundy secondary tube part 1 and part 2.
3. Remove the bundy tube secondary TMC to LSPV.
Tools Required

Size Type Quantity

13 mm / 14 mm / 11 mm Open end spanner 1

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 1375
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.21.3 Removal

1. Using 13 mm open end spanner remove

the secondary brake bundy tube from TMC
unit.

2. Using 14 mm open end spanner hold the

secondary brake bundy tube part 2 (Frame
side) & using 11 mm open end spanner
remove the part 1 bundy tube (TMC side).

17.8.21.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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
1376 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.21.5 Installation

1. Refit the brake bundy secondary tube

om TMC unit, torque tighten the tube to
specified value.

2. Refit the secondary brake bundy tube

part 1, torque tighten the tube to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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 1377
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.22 Bundy Tube Secondary TMC to LSPV Part 2 (Non ABS) R&R

17.8.22.1 Component Location Index

17.8.22.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Tools Required

Size Type Quantity

13 mm / 14 mm / 11 mm Open end spanner 1

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
1378 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.22.3 Removal

1. Using 11 mm open end spanner hold the

secondary brake bundy tube part 1 (TMC
side) & using 14 mm open end spanner
remove the part 2 bundy tube (Frame side).

2. Using 11 mm open end spanner hold the

secondary brake bundy tube part 3 (LSPV
side) & using 14 mm open end spanner
remove the part 2 bundy tube (Frame side).

17.8.22.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1379
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.22.5 Installation

1. Refit the secondary brake bundy tube

part 2. Torque tighten the tube to specified
value.

2. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1380 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.23 Bundy Tube Secondary TMC to LSPV Part 3 (Non ABS) R&R

17.8.23.1 Component Location Index

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 1381
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.23.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Tools Required

Size Type Quantity

11 mm, 14 mm Open end spanner 1

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
1382 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.23.3 Removal

1. Using 14 mm open end spanner hold the

brake bundy tube part 2 (Frame side) & using
11 mm open end spanner remove the part 3
bundy tube (LSPV side).

2. Using 11 mm open end spanner

disconnect the brake bundy tube from LSPV
unit.

17.8.23.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1383
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.23.5 Installation

1. Refit the secondary brake bundy tube

part 3. Torque tighten the tube to specified
value.

2. Refit the brake bundy tube with LSPV

unit, torque tighten the tube to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1384 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.24 Bundy Tube Four Way Tee to LH Flexible Hose 2WD (Non ABS)
R&R

17.8.24.1 Component Location Index

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 1385
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.24.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy tube from four way tee.
2. Disconnect the brake bundy tube from LH flexible hose.
3. Remove the bundy tube four way tee to LH flexible hose.
Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1386 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.24.3 Removal

1. Using 11 mm open end spanner remove

the brake bundy tube from four way tee.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from
flexible hose.

17.8.24.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1387
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.24.5 Installation

1. Refit the brake bundy tube on four way

tee, torque tighten the tube to specified
value.

2. Refit the brake bundy tube on flexible

hose, torque tighten the tube to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1388 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.25 Bundy Tube Four Way Tee to LH Flexible Hose 4WD (Non ABS)
R&R

17.8.25.1 Component Location Index

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 1389
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.25.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy tube from four way tee.
2. Disconnect the brake bundy tube from LH flexible hose.
3. Remove the bundy tube four way tee to LH flexible hose.
Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1390 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.25.3 Removal

1. Using 11 mm open end spanner remove

the brake bundy tube from four way tee.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from
flexible hose.

17.8.25.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1391
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.25.5 Installation

1. Refit the brake bundy tube on four way

tee, torque tighten the tube to specified
value.

2. Refit the brake bundy tube on flexible

hose, torque tighten the tube to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1392 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.26 Bundy Tube Four Way Tee to RH Flexible Hose (Non ABS) R&R

17.8.26.1 Component Location Index

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 1393
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.26.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Disconnect the brake bundy tube from the RH flexible hose.
2. Disconnect the brake bundy tube from four way tee.
3. Remove the bundy tube four way tee to RH flexible hose.
Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1394 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.26.3 Removal

1. Using 11 mm open end spanner

disconnect the brake bundy tube from four
way tee.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from RH
flexible hose.

17.8.26.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1395
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.26.5 Installation

1. Refit the brake bundy tube on four way

tee, torque tighten the tube to specified
value.

2. Refit the brake bundy tube with flexible

hose, torque tighten the tube to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1396 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.27 Bundy Tube LSPV to Four Way Tee (Non ABS) R&R

17.8.27.1 Component Location Index

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 1397
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.27.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Disconnect the brake bundy tube from the four way tee.
2. Disconnect the brake bundy tube from LSPV.
3. Remove the bundy tube LSPV to four way tee.
Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1398 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.27.3 Removal

1. Using 11 mm open end spanner

disconnect the brake bundy tube from four
way tee.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from LSPV.

17.8.27.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1399
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.27.5 Installation

1. Refit the brake bundy tube on four way

tee, torque tighten the tube to specified
value.

2. Refit the brake bundy tube with LSPV

unit, torque tighten the tube to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section..

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
1400 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.28 Rear Flexible Hose (Non ABS) R&R

17.8.28.1 Component Location Index

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 1401
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.28.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the banjo bolt from LSPV end.
2. Remove the banjo bolt from three way connector.
3. Remove the rear flexible hose.
Tools Required

Size Type Quantity

14 mm Socket spanner 1

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
1402 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.28.3 Removal

1. Using 14 mm socket spanner loosen and

remove the rear flexible hose mounting banjo
bolt from LSPV end.

2. Using 14 mm socket spanner loosen and

remove the rear flexible hose from three way
connector end.

3. Remove the rear flexible hose.

17.8.28.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1403
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.28.5 Installation

1. Refit the rear flexible hose on three way

connector, torque tighten the banjo bolt to
specified value.

2. Refit the rear flexible hose on LSPV,

torque tighten the banjo bolt to specified
value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1404 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.29 Bundy Tube 3 way Tee to Rear RH Wheel Cylinder (Non ABS) R&R

17.8.29.1 Component Location Index

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 1405
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.29.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Disconnect the brake bundy tube from TEE connector.
2. Disconnect the brake bundy tube from wheel cylinder.
3. Remove the bundy tube TEE connector to rear RH wheel cylinder.
Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1406 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.29.3 Removal

1. Using 11 mm open end spanner

disconnect the brake bundy tube from TEE
connector.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from rear
RH wheel cylinder.

17.8.29.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1407
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.29.5 Installation

1. Refit the brake bundy tube on rear RH

wheel cylinder, torque tighten the tube to
specified value.

2. Refit the brake bundy tube with TEE

connector, torque tighten the tube to
specified value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1408 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.30 Bundy Tube 3 Way Tee to Rear LH Wheel Cylinder (Non ABS) R&R

17.8.30.1 Component Location Index

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 1409
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.30.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Remove the brake bundy tube from wheel cylinder.
2. Remove the brake bundy tube from TEE connector.
3. Remove the bundy tube TEE connector to rear LH wheel cylinder.
Tools Required

Size Type Quantity

11 mm Open end spanner 1

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
1410 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.30.3 Removal

1. Using 11 mm open end spanner

disconnect the brake bundy tube from TEE
connector.

2. Using 11 mm open end spanner

disconnect the brake bundy tube from rear
LH wheel cylinder.

17.8.30.4 Inspection
1. Inspect the bundy tube for any damage, crack. Replace if found any.

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 1411
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.30.5 Installation

1. Refit the brake bundy tube on rear LH

wheel cylinder, torque tighten the tube to
specified value.

2. Refit the brake bundy tube with TEE

connector, torque tighten the tube to
specified value.

3. Do the brake bleeding. For additional

information refer to Brake bleeding section.

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
1412 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.31 LSPV Unit (Non ABS) R&R

17.8.31.1 Component Location Index

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 1413
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.31.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Do the brake bleeding.

Removal Steps:
1. Disconnect the LSPV spring.
2. Remove the TMC secondary to LSPV bundy tube.
3. Remove the four way tee to LSPV bundy tube.
4. Remove the rear flexible hose mounting banjo bolt.
5. Remove the LSPV mounting bolts.
6. Remove the LSPV unit.
Tools Required

Size Type Quantity

11, 13 mm Open end spanner 1

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
1414 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.31.3 Removal

1. Remove the LSPV spring washer and 4. Using 14 mm socket spanner loosen and
disconnect the LSPV spring. remove the rear flexible hose mounted banjo
bolt.

2. Using 11 mm open end spanner

disconnect the TMC secondary to LSPV 5. Using 13 mm socket spanner loosen and
brake bundy tube from LSPV unit. remove the LSPV mounting bolts.

3. Using 11 mm open end spanner

disconnect the four way tee to LSPV brake
bundy tube from LSPV unit.

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 1415
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.31.4 Inspection
1. LSPV child parts are non-serviceable & should be replaced as assembly if any problem
arises.
2. Inspect the LSPV for any damage, replace if found any.

17.8.31.5 Installation

1. Refit the LSPV unit on cross member, 3. Refit the four way square to LSPV brake
torque tighten the mounting bolts to specified bundy tube, torque tighten the same to
value. specified value.

2. Refit the rear flexible hose on LSPV, 4. Refit the TMC secondary to LSPV brake
torque tighten the mounting bolt to specified bundy tube, torque tighten the same to
value. specified value.

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
1416 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Reconnect the LSPV spring.

6. Do the brake bleeding. For additional

information refer to Brake bleeding section.

7. Do LSPV height setting. For additional

information refer to LSPV height setting
section.

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 1417
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.32 Hand Brake lever Assembly R&R

17.8.32.1 Component Location Index

17.8.32.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Adjust the hand brake.

Tools Required

Size Type Quantity

- Cutting plier 1

13 mm Socket spanner 1

10 mm Open end spanner 1

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
1418 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.32.3 Removal

1. Remove the center console unit. For 5. Using 13 mm socket spanner remove the
additional information refer to Center console hand brake lever mounting bolts.
R&R section.

2. Disconnect the hand brake lever switch

connection.

6. Detach the hand brake front cable from

hand brake lever assembly.

7. Pull-out and remove the parking brake

3. Using 10 mm loosen the adjust nut & lever.
disconnect from the hand brake cable from
the lever assembly.

4. Detach the hand brake front cable from

hand brake lever assembly.

17.8.32.4 Inspection
1. Check for the brake lever operation, lubricate or replace if required.

17.8.32.5 Installation

1. Refit the hand brake front cable on hand

brake lever assembly.

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 1419
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2. Refit the hand brake lever, torque tighten

the mounting bolts to specified value.

3. Refit the front cable adjusting nut.

4. Connect the hand brake lever switch

electrical connection.

5. Refit the center console unit. For

additional information refer to Center console
R&R section.

6. Carry-out parking brake adjustment. For

additional information refer to Parking brake
adjustment section.

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
1420 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.33 Hand Brake Front Cable R&R

17.8.33.1 Component Location Index

17.8.33.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Adjust the hand brake.

Tools Required

Size Type Quantity

10 mm Open end spanner 1

17.8.33.3 Removal

1. Remove the Hand Brake lever Assembly.

For additional information refer to Hand
Brake lever Assembly R&R section.

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 1421
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2. Using a 10 mm open end spanner loosen

the hand brake front cable adjusting nut.

3. Pull-out and remove the Hand Brake

Front Cable.

17.8.33.4 Inspection
1. Inspect the hand brake front cable for any damage or corrosion. Replace if found.

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
1422 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.33.5 Installation

1. Refit the hand brake front cable adjusting

nut on equalizer.

2. Refit the Hand Brake lever Assembly.

For additional information refer to Hand
Brake lever Assembly R&R section.

3. Carry-out parking brake adjustment. For

additional information refer to Parking brake
adjustment section.

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 1423
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.34 Hand brake Rear cable Assembly R&R

17.8.34.1 Component Location Index

17.8.34.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Adjust the hand brake.

Tools Required

Size Type Quantity

- Flat screw driver 1

- Nose plier 1

10 mm Open end spanner 1

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
1424 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.34.3 Removal

1. Remove the rear brake drum. For 4. Using a 10 mm open end spanner loosen
additional information refer to rear Brake the hand brake front cable adjusting nut.
drum R&R section.

2. Using a flat screw driver slide the hand

brake lever & using a nose plier disconnect
the hand brake cable on both the side.

5. Remove the hand brake cable from the

routing clamps.

6. Remove the LH & RH rear cable

assembly.
3. Using a nose plier remove the parking
brake cable lock clip on both the side.

17.8.34.4 Inspection
1. Inspect the hand brake front cable for any damage or corrosion. Replace if found.

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 1425
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.34.5 Installation

1. Install the hand brake cable on the 5. Refit the rear brake drum. For additional
routing clamps. information refer to rear Brake drum R&R
section.
2. Using a flat screw driver slide the hand
brake lever & using a nose plier install the 6. Carry-out parking brake adjustment. For
hand brake cable. additional information refer to Parking brake
adjustment section.

3. Install the hand brake cable locking clip.

4. Refit the hand brake front cable adjusting

nut on equalizer.

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
1426 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.35 Front Wheel Speed Sensor R&R

17.8.35.1 Component Location Index

17.8.35.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Check and clear any DTC if registered.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

- Nose clip plier 1

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 1427
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.35.3 Removal

1. Disconnect the wheel speed sensor

electrical connector and Using a nose clip
plier, detach the mounting clips.

2. Using 10 mm socket spanner loosen and

remove the wheel speed sensor mounting
bolt.

3. Gently pull-out and remove the front

wheel speed sensor.

• Do not pull or twist wire harness more

than necessary when installing front
wheel speed sensor.
• Do not cause damage to surface of
front wheel speed sensor and do not
allow dust, etc. to enter its installation
hole.

17.8.35.4 Inspection
1. Inspect the sensor for any physical damage. Replace if found any.

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
1428 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2. Inspect the sensor for foreign particles segregation. Clean if found.

3. Inspect the sensor connector for any damage.

17.8.35.5 Installation

1. Refit the wheel speed sensor, torque

tighten the mounting bolt to specified value.

Take sufficient care not to damage the

sensor.

2. Route the cable using mounting clips

and Connect the wheel speed sensor
electrical connector.

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 1429
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.36 Rear Wheel Speed Sensor R&R

17.8.36.1 Component Location Index

17.8.36.2 Removal & Installation Summary

Pre Removal Post Installation

• Place the vehicle on a 2 post lift. • Check and clear any DTC if registered.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

- Nose clip plier 1

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
1430 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.36.3 Removal

1. Disconnect the rear wheel speed sensor

electrical connector and Using a nose clip
plier detach the mounting clips.

2. Using a 10 mm socket spanner loosen

and remove the wheel speed sensor
mounting bolt.

3. Gently pull-out and remove the front

wheel speed sensor.

• Do not pull or twist wire harness more

than necessary when installing front
wheel speed sensor.
• Do not cause damage to surface of
front wheel speed sensor and do not
allow dust, etc. to enter its installation
hole.

17.8.36.4 Inspection
1. Inspect the sensor for any physical damage. Replace if found any.

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 1431
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

2. Inspect the sensor for foreign particles segregation. Clean if found.

3. Inspect the sensor connector for any damage.

17.8.36.5 Installation

1. Refit the rear wheel speed sensor,

torque tighten the mounting bolt to specified
value.

Take sufficient care not to damage the

sensor.

2. Route the cable using mounting clips

and Connect the wheel speed sensor
electrical connector.

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
1432 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.37 Brake Switch R&R

17.8.37.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Do brake switch setting.

Tools Required

Size Type Quantity

14 mm Open end spanner 01

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 1433
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.37.2 Removal

1. Disconnect the brake switch connector.

2. Using a 14 mm open end spanner loosen

the lock nut first and then loosen and remove
the brake switch.

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
1434 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.8.37.3 Inspection
1. Inspect the brake switch for any damage. Replace if required.
2. Inspect the connector for any damage.
3. Check proper fitment of connector.

17.8.37.4 Installation

1. Insert the brake switch and rotate

clockwise to tighten.

2. Carry-out brake switch adjustment. For

additional information refer to Brake switch
setting section.

3. Tighten the lock nut.

4. Connect the brake switch connector.

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 1435
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.9 Specifications
17.9.1 Technical Specifications

Figure Description Value

Disc pad Usable thickness 10 mm

Replace disc pad when 1 mm

thickness falls below
Usable thickness of

Disc pad Material Sangsin

SB-
K6369A
asbestos
free

Front disc thickness 26 mm

Minimum disc thickness 24 mm

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
1436 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value

Assembly Run out of rotor 0.08 mm

face- permissible Max limit

Disc thickness variation MEAS-

allowed URED
CIR-
CUM-
FEREN-
TIALLY.
0.010
mm max.
MEAS-
URED
RADIAL-
LY. 0.05
mm max

Maximum brake drum 295.2 /

diameter are allowed to be 294.95
measure at 3 locations mm

Maximum taper/ bell 0.08 mm

mouthing of brake drum

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 1437
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value

Rear brake lining Usable 4.4 mm

thickness

Replace when thickness 1.0 mm.

falls Minimum thickness of
lining below usable.

Brake shoe Material Lining RANE

Asbestos
free a)
RD0011-
M2 b)
RD0011-
M2C

LSPV Setting length (By 92.5 mm

setting gauge)

Master cylinder internal Ø 25.4

diameter. mm

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
1438 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value

Wheel Cylinder internal Ø 25.4

diameter ABS mm
Wheel Cylinder internal Ø 25.4
diameter Non ABS mm

Brake disc diameter Ø 302

mm

Rear Drum I. D to be 295.2 /

measure at 3 location 294.95
mm

Boost ratio-tandem booster 9.5

Booster size 8 + 9 inch

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 1439
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Figure Description Value

Clearance Adjustment- Automat-

ic
Front
Automat-
Rear ic

Free Play of the Brake 3 mm

Pedal

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
1440 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

17.9.2 Tightening Specifications

Description Torque Value (Nm)

FRONT BRAKE CALIPER MOUNTING

90
BOLTS

SLIDING PIN BOLTS 22

BANJO BOLT - CALIPER 24 ± 4

ABS - 15± 1
BRAKE PIPE CONNECTORS – MASTER
CYLINDER
ESP - 25± 2

VACUUM BOOSTER – MOUNTING NUTS 25

BRAKE PIPE CONNECTORS – WHEEL

15
CYLINDER

LSPV BANJO BOLT 24 ± 2

LSPV BRAKE PIPE CONNECTORS 16±2

LSPV SETTING 25±5

HAND BRAKE BRACKET LH / RH 10 ± 2

BRACKET BRAKE HOSE 4WD RH MTG. 25 ± 5

PARKING BRAKE CABLE MTG O LOWER

10 ± 2
ARM BRACKET

BRAKE JOINT MALE 16± 2

BRAKE JOINT FEMALE 16± 2

BRAKE REAR FLEXIBLE HOSE TOP END

(THIN NUT) 16± 2

BRAKE REAR FLEXIBLE HOSE BOTTOM

24±4
END ON BANJO

ABS - 15± 1
BRAKE BUNDY TUBE CONNECTION ON
TMC
ESP - 25± 2

BRAKE PEDAL MTG. ON DASH PANEL 16.5±3

PARKING BRAKE MTG ON FLOOR 25±5

EHCU & EHCU MOUNTING BRACKET

(BOSCH GEN 9.1 ABS) 8±2

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 1441
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Description Torque Value (Nm)

BRAKE PEDAL SWITCH FIT 0.5 ± 0.2

4 CHANNEL ABS SENSOR ON AXLE 8±2

ECU – CIM SCREWS 2.8 ± 0.8

ABS - 15± 1
EHCU PORT - BRAKE LINE FITTINGS
ESP - 25± 2

FRONT - WHEEL SPEED SENSORS

8.94± 0.75
MOUNTING BOLT

LSPV MTG. ON CHASSIS 24 ± 4

PARKING BRAKE CABLE MTG. 4.5 ± 0.5

REAR AXLE BREAK T MTG. REGULAR 8±2

CLEVIS LOCK NUT 17 ± 3

REAR DIFFERENTIAL SPEED SENSOR

20 ± 3
MOUNTING BOLT

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
1442 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18 STEERING SYSTEM

18.1 Description and Operation

18.1.1 Steering System
The steering system has three major components:
1. The steering wheel and steering shaft that transmits the driver’s movement to the
steering gear.
2. The steering gear increases the mechanical advantage while changing the rotary motion
of the steering wheel to liner motion.
3. The steering linkage carries the linear motion to the wheels through knuckle.
The vehicle is fitted with hydraulic power steering for reducing steering effort and easy
maneuverability. The system has the below mentioned features:
1. Rack and pinion type steering gear .
2. Steering column (collapsible type) and intermediate shaft
3. Steering column - tilt type (if equipped)
Power assistance is available during normal operating conditions. in case of any failure in
hydraulic system, the steering can still be operated mechanically but with increased steering
effort.
Power steering system consists of a collapsible steering column with intermediate shaft, rack
and pinion steering gear assembly, belt driven hydraulic steering pump and steering fluid
supply and return hoses with reservoir.
The steering column assembly consists of three shafts interconnected via the universal joint.
While one end of the steering column is connected to the steering wheel, the other end is
bolted to the pinion on the rack.
The rotation of the pinion moves the gear rack sideways. This lateral action of the rack pushes
and pulls the tie rods to change the direction of the front wheels. Power assist is provided by
an engine driven hydraulic pump. The pump supplies hydraulic fluid under pressure to the
steering gear through the pressure hoses. As steering wheel is rotated, the steering fluid is
allowed to pass through the steering gear valve depending on the rotational direction of the
steering wheel. The fluid moves the piston, which forms a part of the steering gear, giving
power assistance to rotate the steering wheel.

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 1443
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.1.2 How rack & pinion power steering system work

The engine driven hydraulic pump supplies oil at a pressure to a control valve (Pinion valve
assembly) situated in housing that supports the pinion shaft.
The movement of steering wheel imparts movement to the control valve through the steering
column. The torsion bar moves the control valve, which in turn directs the oil to one side of the
piston inside the steering housing (Cylinder tube), depending on the direction of rotation of
steering wheel.
The control valve is a rotary spool type valve controlled by the torsion bar integrated in the
steering case. The spool valve is a shaft with flutes and a sleeve, which has internal axial
grooves. Radial ports in the sleeve and shaft pass the oil from the supply to the lines
connected to the piston chamber/rack housing.
The amount of twist of the torsion bar on the movement of the spool valve is proportional to the
effort applied by the driver on steering wheel in any direction.

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
1444 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.1.3 Steering Wheel

The steering wheel is the part of the steering

system that is rotated by the driver; the rest
of the steering system responds to driver
inputs.
The steering wheel houses the driver airbag,
cruise and audio controls along with the horn
pad. It is attached to the collapsible steering
column.

18.1.4 Power Steering Rack

The rack assembly has a pinion gear on the

end of the steering shaft that meshes with a
flat rack of gear teeth. Tie rods connect the
ends of the rack to the steering arms. As the
steering wheel turns, the pinion gear moves
the rack right or left. This moves the tie rods
which turn the steering knuckles and wheels
inward or outward.

18.1.5 Clock Spring

Clock spring is located between steering

wheel and column. It acts as a rotary
electrical connector which maintains the
continuity of circuits of air bag, steering
switches etc. when the steering wheel is in
straight ahead or rotated condition.

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 1445
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.1.6 Intermediate Shaft

The intermediate shaft is mounted between

the steering column and the steering gear.
The intermediate shaft transfers the
rotational movement of the steering column
to the power steering gear input shaft. It
consists of a universal joint which connects
to the steering gear and a splined joint
connection which is firmly fastened to the
steering column. The main function of the
intermediate shaft is to enable the change in
the shaft length when the column is tilted and
also to absorb vibrations which may be
generated by the wheels and suspension up
to the steering wheel.
A-Upper Intermediate shaft
B- Lower Intermediate shaft

18.1.7 Power Steering Pump

The steering pump is a constant flow, vane

type incorporating a flow control valve (with
an integrated relief valve) and it is belt driven
by engine.

18.1.8 Combination Switch

The combination switch is mounted on the

steering column and houses the switches for
head lamps, fog lamps and wipers. It
comprises a central switch assembly and 2
stalks for controlling the lamps and wipers.

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
1446 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.2 Component Location Index

18.2.1 Steering System Layout

A. Steering Column Assembly G. Suction Hose

B. Intermediate Upper Shaft H. Return Hose

C. Steering grommet I. Pressure Hose

D. Tie Rod End Ball Joint J. Power steering pump

E. Intermediate Lower Shaft K. Assembly Steering Gear

F. Power steering reservoir

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 1447
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.3 Trouble Shooting

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 and it warms up the power assist gradually comes back.
This normally indicates that grooves have worn into the bore of the pinion aluminum housing
by control valve seals which may have hardened due to ageing.
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, thunking noise is the deterioration of rack
mounting bushings.
Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but
no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full
of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows,
clean the rack housing and then operate the system to observe the seepage directly.
A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems.

18.3.1 Visual Inspection

1. Check the tyre pressure.
2. Check the accessory drive belt for any damage.
3. Check the Tie-rod ends for bend or damage.
4. Check the steering inner ball joints for any bend or external damage.
5. Check ball joint rubber boots for signs of cracking or deterioration.
6. Check inner and outer ball joints for excessive wear.
7. Inspect all the steering bushes for signs of wear and deterioration.
8. Check the steering oil level in the reservoir. If the level is below “MIN” mark, top up
steering fluid.
9. Check the steering gear assembly for any external damage or steering fluid leakage.
10. Check the power steering pressure lines for fluid leakage and deterioration.
11. Check the power steering pump and the reservoir for fluid leakage.
12. Check the steering gear rubber bellows for cuts, cracks, deterioration and oil traces.
If the cause is not visually evident, verify the symptom and refer to the Troubleshooting 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 the vehicles are manufactured. The reproduction, translation, transmission, in part of
1448 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.3.2 Trouble shooting chart

Symptom Causes Remedial action

Abnormal Hissing Noise Noisy relief valve in hydraulic ● Some noise is allowable in
pump. Steering gear noise is all the power steering
transmitted through the system. One of the most
steering column or open- air common is a hissing sound
passages in the area where most evident at stand still
the column pass through the parking. Hiss is a high
floor into the engine frequency noise that is
compartment. 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.

1. Gear loose on frame. ● Check the gear mounting

bolts. Torque the bolts to
specifications.

2. Steering linkage ● Check the IBJ and OBJ for

Rattle or chuckle noise in looseness. wear.
Steering Gear
3. Pressure hose touching ● Adjust the hose position.
other parts of the vehicle. Do not bend the tubing by
hand.

4. Loose IBJ or OBJ ● Replace.

1. Air in the steering. ● Add oil to the pump

reservoir and bleed.

2. Steering gear mounting ● Tighten attaching bolt to

loose the specified torque.
Excessive wheel kick back ● Replace loose parts.
or Loose Steering
3. Front wheel bearings ●Replace the wheel bearing.
worn.

4. Damaged or worn steering ● Overhaul or replace the

gear. steering gear.

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 1449
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

5. Worn or damaged rubber ● Replace the rubber busing.

bushing of steering gear
mounting.

1. Wheel Alignment not ● Adjust the wheel alignment

Vehicle pulls to one side or correct. to specification.
the other
2. Steering linkage not level. ● Adjust as required.

1. Low oil level in reservoir. ● Add steering fluid as

required.
Momentary increase in
steering effort when
2. Pump belt slipping ● Replace the belt.
turning the wheel quickly
to the right or left
3. High internal leakage's ● Refer to pump test.
(Steering gear or pump)

1. Tyres under inflated ● Inflate the tyres to specified

pressure.

2. Steering wheel rubbing ● Adjust the steering column.

against directional signal
housing.

3. Tight or seized steering ● Replace the bearings.

shaft bushing/bearings.
Poor return of Steering
4. Steering joint or linkage ● Re-lubricate/replace the
binding joints.

5. Steering column ● Align the steering column.

misaligned.

6. Improper wheel alignment. ● Check and adjust to

specification.

7. Kink in return hose. ● Replace the hose.

1. Low oil level in the pump. ● Add oil as required.

2. Loosened pump belt. ● Replace the belt and auto-

Steering wheel surges or tensioner if required.
jerks when turning with
engine running, especially 3. Sticky flow control valve. ● Replace the pump.
during parking.
4. Incorrect wheel alignment. ● Adjust the wheel alignment
to recommended
specifications.

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
1450 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

1. Low tyre pressure ● Adjust the tyre pressure to

recommended value.

2. Steering gear to column ● Align the steering column.

misalignment.

3. Pump belt slipping. ● Tighten or replace belt.

4. High internal leakage. ● Fill to proper level and

inspect for leaks.
Hard steering effort in both
the directions. 5. Sticky flow control valve. ● Replace the pump.

6. Lower coupling flange ● Loosen the pinch bolt and

rubbing against steering assemble correctly.
gear.

7. Steering gear preload ● Replace the steering gear.

high.

8. Improper wheel alignment. ● Check and adjust to

specification.

1. Air in the fluid and loss of ● Check for leak & correct.
fluid due to internal pump Bleed the system. Extremely
leakage causing overflow. cold temperature will cause
aeration problems if the oil
level is low. If oil level is
correct and the pump still
Foaming Milky Looking foams then check for the air
Power Steering Fluid/ Low leakage caused by loose
Level and Possible low joint.
pressure
2. Check for kinks in the ● Remove the kinks or
hose. replace the hoses.

3. Foreign objects stuck in ● Remove the foreign object

the hose. or replace the hose.

Chirp Noise in Steering Pump belt slipping. ● Replace belt.

Gear

Belt squeal ( Particularly Pump belt slipping. ● Replace belt.

noticeable at Full wheel
Travel & Standstill Parking)

Growl noise in Steering 1. Low oil level ● Add the power steering
Pump fluid.

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 1451
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

2. Air in the oil. Poor ● Bleed the system.

pressure hose connection.

1. Pump vanes sticking in ● Replace pump, flush

rotor slot. system.
Rattle or knock noise in
steering Pump
2. Pressure hose touching ● Adjust hose position.
other parts of the vehicle.

Swish Noise in steering Faulty flow control valve. ● Replace the pump.
Pump

Whine Noise In Steering Pump shaft bearing scored. ● Replace the pump.
Pump

1. Low oil level ● Add power steering fluid as

required.

2. Pump belt slipping. ● Tighten or replace belt as

required.

3. Damaged hoses or ● Replace as necessary.

steering gear.

Low oil pressure due to 4. Check for kinks in the ● Remove the kinks or
steering pump hose. Replace the hose.

5. Foreign object struck in the ● Remove the foreign object

hole. or replace the hose

6. Extreme wear of the cam ● Replace pump, flush

ring. system.

7. Air in oil. ● Locate source of leak and

correct. Bleed the system.

1. Excessive total toe-in or ● Check the front toe settings

out. and adjust if necessary.

2. Unevenly loaded or ● Educate the customer

overloaded vehicle. about correct vehicle loading.

Vehicle Wander 3. Worn out steering inner ● Inspect the steering ball
ball joints. joint. Replace the steering
rack assembly if necessary.

4. Loose, worn or damaged ● Inspect the front wheel

front wheel bearings. bearings. Replace wheel
bearings if necessary.

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
1452 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Symptom Causes Remedial action

5. Worn or damaged front ● Check and replace

suspension components. necessary components.

6. Loose suspension ● Tighten the fasteners to the

fasteners. required specification.

1. Loose wheel nuts. ● Tighten the nuts to the

specification.

2. Loose front suspension ● Tighten the fasteners and

fasteners and mountings. mountings to the
specification.

3. Loose front wheel ● Inspect the front wheel

bearings. bearings. Replace the
bearings if necessary.
Steering wheel shimmy
4. Problem in Front shock ● Replace the shock
absorbers. absorbers if necessary.

5. Damaged wheel. ● Inspect the wheel rims for

damage and balance the
wheel & tire assemblies.

6. Worn out or loose UJ and/ ● Tighten the bolts or replace

or coupling. the shaft assembly.

1. Loose wheel nuts. ● Tighten the wheel nuts to

the specification.

2. Loose front suspension ● Tighten the fasteners and

fasteners and mountings. mountings to the
specification.

3. Loose front wheel ● Inspect the front wheel

bearings. bearings. Replace the
bearings if necessary.
Steering wheel wobble
4. Tyres worn or wheels out ● Balance the wheels.
of balance. Replace the rims and tires if
necessary.

5. Incorrect wheel alignment. ● Adjust the wheel alignment

to the specification.

6. Worn out steering inner ● Replace the inner ball

ball joints. joints.

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 1453
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.3.3 Component Inspection and Remedy Action:

Component Inspection Action

Check steering wheel for ● Replace as necessary.

Steering Wheel physical damage and/or
distortion.

1. Check steering column for ● Tighten the bolts as per

loose mounting bolts. torque specification.

Steering Column 2. Check for axial play. ● Replace steering column if

required.

3. Check for splines wear ● Replace steering column if

and tear. worn.

1. Check for bend in the ● Replace the shaft if found

shaft. bend.

2. Check for physical ● Replace the shaft if

damage. damaged.
Intermediate Shaft
3. Check for wear and tear. ● Replace the shaft if wear
and tear is found.

4. Check if column is ● Replace the shaft

collapsed. assembly if shaft is
collapsed.

1. Check for physical ● Replace steering rack if

damage. found any physical damage.

2. Check for abnormal noise ● Replace steering rack if

during steering action. noise is found.
Steering Rack
3. Check for oil leakage from ● Replace steering rack if
bellows or spool valve. leakage is found.

4. Check inner ball joint play. ● Check and rectify.

1. Check ball joint play. ● Replace the tie rod end if

play is excessive.
Tie rod end
2. Check for bellows ● Replace the bellow if found
damage. damaged.

Power steering fluid 1. Check for cracks or ● Replace the reservoir if

reservoir. distortion. damaged.

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
1454 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Component Inspection Action

2. Check for fluid leakage ● Replace the reservoir if

from cap or reservoir. leakage found.

1. Check for leakage from ● Replace the pump if

pump body. leakage found.

2. Check for physical ● Replace the pump if found

Power steering pump. damage to pump body or any damage.
pulley bend or distortion.

3. Check for pumping ● Conduct power steering

pressure. pump pressure test.

1. Check lines for cracks, ● Replace the concerned

distortions, damages or hose if found any damage,
flaring especially at joints. crack or distortion.
Power steering lines.
2. Check for material ● Replace the concerned
deterioration. hose.

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 1455
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.4 Standard Checking Procedure:

18.4.1 Check for Power Steering Fluid Leaks
1. Lower the vehicle.
2. Run the engine at idle and slowly turn the steering wheel to the left-hand steering lock
position. Hold the steering wheel in this position for about 5 seconds
3. Slowly turn the steering wheel to the right-hand steering lock position. Hold the steering
wheel in this position for about 5 seconds.
4. Turn the steering wheel away from the right hand steering lock and stop for about 3 seconds
5. Check the power steering fluid leaks at steering gear housing, power steering hoses and
connections. If there is a power steering fluid leak at any of these parts, replace as necessary.

18.4.2 Free Play Check

1. Start the engine and place the wheels at

straight ahead direction. For additional
information refer to Steering straight ahead
setting procedure.
2. Turn the steering wheel until the tyres
starts to move and measure the distance on
the circumference of the steering wheel.
Free Play Value ± 5°

If the free play is out of the specified value,

check the free play in steering column shaft
connection and steering linkage. Replace or
repair if necessary

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
1456 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.4.2.1 Steering Angle Check

1. Place the front wheel on a turning radius

measuring tool.
2. Turn the steering wheel to the its both
ends and measure the maximum steering
angle.

Wheel Lock Left Wheel Right Wheel

angle (deg)

Left Lock 31.2 29

Right Lock 29 31.2

If the steering angle is out of the specified

value, check and adjust the toe.

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 1457
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.4.3 Clock Spring Setting Procedure.

1. To re-centre the clock spring , from 2. From RH lock position rotate the clock
default position rotate the clock spring in spring in opposite direction (anti-clockwise)
clockwise rotation (Towards right hand approximately 3 turns and align the ��marks.
side) until tight (RH lock position).

Failure to follow the instructions can

cause the clock spring failure. Clock
spring if failed and not corrected can be a
concern if the vehicle meets an accident
which is above the threshold for airbag
deployment. In such cases the airbag
may not be deployed even though the
signal is given. Even if airbag not
deployed it will be giving a signal of
airbag failure which will mean a return of
customer with a complaint added on

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
1458 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5 Care of the System

18.5.1 Service Tips and Precautions
1. Always work in a dust free environment Hydraulic system can not tolerate dust
contamination.
2. Before reinstalling the old parts, clean them thoroughly.
3. While cleaning the hydraulic system parts- do not use kerosene or diesel or brake fluid. Use
only hydraulic fluid
4. Use only genuine Mahindra recommended spare parts only.
5. Use only Mahindra recommended steering fluids from a sealed container. Ensure steering
fluid is not contaminated, during filling in reservoir.
6. Ensure that recommended tightening torque values are maintained during assembly.
7. Steering Hoses to be checked for open ends closure with the caps on it before assembly, if
not found then needs to be replaced. (This is to avoid, entry of any foreign particle inside.)
8. Steering Pump to be checked before assembly for proper closure of fluid inlet and pressure
hose port with cap to avoid, entry of any foreign particle inside.
9. Used Steering Oil not to be used at any condition, to eliminated any foreign contamination.
10. Do not spill the steering fluid on the vehicle, as it may damage the paint. To keep fluid from
spraying or running out of lines and hoses, drain it in a suitable collector.
11. Perform functional tests wherever required.
12. All preventive and schedule maintenance must be performed only by an authorized
Mahindra dealer.

Some service operations affect the Restraint System. Be sure to read the precautionary
notices for Restraint system before commencing the service.

• Do not start the engine while working on steering system, this may lead to personal injury
and/or component damage.
• Improper or incorrect removal & installation of restraint components may unintentionally
activate the system, which can lead to personal injury.
• The service operations should be followed in correct sequence. Failure to do so may cause
the restraint system to unexpectedly deploy during service leading to a serious accident.
• Do not use electrical test equipment on circuits related to the restraint system, unless
instructed to do so.

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 1459
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5.2 Power Steering Fluid Level & Leak — Inspect

Power Steering Oil -SHELL SPIRAX S3 ATF MD3 / CALTEX MAKE "TEXAMATIC" 1888
Capacity – 0.8 Liters.

1. Check Power Steering fluid level , if found

less than MIN mark, top up to MAX mark.
2. Check the reservoir for leakage and check
the level of fluid, if found less top up till MAX
mark.
3. Always maintain fluid level at MAX mark
on reservoir.

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
1460 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5.2.1 Check for Power Steering Fluid Leak at:

1. Fluid reservoir outlet and return hose 4. Power steering rack feed tube
connection to reservoir. connections.

2. Power steering pump inlet and outlet

connection.

• Power steering oil level and leak to be

3. Power steering gear fluid inlet and outlet inspected in every regular service.
connection.
• No other Brand Recommended.
• For Non – ABS vehicles, 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
the correct LSPV setting height.

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 1461
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5.3 Power Steering Fluid — Replace

Power Steering Oil -SHELL SPIRAX S3 ATF MD3 / CALTEX MAKE "TEXAMATIC" 1888
Capacity – 0.8 Liters.

• No other Brand Recommended.

• For Non –ABS vehicles, 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
the correct LSPV setting height.

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
1462 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5.3.1

1. Rotate in anti-clockwise and remove the 3. Using a 17 mm open end spanner,

power steering fluid reservoir cap. loosen the nut and disconnect hose from
pump to rack.

2. Using 10 mm socket spanner remove the

mounting bolts and then remove the
Pressure hose bracket and detach the
Position a tray below the rack to collect
brackets.
the fluid.
.

4. Drain the complete fluid in a neat

container or bottle.

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 1463
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5.3.1 Power Steering Fluid Filling Procedure

1. Refit the fluid hose from pump on rack. 4. Carry-out Power steering circuit air
Torque tighten the nut to specified value. bleeding procedure. For additional
information refer to Power steering circuit air
bleeding procedure.

5. Refit the reservoir cap.

2. Refit the fluid line mounting clamp with

the help of mounting bolt. Torque tighten the
bolt to specified value.

3. Fill the recommended fluid to MAX mark

on reservoir.

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
1464 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.5.3.1.2 Power Steering Circuit Air Bleeding Procedure

• Do not operate the steering system without power steering fluid. Failure to follow this
precaution will lead to the damage of the steering system components.
• Whenever air enters the power steering hydraulic system, the system must be bleed to
ensure free of air. Filling and bleeding the power steering system helps to ensure trouble-
free operation as well as prevents the damage of the power steering system components.

1. Position the vehicle on a 2 post/ 4 post 4. Fill the power steering fluid reservoir to
lift. the “MAX” mark.

2. Inspect the fluid pressure hoses and

clips for proper fitment.

3. Rotate in anti-clockwise and remove the

power steering fluid reservoir cap.

During the bleeding procedure, ensure that

the power steering fluid in the power steering
fluid reservoir does not fall below the “MIN”
mark, as air could enter into the system.

5. Start the engine

6. Slowly turn the steering wheel to left lock

position and hold for about 10 seconds

7. From left lock position turn the steering

wheel slowly to Right lock position.

8. Continue steps 6– 7 till there is no air

bubbles visible in the power steering fluid
reservoir and smooth operation of power
steering is attained.

If the air bleeding is not properly performed,

the life span of the power steering pump may
be shortened.

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 1465
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

9. Top up the fluid to MAX mark on

reservoir.

10. Close the reservoir cap.

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
1466 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6 In Car Repairs

18.6.1 Steering Wheel R&R

18.6.1.1 Component Location Index

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 1467
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface and • Check for steering straight head position.
Open the bonnet.
• Refit the DAB module
• Disconnect battery negative cable and • Check for air bag warning indication.
wait for about 2 minutes.
• Connect the battery negative cable.
• Remove the DAB module.

Removal Steps:
1. Remove the driver airbag module.
2. Remove the steering wheel nut.
3. Remove the steering wheel using steering wheel puller.
Tools Required

Size Type Quantity

0112AAW0001ST DAB Removal tool 01

17 mm Socket spanner 01

0604BAA0001ST Steering wheel puller 01

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
1468 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.1.3 Removal:

1. Disconnect the battery negative terminal 5. Insert the DAB removal special tool
and wait for about 2 minutes before doing (MST : 0112AAW0001ST) into slot from
any activity on DAB module. upper side of combination switch and push
so that DAB gets unlocked from both that
2. Rotate the steering wheel to 90 degree sides.
both clockwise and anti-clockwise to remove
the steering Upper shroud mounting screws
by using a star screw driver.

6. Using a suitable tool, lift and unlock the

DAB yellow connector.

3. There are two slots located behind the

steering wheel, where DAB can be removed
using special tool.

7. Press the two locks and disconnect the

horn connector and remove the DAB.

4. Rotate the steering wheel to 90 degree

so that both slots can be accessed.

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 1469
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Press the lock and pull out the audio and 10. Insert the steering wheel puller (MST :
cruise control electrical connectors from the 0604BAA0001ST) into the driver airbag lugs,
clock springs. tighten the center long bolt of the tool by
using a 22 mm socket spanner and remove
the steering wheel from the steering column
shaft.

9. Using a 17 mm socket spanner remove

the steering wheel mounting nut.

• Do not use excessive force to the

steering wheel for removal. This may
cause steering wheel bend. Gently tap
if needed. While installing steering
wheel ensure the splines are aligned
properly and the steering wheel slides
easily on the column shaft.

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
1470 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.1.4 Installation:

Ensure the front wheels are in straight ahead position.

1. Carry-out clock spring setting. For 4. Install the audio and cruise control
additional information refer to clock spring electrical connector to the clock springs.
setting procedure.

2. Install the steering wheel on the steering

column shaft by keeping the steering in
straight ahead position as shown in the
figure.

3. Refit the steering wheel with the help of

mounting nut. Torque tighten the nut to
specified value.

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 1471
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Connect the DAB and horn connectors

and press the DAB on the steering wheel.

The service operations should be

followed in the correct sequence. Failure
to do so may cause the SRS to
unexpectedly deploy during service
leading to a serious accident.

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
1472 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.2 Clock Spring R&R

18.6.2.1 Component Location Index

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 1473
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Disconnect the battery negative cable. • Check for steering straight head position.
• Remove the steering lower and upper • Check for air bag warning indication.
shrouds.
• Refit the steering lower and upper
shrouds.
• Connect the battery negative cable.

Removal Steps:
1. Remove the driver airbag.
2. Remove the steering wheel.
3. Remove the clock spring electrical connections.
4. Remove the clock spring.
Tools Required

Size Type Quantity

- Flat end screw driver / Star

Each 01
Screw driver

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
1474 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.2.3 Removal:

1. Remove the Steering wheel. For 5. Using a flat end screw driver, unlock
additional information refer to steering wheel clock spring locks.
removal & installation section.

2. Remove the mounting screws of steering

column lower shroud.

6. Disconnect the electrical connectors

from clock spring.

3. Remove the Steering column lower trim.

7. Remove the clock spring from steering

column.

4. Remove the steering column lower

shroud and upper shroud.

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 1475
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.2.4 Installation:

1. Insert the clock spring in to the steering 4. Carry-out clock spring setting. For
column and connect the electrical additional information refer to clock spring
connectors. setting procedure.

Failure to do clock spring setting may

result in clock spring damage.

5. Refit the steering wheel. For additional

information refer to Steering wheel R& R
section.

2. Gently Press the clock spring over the

combination switch.

3. Fit the steering column lower trim, lower

& upper shroud.

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
1476 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.3 Combination Switch R&R

18.6.3.1 Component Location Index

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 1477
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check for steering straight head position.
• Disconnect the battery negative cable. • Check for air bag warning indication.
• Remove the clock spring. • Refit clock spring.
• Connect the battery negative cable.

Removal steps:
1. Remove the driver airbag.
2. Remove the steering wheel.
3. Remove the clock spring.
4. Disconnect the electrical connectors.
5. Remove the mounting screws.
6. Remove the combination switch.
Tools Required

Size Type Quantity

- Star screw driver 01

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
1478 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.3.3 Removal:

1. Remove the Clock spring. For additional

information refer to clock spring setting
procedure.

2. Disconnect the electrical connectors

from combination switch.

3. Remove combination switch mounting

screws by using star screw driver.

4. Gently pull-out and remove the

combination switch from steering column.

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 1479
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.3.4 Inspection
1. Inspect the combination switch for any damage.
2. Inspect the combination switch connectors for any damage or loose connection.

18.6.3.5 Installation:

1. Insert the combination switch in to the

steering column and connect the electrical
connectors..

2. Tighten the mounting screws by using

star screw driver.

Tighten the combination switch

mounting screw as per the specification.
over tightening will lead to damage of the
switch

3. Refit the clock spring. For additional

information refer to clock spring setting
procedure.

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
1480 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.4 Steering Column R&R

18.6.4.1 Component Location Index

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 1481
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.4.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check for steering straight head position.
• Disconnect the battery negative cable. • Remove the combination switch.
• Remove the combination switch. • Check for air bag warning indication.
• Connect the battery negative cable.

Removal steps:
1. Remove the intermediate shaft mounting bolt.
2. Remove the ignition key barrel.
3. Remove steering column mounting bolts/nuts on CCB.
4. Remove the steering column.
Tools Required

Size Type Quantity

12 mm Socket spanner 01

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
1482 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.4.3 Removal:

1. Remove the Combination switch. For 5. Using 12 mm socket spanner remove the
additional information refer to combination mounting bolts/nut of steering column
switch removal & installation section. mounted on the cross car beam.

2. Remove the Ignition key barrel. For

additional information refer to Ignition key
barrel R&R section.

3. Using 12 mm socket spanner remove the

joint connected to the steering column and
the intermediate shaft.

6. Remove the steering column.

4. Using 12 mm socket spanner remove the

steering column mounting bracket nut.

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 1483
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.4.4 Installation:

1. Install the steering column Assembly. 4. Refit the mounting bolts/nut of steering
column on the cross beam and torque tighten
the bolts/nut to specified value.

2. Refit the steering column & the

intermediate shaft mounting bolt and torque
tighten the nuts to specified value. 5. Refit the Ignition key barrel. For
additional information refer to Ignition key
barrel R&R section.

6. Refit the combination switch. For

additional information refer to Combination
switch R&R section.

3. Insert the steering column bracket

mounting nut and torque tighten the nuts to
specified value.

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
1484 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.5 Intermediate Shaft Upper R&R

18.6.5.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the Steering column lower trim.
• Open the bonnet.
• Remove the Steering column lower trim.

Tools Required

Size Type Quantity

12 mm Socket spanner & Ratchet 01

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 1485
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.5.2 Removal:

While attempting to remove the intermediate shaft, lock the steering wheel at center
position.

1. Remove the Steering column lower trim. 3. Using a 12 mm socket spanner remove
the intermediate shaft upper mounting bolts
on lower shaft.

2. Using a 12 mm socket spanner remove

the intermediate shaft upper mounting bolt
on steering column.

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
1486 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.5.3 Installation:

1. Refit the upper intermediate shaft on

steering column with the help of mounting
bolt. Torque tighten the bolt to specified
value.

2. Refit the upper intermediate shaft on

lower shaft with the help of mounting bolts.
Torque tighten the bolts to specified value.

3. Refit the Steering column lower trim.

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 1487
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.6 Intermediate Shaft Lower R&R

18.6.6.1 Component Location Index

18.6.6.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check for steering straight head position.
• Open the bonnet.

Tools Required

Size Type Quantity

12 mm Socket spanner 01

Open end spanner/Ring

13 mm spanner 01

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
1488 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.6.3 Removal:

While attempting to remove the intermediate shaft, lock the steering wheel at center
position.

1. Using 12 mm socket spanner loosen and 3. Remove the intermediate shaft along
remove the lower intermediate shaft top with the universal joint.
mounting bolts.

2. Using 12 mm socket spanner loosen and

remove the intermediate shaft universal joint
mounting bolt on gear input shaft.

18.6.6.4 Inspection:
1. Inspect the shaft for any damage, crack or bend. Replace if found any.
2. Inspect the sleeve joint for any damage.
3. Inspect the universal joint for any damage.

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 1489
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.6.5 Installation:

1. Insert the intermediate shaft on steering

gear input and fasten using the mounting
bolt. Torque tighten the bolt to specified
value.

2. Connect the intermediate shaft on upper

shaft using sleeve joint, fasten the joint using
bolts. Torque tighten the bolts to specified
values.

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
1490 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.7 Tie-Rod End Ball Joint R&R

18.6.7.1 Component Location Index

18.6.7.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the respective front wheel.
• Remove the respective front wheel. • Check for wheel alignment.

Tools Required

Size Type Quantity

17 mm Socket spanner 01

19 mm Socket spanner & Ratchet 01

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 1491
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.7.3 Removal:

1. Remove the respective front wheel. For 4. Using a 17 mm ring/socket spanner

additional information refer to Wheel R&R remove the tie rod end ball joint mounting nut
section. on knuckle.

2. Remove the tie rod end cotter pin from

the knuckle assembly.

5. Rotate the tie rod end ball joint in anti-

clockwise direction and remove.

3. Loosen the tie-rod end ball joint locking

nut using 19 mm open end spanner.

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
1492 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.7.4 Inspection:
1. Inspect the ball joint for proper functioning.
2. Inspect the ball joint for any physical damage. Replace if found.
3. Inspect the rubber boot for any damage. Replace if damaged.

18.6.7.5 Installation:

1. Insert the tie-rod end and rotate in 3. Insert the tie rod end cotter pin.
clockwise direction to tight.

Always use a new cotter pin.

2. Refit the tie rod end ball joint on knuckle

with the help of mounting nut. Torque tighten
the nut to specified value.
4. Tighten the tie rod end ball joint locking
nut.

5. Refit the wheel. For additional

information refer to Wheel R&R section.

6. Perform wheel alignment. For additional

information refer wheel alignment section.

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 1493
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.8 Power Steering Rack Assembly R&R

18.6.8.1 Component Location Index

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
1494 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.8.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refill the power steering oil and carry-out
• Remove the front wheels. bleeding procedure.
• Do wheel alignment.
• Drain the power steering oil

Removal Steps:
1. Detach tie rod end ball joints from knuckle.
2. Detach intermediate shaft.
3. Remove the fluid lines bracket.
4. Disconnect fluid lines.
5. Remove rack assembly mounting bolts.
6. Remove the rack assembly.
Tools Required

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 1495
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Size Type Quantity

17 mm Open end / Ring spanner Each 01

12 mm/ 19 mm / 10 mm Socket spanner & Ratchet 01

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
1496 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.8.3 Removal:

Lock the steering wheel in center position. The front wheels should be in straight
ahead position before disconnecting the steering rack assembly from the vehicle.

1. Remove both the front wheels. For 4. Using 12 mm socket spanner loosen and
additional information refer to Wheel R&R remove the intermediate shaft universal joint
section. mounting bolt on gear input shaft.

2. Remove the tie rod end cotter pin first

using a plier on either sides.

5. Remove the 10 mm mounting bolt of

power steering suction and return hose
brackets.
3. Using 17 mm socket/Ring spanner
remove the ball joint mounting nut on knuckle
and then detach the tie rod ends ball joints
from knuckle on either sides.

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 1497
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Using a 17 mm open end spanner, 9. Carefully remove the power steering rack
loosen the nut and disconnect power from the frame.
steering suction & return pipe.

Plug the steering rack assembly inlet and

outlet hose oil passage with dust cap to
avoid any foreign particles entry.

7. Drain the power steering fluid. For

additional information refer to Power steering
fluid R&R section.

8. Using 19 mm socket spanner remove the

steering rack assembly mounting bolts.

18.6.8.4 Inspection:
1. Check power steering rack boot for any damage. Replace if necessary.
2. Check the power steering rack mounting bushes for any damage.
3. Check for any oil leaks on the steering rack.

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
1498 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.8.5 Installation:

1. Install the power steering rack on the 4. Connect the fluid lines and torque tighten
frame. the nuts to specified value.

2. Connect the intermediate shaft universal 5. Fit the bracket of power steering suction
joint into gear input shaft and then mount the and return hose to the steering rack.
rack assembly with the help of mounting
bolts. Torque tighten the bolts to specified
value.

6. Connect tie rod end ball joint on knuckle

(both the sides) with the help of mounting
nut. Torque tighten the nut to specified value.
3. Insert the intermediate shaft UJ
mounting bolt, torque tighten the bolt to
specified value.

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 1499
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit the cotter pin on both sides.

8. Fill the power steering fluid and do the air

bleeding procedure. For additional
information refer to Power Steering Fluid
Filling Procedure section.

9. Refit both the front wheels. For additional

information refer to Wheel R&R section.

10. Perform wheel alignment. For additional

information refer wheel alignment section.

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
1500 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.9 Bellow R&R

18.6.9.1 Component Location Index

18.6.9.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post /4post lift. • Refit the tie rod end ball joint
• Remove the tie rod end ball joint

Tools Required

Size Type Quantity

— Hose Clip Plier 01

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 1501
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.9.3 Removal:

1. Remove the tie rod end ball joint. For

additional information refer to Tie rod end ball
joint R&R section.

2. Unclip the mounting clamps using hose

clip plier and flat end screw driver and then
remove the bellow.

18.6.9.4 Installation:

1. Insert the bellow, mount with the help of

mounting clamps.

2. Refit the tie rod end ball joint. For

additional information refer to Tie rod end ball
joint R&R section.

3. Perform wheel alignment. For additional

information refer wheel alignment section.

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
1502 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.10 Power Steering Pump R&R

18.6.10.1 Component Location Index

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 1503
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.10.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post /4post lift. • Refit the power steering pump/ alternator
• Remove the power steering pump/ drive belt.
Alternator drive belt.

Removal Steps:

1. Remove power steering pump/ Alternator 4. Remove the power steering pump
drive belt. mounting bolts.
2. Disconnect the fluid inlet hose. 5. Remove the power steering pump.
3. Disconnect the fluid outlet hose.

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
1504 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

17 mm Open end spanner 01

12 mm Socket spanner 01

— Hose Clip Plier 01

12 mm Ring spanner 01

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 1505
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.10.3 Removal:

1. Drain the power steering fluid. For 5. Using 12 mm socket and ring spanners
additional information refer to Power steering remove power steering pump mounting bolts.
fluid R&R section.

2. Remove the power steering pump/

Alternator drive belt. For additional While loosening the bolt hold the nut
information refer to Auto tensioner & belt using 12 mm ring spanner.
(Alternator/Power Steering) - Replace)

3. Using a hose clip plier, unclip the spring

band clamp and then disconnect the fluid
inlet hose to pump.

6. Remove the power steering pump.

4. Using a 17 mm open end spanner loosen

the mounting nut and disconnect the fluid
outlet tube from pump.

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
1506 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.10.4 Inspection:
1. Inspect the pump for any physical damage. Replace the pump if found.
2. Inspect the pump for any fluid leakages.
3. Inspect the pulley for any damage.

18.6.10.5 Installation:

1. Refit the power steering pump with the 2. Connect fluid inlet hose and outlet tube.
help of mounting bolts, torque tighten the Torque tighten the tube mounting nut to
bolts to specified values. specified value and fasten the inlet hose
using spring band clamp.

While tightening the bolt hold the nut

using 12 mm ring spanner.

3. Refit the power steering pump/ Alternator

drive belt. For additional information refer to
Auto tensioner & belt (Alternator/Power
Steering) - Replace)

4. Carry-out power steering fluid filling and

bleeding procedure. For additional
information refer to Power steering circuit air
bleeding procedure.

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 1507
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.11 Suction Hose (Power Steering Reservoir to Pump) R&R

18.6.11.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post/ 4 post lift. • Fill the power steering fluid and do
• Drain the power steering fluid. bleeding.

Size Type Quantity

- Hose clip plier 01

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
1508 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.11.2 Removal:

1. Drain the power steering fluid. For

additional information refer to Power steering
fluid draining section.

2. Using a hose clip plier, unclip the spring

band clamps and detach and remove the
suction hose.

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 1509
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.11.3 Installation:

1. Connect the suction hose to reservoir

and pump, fasten using spring band clamps.

2. Refill the fluid and carry-out air bleeding.

For additional information refer to Power
steering circuit air bleeding procedure.

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
1510 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.12 Reservoir R&R

18.6.12.1 Component Location Index

18.6.12.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post/ 4 post lift. • Fill the fluid and carry-out air bleeding.
• Drain the power steering fluid.

Tools Required

Size Type Quantity

- Hose clip plier 01

- Star screw driver 01

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 1511
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.12.3 Removal:

1. Drain the power steering fluid. For

additional information refer to Power steering
fluid draining section.

2. Disconnect suction and return hoses

from reservoir.

3. Using a star screw driver remove the

mounting screw and then gently pull-out and
remove the reservoir.

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
1512 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.12.4 Installation:

1. Refit the reservoir with the help of

mounting screw.

2. Connect suction and return hose. fasten

using spring band clamp.

3. Fill the fluid and carry-out air bleeding.

For additional information refer to Power
steering circuit air bleeding procedure.

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 1513
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.13 Inner Ball Joint (IBJ) R&R

18.6.13.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit the bellow.
• Remove the bellow. • Do wheel alignment.

Tools Required

Size Type Quantity

- Chisel 01
- Mallet 01

32 mm Open end spanner 01

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
1514 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.13.2 Removal:

1. Remove the steering rack bellow. For

additional information refer to Bellow R&R
section.

2. Using a chisel and mallet, unlock the

locking washer.

3. using a 32 mm open end spanner loosen

and remove the IBJ.

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 1515
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.13.3 Installation:

1. Insert a new locking washer.

2. Refit the IBJ, tighten to specified value.

3. Lock the IBJ with the help of locking

washer.

Ensure that the washer is locked

properly.

4. Refit the steering rack bellow. For

additional information refer to Bellow R&R
section.

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
1516 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.14 Tube Pump to Rack R&R

18.6.14.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post/ 4 post lift. • Fill the fluid and carry-out bleeding.
• Drain the power steering fluid.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

17 mm Open end spanner 01

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 1517
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.14.2 Removal:

1. Using a 10 mm socket spanner remove 3. Disconnect the tube from pump by

the mounting bolts and then gently detach loosening the mounting nut using a 17 mm
the clamps. socket spanner.

2. Using a 17 mm open end spanner, 4. Remove the tube assembly.

loosen the nut and disconnect hose from
pump to rack and collect the fluid into a
container.

Position a tray below the rack to collect

the fluid.

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
1518 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.14.3 Installation:

1. Connect the tube on gear housing and 4. Fill the fluid and carry-out air bleeding
torque tighten the mounting nut to specified procedure. For additional information refer to
value. Power steering circuit air bleeding procedure.

2. Connect the tube on pump, torque

tighten the mounting nut to specified value.

3. Mount the tube with the help of clamps.

Torque tighten the clamp bolts to specified
value.

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 1519
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.15 Tube Return (Rack to Reservoir) R&R

18.6.15.1 Component Location Index

Pre Removal Post Installation

• Position the vehicle on a 2 post/ 4 post lift. • Fill the fluid and carry-out bleeding.
• Drain the power steering fluid.

Tools Required

Size Type Quantity

17 mm Open end spanner 01

10 mm Socket spanner 01

- Hose clip plier 01

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
1520 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.15.2 Removal:

1. Using a 10 mm Socket spanner remove 4. Using a hose clip plier, unclip the spring
the mounting bolts and then gently detach band clamp and disconnect the return hose
the clamps. from reservoir.

2. Drain the power steering fluid. For 5. Remove the return tube assembly.
additional information refer to Power steering
fluid draining section.

3. Using a 17 mm open end spanner loosen

the nut and disconnect the return hose from
steering gear housing.

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 1521
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.6.15.3 Installation:

1. Connect the return hose on reservoir. 4. Fill the power steering fluid and carry-out
Fasten using spring band clamp. air bleeding procedure. For additional
information refer to Power steering circuit air
bleeding procedure.

2. Route the tube using mounting clamp.

Torque tighten the clamp bolts to specified
value.

3. Connect the return tube on steering gear

housing, torque tighten the mounting nut to
specified value.

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
1522 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.7 Technical Specifications

POWER STEERING SYSTEM

Description Specification

Steering system - Type Hydraulic - power assisted.

Make Sona Koyo Steering Systems Ltd

Steering wheel

Position Center

Outside Diameter 380

No of spokes 4

Steering Column

Type Guided Collapsible Tilt Steering column

Intermediate shaft

Type I shaft with rubber coupling

Maximum No. of rotation of steering wheel 3.35

from lock to lock

Offset of the steering column with respect to 0

the seat

Steering Gear

Type Rack & Pinion type, Hydraulic Power

Steering

Steering gear ratio 40:1

Steering Setting Angle

Wheel Lock angle (deg) Left Wheel Right Wheel

Left Lock 31.2 29

Right Lock 29 31.2

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 1523
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

POWER STEERING SYSTEM

Description Specification

Power Assistance

Type of assistance Hydraulic

Pressure setting (kg /cm2 / bar /kPa) 75

Minimum turning circle diameter (mm) 13.6±0.3

Steering wheel free play ±5°

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
1524 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18.8 Tightening Specifications

Description Torque Nm

DAB MTG ON STEERING 8±2

STEERING SHROUD 2.5±0 5

TIE ROD BALL JOINT NUT ON SIG 45±9

KNUCKLE (STEERING OBJ ID KNUCKLE)

FITMENT OF POWER STEERING GEAR 85 ± 13

RHD/LHD

STEERING GEAR TIE ROD END TO 80 ± 12

KNUCKLE BALL JOINT RH/LH

STEERING LINK ASSY. ON GEAR 22±4

FITMENT OF POWER STEERING RETURN 22 ± 5

PIPE ON STEERING GEAR

STEERING PRESSURE PIPE MOUNTING 22 ± 5

ON PUMP

STEERING COLUMN ON DASH AND 22 ± 4

PLENNUM

STEERING LINK CONN. UPPER 22 ± 4

STEERING LINK CONN. LOWER 22 ± 4

STEERING TIE ROD END CHECK NUT 56 ± 7

STEERING WHEEL MOUNTING ON 47 ± 7

COLUMN

STEERING COLUMN IGNITION LOCK 14 ± 3

POWER STEERING HOSE CLAMP MTG. 4.5 ± 0.5

PAS RESERVOIR PLASTIC MTG. 2.5 ± 0.5

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 1525
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1526 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

19.1 Description and Operation

19.1.1 HVAC
The Heater, Ventilation and Air conditioning combines air conditioning, heating and ventilating
functions.
The system comprises of:
• Blower & Air Inlet system.
• Heater core, and Air distribution assembly.
• Air Conditioning system.
Foot ducts are provided for better comfort for driver and co-driver. All the flaps are controlled
electrically by actuators. HVAC system also helps in defrosting and defogging the windshield.
Fresh air and recirculation mode can also be selected
For second row passengers ducts are provided on the centre console assembly.
Full Automatic Temperature Control (FATC) is provided for automatic control of cabin air
temperature. FATC also controls the circulation and humidity of the air inside the vehicle. With
FATC, the driver selects the temperature and the FATC maintains the user selected
temperature, regardless of outside temperature changes. The FATC control module controls
air conditioning, ventilating, heating, and defrosting systems. The FATC automatically adjust
doors, blower speeds, and compressor cycling to maintain a given temperature.
Air Circulation
The primary components are:
• Nylon mesh filter.
• Front blower motor.
• Field effect transistor.
• Air distribution housings.
• Flaps.
• Air ducts and vents.
Depending upon fresh or recirculation mode selected at HVAC control panel, a flap located on
blower housing is operated and the air is sucked by the blower either from outside or inside the
cabin. Before air is sucked inside the system, it is filtered by HVAC filter.
Filtered air is then forced towards the main distribution hosing where multiple flaps are
provided. By selecting a particular distribution mode at HVAC control panel, different flaps get
operated in pre-defined way thereby air flow is distributed among different vents. Air flow
volume or speed is controlled via a blower resistor and can be adjusted by adjusting blower
speed knob on the HVAC control panel. Flow direction of air flow coming out of vents can be
controlled by manually adjusting the vents. Depending upon selected temperature knob
position on HVAC control panel, amount of air passing through evaporator and heater is
controlled. Finally both cold and hot air streams are mixed together and are distributed further.
Air Conditioning
The air conditioning function is carried out using closed circuit configuration based on Vapour
compression refrigeration cycle. The system uses R– 134a as refrigerant and suitable

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 1527
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

lubricating oil. Refrigerant gets circulated through a closed loop as long as air conditioner is in
operation

The primary components are:

• Suction hose.
• Compressor assembly.
• Discharge hose.
• Condenser, receiver/drier, condenser fan.
• Liquid pipe.
• Triple pressure switch.
• Thermostatic expansion valve.
• Evaporator.
• Evaporator inlet and outlet pipes.
• Thermo sensor (Thermistor).
• Refrigerant and refrigerant oil.

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
1528 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

The compressor used in system is of swash plate type, fixed displacement Compressor. In this
compressor a fixed angle swash plate, attached to the drive shaft, rotates to reciprocate
double acting pistons. The axially reciprocating pistons suck refrigerant from suction side and
deliver compressed refrigerant to discharge side.
The compressor pulley is driven by the engine belt. If electromagnetic clutch is not engaged,
drive shaft does not rotate even as pulley keeps on rotating with engine through drive belt.
Once electrically energized, electromagnetic clutch engages and the rotary motion of the
compressor pulley is transferred to drive shaft which in turn start reciprocating the pistons.
The compressor is lubricated by refrigerant oil which circulates throughout the refrigerant
system along with the refrigerant. When in operation, compressor draws in low-pressure and
low-temperature refrigerant vapour from the evaporator and compresses it to a high pressure
and high-temperature refrigerant vapour, which is then pumped to the condenser.
The condenser is basically a heat exchanger where atmospheric air flowing across it's core is
used to cool the refrigerant flowing inside tubes. Inside condenser, high-pressure and high
temperature refrigerant vapour gets converted into high-pressure and moderate temperature
liquid in sub cooled state. Condenser also has an integrated receiver/ drier which removes
impurities and moisture from circulating refrigeration by using strainer and Desiccant inside it.
Then the refrigerant flow toward thermostatic expansion valve through liquid pipe.
The system uses box or block type of thermostatic expansion valve. While passing through
metering orifice of the thermostatic expansion valve, high pressure and moderate temperature
refrigerant liquid get throttled to low-pressure and low temperature liquid. The refrigerant then
flows to the evaporator. Based upon pressure and temperature of refrigerant vapour coming

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 1529
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

out of evaporator, thermostatic expansion valve regulates the amount of liquid refrigerant
flowing towards evaporator
Evaporator is also a heat exchanger where refrigerant flowing inside tubes is used to cool the
cabin air flowing across the evaporator core. While flowing through condenser low pressure
and low temperature liquid refrigerant gets converted into low-pressure and low temperature
vapour in superheated state. The cabin air while passing through the evaporator core, gets
cooler and gets dehumidified. The condensate water gets drained Off to atmosphere through
drain hose, located below the evaporator housing. Finally this low pressure and low-
temperature refrigerant vapour gets sucked by compressor and the cycle repeats itself.
A trinary pressure switch is located on the liquid pipe connecting condenser to thermostatic
Expansion valve. To prevent system failure, depending upon actual refrigerant pressure, the
Trinary pressure switch sends a signal to EMS ECU which in turn engages and disengages
the compressor clutch. Pressure switch shutoff compressor when refrigerant pressure either
exceed a specified limit or if it falls below specified limit. It allows/restarts the compressor if
refrigerant pressure is within normal operating range. Additionally the pressure switch starts
condenser fan once refrigerant pressure exceed a specified limit and shuts it off when
refrigerant pressure falls below a specified limit.
A thermo sensor is provided, which depending upon the air temperature just besides the
coolest portion of evaporator core, makes compressor clutch get engaged or disengaged, in
order to prevent ice formation near evaporator. If cabin air temp just beside the evaporator falls
below certain limit, thermo sensor shuts the compressor off and restarts It again once air
temperature rises back above certain limit.
For recovering/recharging refrigerant and refrigerant oil, a high pressure side port located on
liquid pipe and a low pressure side charging port located on suction hose has been provided.
Heating
The primary components are:
• Cabin Heater
• Heater inlet and outlet pipes
Cabin Heater is essentially a heat exchanger where hot engine coolant is passed through the
heater tubes which heats-up the cabin air flowing across the heater core. Engine coolant
keeps flowing through the heater as long as engine and hence water pump is in operation.

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
1530 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.1.2 Centre / Side Vents

Two Centre vents are located above the

audio system. The two side vents are located
one each at the left and right extreme ends of
the instrument panel. Both the Centre and
side vents provide air flow to the front seat
passengers. Rotate the thumb wheel (B) up
to close or down to open the air vent. Direct
air to the desired direction by the adjusting
louvers (A) left/right.
A- Adjustable Louvers
B- Thumb Wheel (Open/Close)

19.1.3 Second Row Floor Vents

Two vents for the second row are provided at

the rear of the floor console. The vents have
adjustable louvers (A) to direct the air flow
and thumb wheels (B) for vents open/close
operations.
A- Adjustable Louvers
B- Thumb Wheel (Open/Close)

19.1.4 HVAC Controls

A- Air Distribution Control

B- Blower Speed Control
C- Temperature Control
D- AC High
E- AC Low
F- Air Re-circulation Switch

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 1531
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

A- Air Distribution Control

B- Blower Speed Control
C- Temperature Control
D- AC
F- Air Re-circulation Switch

19.1.5 Air Distribution Control

The air flowing out of various vents can be

controlled by the air distribution control
Knob/button. Following are the five different
distribution modes to choose from:

Face Mode — air is discharged from the

center vents, rear vents and side vents. This
mode is most suitable for directing air flow
towards face of passengers.
Face-Foot Mode — air is discharged from
the center vents, side vents and foot vents.
This mode is most suitable for directing air
flow towards both the face and feet of
passengers at the same time.
Foot Mode — air is discharged from the two
foot vents. This mode is most suitable for
directing air flow towards the feet of
passengers seated on front seats.
Foot-Defrost Mode — air is discharged from
the foot vents, side defrost vents and
windshield defrost vents. This mode is most
suitable for directing air flow towards the feet
of passengers while defrosting or de-misting/
defogging. Keep the air recirculation in fresh
air mode.
Defrost Mode — air is discharged from the
side defrost vents and windshield defrost
vents. This mode is most suitable for
directing air flow towards the front windshield
to ensure defrosting or de-misting/
defogging. Keep the air recirculation in fresh
air mode.

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
1532 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Face Mode — air is discharged from the

center vents, rear vents and side vents. This
mode is most suitable for directing air flow
towards face of passengers.
Face-Foot Mode — air is discharged from
the center vents, side vents and foot vents.
This mode is most suitable for directing air
flow towards both the face and feet of
passengers at the same time.
Foot Mode — air is discharged from the two
foot vents. This mode is most suitable for
directing air flow towards the feet of
passengers seated on front seats.
Foot-Defrost Mode — air is discharged from
the foot vents, side defrost vents and
windshield defrost vents. This mode is most
suitable for directing air flow towards the feet
of passengers while defrosting or de-misting/
defogging. Keep the air recirculation in fresh
air mode.
Defrost Mode — air is discharged from the
side defrost vents and windshield defrost
vents. This mode is most suitable for
directing air flow towards the front windshield
to ensure defrosting or de-misting/
defogging. Keep the air recirculation in fresh
air mode.

19.1.6 Blower Speed Control

Blower force-circulates air through the HVAC

unit and distributes it throughout the
passenger compartment.

Blower is OFF when the blower speed

control knob is set in the ‘0’/‘—’ position. To
switch-on the blower, rotate the control knob
clockwise to position ‘1’/‘+’. To increase the
blower speed, rotate the control knob
clockwise further. To reduce the blower
speed, rotate the knob counter clockwise and
select a lower number.

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 1533
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.1.7 Temperature Control

By operating the temperature control knob,

temperature of air being discharged from
various vents can be adjusted to the desired
level. Engine coolant is utilized to heat,
whereas the air conditioner is used to cool
the air inside the AC unit. Based upon
selected position of the temperature control
dial, the desired discharged air temperature
can be obtained.
By rotating the dial counter-clockwise and
setting it to the extreme left position, cool air
is discharged.
When the dial is rotated clockwise, the
discharged air progressively starts getting
warmer.
By rotating the dial further in the clockwise
direction and setting it to the extreme right
position, hot air is discharged.

‘—’ represents cooling and ‘+’ represents

heating.

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
1534 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

By rotating the dial counter-clockwise and

setting it to the extreme left position, cool air
is discharged. When the dial is rotated
clockwise, the discharge air progressively
starts getting Warmer.
By rotating the dial further in the clockwise
direction and setting it to the extreme right
position, hot air is discharged.

19.1.8 AC Compressor Assembly

Commonly referred to as the heart of the

system, the Compressor is driven by engine
through accessory drive belt. It is responsible
for compressing and transferring refrigerant
gas.
The purpose of the compressor is to circulate
the refrigerant in the system under pressure,
this concentrates the heat it contains. At the
compressor, the low pressure gas is changed
to high pressure gas.
The compressor used is Swash plate type.

19.1.9 Condenser

The purpose of the condenser is to dissipate

the heat accumulated during gas evaporation
and compression. Once it is cooled, the gas
becomes a liquid and remains under high
pressure. To improve thermal exchange, the
fluid is exposed to air flow produced by the
engine cooling fans and vehicle movement.
This step allows for fluid expansion.
Its location is in front of the radiator. From
compressor high pressure high temperature
refrigerant is introduced into the top of the
condenser as the gas moves through the
condenser it gets cooled. As the refrigerant
cools, it condenses and exits the bottom of
the condenser as a high pressure low
temperature liquid.

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 1535
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.1.10 The Receiver/ Drier

The Receiver/Dryer is integrated into

condenser unit. To ensure that the valve gets
liquid refrigerant, a receiver is used. The
primary function of the Receiver/Dryer is to
separate gas and liquid. The secondary
purpose is to remove moisture and filter out
debris.

19.1.11 Thermal Expansion Valve

This serves two functions:

1. Send the fluid from high to low
pressure: this is expansion.
2. Continuously adjust the quantity of fluid
expanded according to the evaporator
outlet temperature.
In this Thermostatic expansion valve is used.
The lower section of the thermostatic
expansion valve is composed of an inlet pipe
regulated by a valve, while the upper section
is composed of an outlet pipe and a
thermostatic capsule.
The thermostatic capsule contains a dilatable
fluid as well as a plunger exposed to the
temperature of the fluid exiting the
evaporator. If this temperature is high, the
fluid contained in the plunger expands,
pressure in the capsule increases and the
diaphragm pushes the plunger down. The
plunger opens the valve, and expansion and
evaporation increase: the temperature drops
quickly in the evaporator, causing contraction
of the dilatable fluid. The valve closes and
the cycle starts over.

• Note that the spring holding the valve

is preloaded in the factory and the
expansion valve cannot be repaired or
adjusted.

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
1536 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.2 Component Location Index

19.2.1 HVAC Overview

A. Side Defrost Vents E. Foot Vents

B. Windshield Defrost Vents F. Rear Vents

C. Side Vents G. HVAC Controls — FATC/ Manual

D. Centre Vents

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 1537
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.3 Standard Checking Procedure

19.3.1 AC PERFORMANCE TEST
Before going to performance test, ensure following points are taken care –
1. AC Filters – Clean if necessary.
2. AC Gas – Use only R134a AC gas and only from recommended suppliers.
3. Ensure correct amount of AC gas is filled in the system.
4. Ensure cleanliness of the condenser surface at regular interval.
5. Ensure proper function of condenser fan.
6. For AC System testing use only approved Tools & Equipment.

• This AC performance test is only to check mechanical performance of the HVAC

system and not the flow or circulation related complaints.

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
1538 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.3.2 AC Working Logic

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 1539
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4 Care of the System

19.4.1 Service Tips and Precautions.
Precautions to be taken while servicing air conditioning system.
• Air Conditioning system in this vehicle uses R134a as refrigerant and PAG (Polyalkylene
Glycol) Oil' as refrigerant oil.
• Never use or mix other refrigerants (e.g. R12) and other oil.
• Environment friendly refrigerant R134a is not an ozone depleting substance but its release
would add to the greenhouse warming effect.
• Refrigerant R134a is transparent and colourless in both the gaseous and liquid state. At
Ambient temperature and pressure it will be in vapour state. The vapour is heavier than air
and is non-flammable, non-explosive, non-poisonous and non-corrosive (except when in
contact with moisture).

• Refrigerant is stored under high pressure inside the system, hence under certain
circumstances, refrigerant lines and other system components may be extremely
hot or cold.
• Exposure of refrigerant in liquid or vapour form to skin or eyes may cause irritation
and frostbite. Avoid exposure to skin, eyes and clothing.
• R134a vapors are heavier than air and can cause suffocation, dizziness and loss of
concentration. Always work in well ventilated space.
• R134a when mixed with compressed air or oxygen, forms flammable mixture. Never
use compressed air for pressure testing or leak testing of system/components.
When R134a is mixed with other refrigerants, it may become flammable. Never use
or mix any other refrigerant.

It must be noted that R134a must always be extracted from the system and collected
using the recommended servicing units. Care should be taken when discharging the
air conditioning system to ensure the refrigerant is not released into atmosphere but
captured for recycling.
The following precautions in handling R134a should be observed at all times:
1. R134a is a hazardous gas and when not handled properly can cause serious injury.
Suitable protective clothing must be worn when carrying out servicing operations on the
air conditioning system.

When handling refrigerant, always wear protective goggles and gloves, made of
suitable material like fluoro elastomer. Leather or plastic gloves are unsuitable.
2. R134a is odorless and colorless. Do not handle or discharge in an enclosed area, or in
any area where the vapor or liquid can come in contact with naked flame or hot metal.
R134a is non- flammable, but can form a highly toxic gas so always work in a well-
ventilated area.

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
1540 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Do not smoke or weld in areas where R134a is in use. Inhalation of concentrations of the
vapor can cause dizziness, disorientation, narcosis, nausea or vomiting.
4. Do not allow fluids other than R134a or compressor lubricant to enter the air conditioning
system this may lead to spontaneous combustion.
5. Avoid contact with liquid refrigerant R134a. At atmospheric pressure R134a evaporates
at approximately -26ºC and causes frost bite. In the event of skin or eye contact with
liquid refrigerant, wash the affected areas immediately with plenty of water. Seek medical
treatment immediately.
6. The refrigerant used in an air conditioning system must be reclaimed in accordance with
the recommendations given along with the refrigerant recovery recycling recharging
station.
7. Do not weld or steam clean on or near any air conditioning components when
pressurized. This may cause a dangerous pressure build up in the system.
8. When purging a system, discharge the refrigerant slowly.
9. Refrigerant cylinders should always be protected from the radiant heat of the sun and
kept in a cool place.
10. Never discharge a system or do brazing / welding/ operation when the main engine is
ON.
11. Do not drop, dent or abuse refrigerant gas cylinders.
12. Always chain or strap cylinders in place to prevent them from tripping over.
13. Always keep refrigerant cylinders capped.
14. Never heat a cylinder with open flame or place it in direct contact with an electric heater.
15. Always double check that you have the correct refrigerant container. The refrigerant
cylinders are color coded to avoid confusion. (R 134a is generally BLUE)
16. Use proper size spanners, wrenches to avoid damages to valve & threads.
17. Make sure that tools, measuring equipment and replacement parts are clean and dry.
18. Never use oxygen for pressure testing a system. It may explode in presence of oil.
Instead use nitrogen from a cylinder equipped with proper pressure regulator.
19. When filling a refrigerant cylinder, never completely fill it. Always leave space for
expansion. If the cylinder was completely filled and the temperatures increases, the
hydraulic pressure with its tremendous force would result to cylinder bursting accidents.
One of the most important requirements when filling the air conditioning system is to use clean
refrigerant. Any foreign substances – including air, moisture and dirt - in the air conditioning
circuit influence temperature and pressure of the system. This will have an adverse effect on
the operation of the system. In addition, these foreign substances can cause defects such as
failure of the compressor due to excessive wear.
First aid measures
• In case refrigerant is inhaled, move to fresh air. Get immediate medical attention. Artificial
respiration and/or oxygen may be necessary.
• If refrigerant comes in contact with skin, take off all contaminated clothing immediately.
Flush skin with lukewarm water until all chemical is removed. Do not use hot water. If there
is evidence of frostbite, do not rub and never use hot water. If water is not available, cover
with a clean, soft cloth or similar covering. Get immediate medical attention.

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 1541
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• If refrigerant vapors come in contact of eyes, hold eyelids apart and flush eyes with plenty of
water for at least 15 minutes. If there is evidence of frostbite, water should be lukewarm, not
hot. Get immediate medical attention. Precautions to be taken while servicing HVAC system
• Only trained and certified person should service the HVAC system, if repair involves
refrigerant handling.
• Ensure that the refrigerant handling equipment and accessories are compatible with R134a.
• While recovering, recycling or recharging refrigerant always follow the instructions of
refrigerant handling equipment manufacturer.
• In case leakage is detected from the HVAC system, repair should be done only after
recovering all the refrigerant from the system.
• For purging the system only Nitrogen should be used. Compressed air should never be
used, which will produce flammable mixture.
• Keep moisture and dirt out of the HVAC system and refrigerant handling equipment’s/
fittings. When disconnecting any system components, plug or cap the fittings immediately.
Do not remove the caps or plugs until just before you reassemble the component.
Absorption of moisture and dirt will adversely affect system working and cabin cooling
performance.
• Immediately after using the oil, reinstall the cap on the container, and seal it to avoid
moisture absorption.
• Before connecting any hose or line, always apply few drops of refrigerant oil to the O-ring.
However prevent oil from coming in contact with threaded joints, else joint may get loosen
afterwards.
• Do not spill the refrigerant and oil on the vehicle. It may damage the paint. If it gets on the
paint, wash it OFF immediately.
• Care must be taken while handling the refrigeration system components. Hoses and lines
should not be twisted or stressed. Ensure that hoses are positioned in their correct run
before fully tightening the joints. Torque wrenches must be used while tightening refrigerant
connections to specified value.
• Do not operate compressor without enough refrigerant and oil in the system, otherwise
compressor may burnout.
• When the engine is running, never discharge the refrigerant system, which may damage
both compressor and refrigerant handling equipment.
• When discharging the system, do not let refrigerant escape too fast. It may draw lot of the
refrigerant oil out of the system.
Refrigerant Oil Replacement
The Polyalkylene glycol (PAG) oil is used as refrigerant oil. The PAG oil in the compressor
circulates through the A/C system with the refrigerant. The PAG oil is added to the compressor
when replacing any component or after large refrigerant leakage has occurred.

Lack of oil in the compressor leads to compressor seizing. Excessive oil in the
compressor may cause inadequate cooling.

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
1542 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Since PAG oil is highly hygroscopic (moisture absorbent) in nature, open the PAG oil
containers only when they are ready to use and cover the containers with the cap
immediately after usage.

Avoid PAG oil contacting the bare skin or vehicle body. It is toxic and corrosive in
nature.

Mixing different types or different manufacturers oil may form a glue like substance
which causes failure of lubrication and seizure of the compressor.
Only pale yellow color PAG oil must be used when adding or changing the PAG oil. This PAG
oil is not compatible with any other PAG oil. It is not necessary to regularly check the oil level in
the system. It should be remembered that the PAG oil gets circulated within the whole system.
Therefore, whenever the AC system component is replaced a certain quantity of new
refrigerant oil must be added to the system.
If there is a major loss of system oil, due to
• A broken hose or leak.
• Collision damage. In this case ensure following:
1. Recover refrigerant from the A/C system and remove the compressor.
2. Carefully drain the refrigerant oil.
3. Using R134a refrigerant, flush the remaining oil from the A/C system.
4. Add recommended quantity of new refrigerant oil to the compressor.
5. Replace the suction and discharge O-rings if damaged.
6. Install the compressor.
7. Evacuate and recharge the A/C system.

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 1543
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4.2 Refrigerant Recovery Recycling and Recharging

The charging procedure comprises of the following distinct steps
• Discharging the system.
• Evacuation of the system and checking for low vacuum leak.
• Purging – if required.
• Preliminary charging & High Pressure leak test.
• Charging the system.

19.4.3 Discharging the system

Avoid discharging the refrigerant in an enclosed area, or in any area where the vapour
or liquid may contact naked flame or hot metal. R134a is not flammable, but can form
highly toxic gas.

Do not smoke or weld in areas where R134a is in use. Inhalation of concentrations of

the vapour can cause dizziness, disorientation, narcosis, nausea or vomiting.
The following procedure is recommended for evacuation.
1. Connect the hose of Recovery unit to the vehicle circuit. Red hose to the high pressure
Charging port. Blue hose the low pressure charging port.
2. Open the quick coupler valves on the hose after they are connected to the system.
3. Check the manifold gauges the units control pane. They should register above zero. If it
is indicating zero then either the hose is not connected properly/or/quick coupler valves
are not opened or the system is empty.
4. Make sure that the drain valve at the bottom is closed.
5. Open both the manifold valves on the control panel.

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
1544 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Open the Gas (vapour valve and liquid valve on the tank).
7. Switch on the power.
8. Choose Recover option from the panel.
9. To assure that the complete recovery of the refrigerant. Wait for 5 minutes and watch the
manifold gauges for a rise above zero.
10. If a rise occurs, press HOLD/CONT. repeat until the system pressure hold for at least 2
minutes
11. The system displays the weight of the refrigerant recovered.
12. Confirm that the oil catch bottle is empty. Then slowly open the drain valve and allow the
oil to be drained into the bottle. When all the oil has been recovered, close the valve
immediately. New clean oil must be added to system before recharging with the
refrigerant.
13. The automatic recovery unit will operate until the air conditioning system has been
emptied of refrigerant down to atmospheric pressure. The cylinder can now be closed.

19.4.4 Evacuation of the system

1. The evacuation and leak test ensues that the system does not leak under low-pressure
conditions.
2. Ensure that the hoses are connected to the charging ports and valves on the hoses.
Tank & manifold are open.
3. Choose vacuuming program (Shift/Reset option) from the control panel.
4. Set up the vacuuming time in minutes. Approximately 15 minutes of vacuuming time is
recommended.

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 1545
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. The unit displays the complete message after the vacuuming is over.
6. Check the moisture indicator. If it is green, it means that the system is ready for
recharging. If it is not green then manual recycling has to be done for one hour. In case
the moisture indicator still does not turn green, the reason could be saturated receiver
drier. It should be replaced.
7. The charging station is equipped with recycling facility. During evacuation the refrigerant
is automatically recycled to assure recharging with the cleanest possible refrigerant.
Recycling begins automatically after 5 second of the vacuum pump starting. Non
condensable gases (mostly air) are automatically vented from the tank.
8. The system must hold the vacuum of –100 Kpa for a minimum of 15 minutes. If vacuum
is held then the system has no and should be evacuated for further 15 minutes This
completes the evacuation process.

19.4.5 Purging – if required

Where the system has been ruptured, contaminated, or a compressor has to be removed,
Reinstalled or replaced, the system should be checked for contamination, and if so then the
entire system must be flushed.
The system can be flushed with Nitrogen.

19.4.6 Preliminary Charging and High Pressure Leak Test

This ensures that the system does not leak under high pressure conditions.
1. Confirm that the hoses are connected to the charging ports and valves on the hose, Tank
& manifold are open
2. Enter the refrigerant quantity by weight and press ENTER. (At least 200 grams of charge
are required to do the high] pressure leakage test).
3. Press CHG to start charging. The unit displays the completed message after the
charging is completed.
4. Use the electronic leak detector to probe the leakages. Leakage checking to be done at
the following points
• Expansion valve joints
• All pipe joints
• Suction & discharge ports
• Both the charging ports

Inspect for leaks by slowly moving the probe of the detector around all the hose
connections and points of possible leakages. The R134a is heavier than air; hence, any
leakage will be more apparent at the bottom of fitting.

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
1546 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4.7 Charging the System

1. If no leaks are found then do charging as per the recommended quantity.
2. However in case of leakage, the system should be discharged. After that repeat, the
steps from evacuation onwards till the above steps. Then proceed.
3. In case the system was checked for High pressure leaks by using Nitrogen, Evacuation
should done first and then system should be directly charged.
4. Close both the manifold valves and then start the vehicle.
5. Start the vehicle’s AC system and set it to maximum cooling. Check the pressure gauges
and temperatures in the vehicle.
6. Turn off the engine.
7. Disconnect the high side hose and start the vehicle. Open both the manifold valves to
pull the refrigerant from both the hoses into the system.
8. At the lowest operating pressure close the low side valve and switch off the vehicle.
Disconnect the low side hose and remove adapters if used.
9. Close the high side manifold valve. Both the valves should now be in closed position.

• Do not start the engine when the valve on the manifold and tank are open.
• Ensure that the valves are closed before starting the engine.
• Never run the compressor without the refrigerant in the system as the lubricant
relies on the refrigerant flow.
Accurate system refrigerant charge can only be determined by charging the correct amount of
R134a.
If in doubt as to gas charge, e.g.
Suction pressure low
Or
Discharge pressure low
Or
Air outlet temperature at the face high.
Then: Evacuate the system and recharge
Carry out cooling system pressure test and suction (low side) pressure reading comparison.

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 1547
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4.8 Contaminated Refrigerant Handling

Any contaminated R134a refrigerant should be extracted only by a suitable servicing

Unit designed for the purpose of collecting and storing contaminated refrigerant.
1. If the A/C system is damaged, or the compressor is removed, reinstalled or replaced, the
A/C system should be checked for contamination of oil, if so the entire system must be
flushed with refrigerant R134a.

To avoid possible internal damage avoid flushing the compressor.

2. Recover/recycle the flushing refrigerant. The recovery device will remove contaminants
through the filtering system.

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
1548 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4.9 HVAC Filter R&R

19.4.9.1 HVAC Filter Removal Procedure

Tools Required

Size Type Quantity

- Small flat end screw driver 01

19.4.9.1.2 Removal

1. Position the vehicle on a flat surface and 4. Gently slide and remove the filter cover.
open the front co-driver door.

2. Pull the lock and open the glove box.

5. Pull-out and remove the HVAC particle

filter.

3. Using a small flat end screw driver,

gently pull-out and detach the locks on either
sides of the glove box.

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 1549
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4.9.3 Inspection:
1. Inspect the actuator for mechanical damage.
2. Check and clean the connector pins for sulphation and deposits.

19.4.9.4 Installation:

1. Insert the New HVAC particle filter. 3. Engage the glove box assembly locks.

2. Refit the filter cover. 4. Close the glove box.

• While installing the filters take sufficient care to prevent bent, damage etc.

• Use only genuine filter element.

• Never clean and reuse the filter element
• HVAC particle filter need to be replaced first at 20,000 kms/12 Months and then every
20,000 kms/12 Months. (Distance covered in kms / months in service whichever is
earlier.)

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
1550 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.4.10 HVAC System Do’s & Dont’s

Sl .NO DO’S DO’S

Clean the condenser during regular service of Dirty and clogged condenser
1. the vehicle. results in HVAC tripping and
Inefficient cooling.

Maintain the proper refrigerant level. Low refrigerant level results in

inefficient cooling. Excessive
2. refrigerant results in HVAC
tripping and again inefficient
cooling.

Add recommended oil quantity in the Adequate quantity of the

compressor during refrigerant charging. compressor oil prevents poor
3. pumping and premature
wearing of internal components.

Clean the evaporator periodically to remove Clogged evaporator results in

4. dust and foreign particles. less air flow and reduced
cooling.

Check coolant level. To prevent overheating of the

5. engine.

Check for proper belt tension. Loose belt will slip and over
tightened belt will result in noise
6. and premature failure of
compressor clutch of the A/C
compressor.

Do not operate HVAC Without refrigerant. This will result in premature

7. failure of the compressor.

Do not leave HVAC joints open. Moisture tends to enter the

8. HVAC system if the joints
remain open for a long time.

Do not charge the refrigerant in the HVAC Improper evacuation in the

9. system unless proper evacuation is carried HVAC system results in
out. improper cooling conditions.

Do not by pass/short pressure switch. It may seize the compressor if

10. pressure goes above 32 bars

Do not by pass/short the thermo sensor. Formation of ice in the

evaporator liquid return line to
11. compressor and it may cause
compressor to seize.

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 1551
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5 In Car Repairs

19.5.1 HVAC Unit R&R

19.5.1.1 Component Location Index

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
1552 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post/ 4 post lift. • Refit the CCB & Instrument panel
Assembly.
• Remove the Instrument panel & CCB
Assembly. • Recharge the refrigerant.
• Recover the refrigerant. • Check and ensure the proper functioning
of HVAC system.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

13 mm Socket spanner 01

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 1553
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.1.3 Removal

1. Recover the A/C gas. For additional 6. Using 13 mm socket spanner, remove
information refer to Refrigerant recovery Evaporator unit top & bottom mounting nuts.
recycling and recharging section.

2. Remove the IP assembly. For additional

information refer to IP R&R section.

3. Remove the CCB assembly. For

additional information refer to CCB R&R
section.

4. Using a 10 mm deep socket spanner

remove the mounting nut and detach HVAC
Liquid and suction tube.

7. Using 10 mm socket spanner, remove

Evaporator unit top mounting bolts.

5. Press the lock and disconnect heater

hoses.

8. Gently detach and remove the HVAC

assembly from vehicle.

19.5.1.4 Inspection:
1. Inspect the HVAC assembly for any physical damages. Repair if found.
2. Inspect the kinematics for proper functioning.
3. Inspect the filter element and clean if required.

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
1554 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.1.5 Installation:

1. Position the HVAC assembly. 5. Connect suction and liquid hose with
expansion value using mounting nut. Torque
2. Refit the Evaporator unit top mounting tighten the nut to specified value.
bolts and torque tighten to specified value.

6. Refit the CCB assembly. For additional

3. Refit the Evaporator unit top & bottom information refer to CCB R&R section.
mounting nuts and torque tighten to specified
value. 7. Refit the IP assembly. For additional
information refer to IP R&R section.

8. Top-up the coolant. For additional

information refer to Coolant filling and de-
aeration section.

9. Recharge the Refrigerant. For additional

information refer to Refrigerant recovery
recycling and recharging section.

10. Start the engine, check the coolant

level. Refill if required.

4. Refit the heater hoses. 11. Check the coolant leak when engine is
started.

12. Check the A/C system cooling and

operation.

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 1555
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.2 Temperature Actuator R&R

19.5.2.1 Component Location Index

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
1556 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Remove the Instrument panel & CCB • Refit the CCB & Instrument panel
Assembly. Assembly.
• Check and ensure the proper functioning
of HVAC system.

3
Removal steps:
1. Remove the mounting screws
2. Disconnect the electrical connectors.
3. Remove the actuator.
Tools Required

Size Type Quantity

- T20 01

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 1557
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.2.3 Removal:

1. Remove the IP assembly. For additional

information refer to IP R&R section.

2. Remove the CCB assembly. For

additional information refer to CCB R&R
section.

3. Remove the temperature actuator

mounting screws using a T20 spanner.

4. Press the lock and disconnect the

electrical connector and separately detach
the actuator from HVAC unit.

19.5.2.4 Inspection:
1. Inspect the actuator for mechanical damage.
2. Check and clean the connector pins for sulphation and deposits.

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
1558 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.2.5 Installation:

1. Connect the electrical connector to the

temperature actuator.

2. Refit the actuator and tighten the

mounting screws.

3. Refit the CCB assembly. For additional

information refer to CCB R&R section.

4. Refit the IP assembly. For additional

information refer to IP R&R section.

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 1559
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.3 Heater Coil R&R

19.5.3.1 Component Location Index

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
1560 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post/ 4 post lift. • Refit CCB & IP assembly.
• Remove IP & CCB assembly. • Check and ensure proper functioning of
HVAC system.

Removal steps:
1. Remove the Bracket.
2. Remove the lock & disconnect the heater pipe.
3. Remove the Heater coil mounting screws.
4. Remove the Heater coil.
Tools Required

Size Type Quantity

- T20 01

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 1561
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.3.3 Removal:

1. Remove the IP assembly. For additional 5. Using the T20 spanner, remove the
information refer to IP R&R section. heater coil mounting screws.

2. Remove the CCB assembly. For

additional information refer to CCB R&R
section.

3. Loosen the bracket mounting screw and

remove the heater coil bracket.

6. Separately detach the heater coil from

HVAC unit.

4. Remove the lock and detach the heater

inlet and outlet pipe.

19.5.3.4 Inspection:
1. Inspect the heater coil for any damage. Replace if found.
2. Inspect the heater coil for free flow. If found any obstruction repair/clean or replace.
3. Inspect the heater coil for any foreign particles. Clean if found.

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
1562 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.3.5 Installation:

1. Refit the heater coil into HVAC unit and 3. Refit the heater coil bracket and tighten
tighten the heater coil mounting screws. the mounting screw.

4. Refit the CCB assembly. For additional

information refer to CCB R&R section..

5. Refit the IP assembly. For additional

information refer to IP R&R section.

2. Attach the heater inlet and outlet pipe

and refit the lock.

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 1563
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.4 Mode Actuator R&R

19.5.4.1 Component Location Index

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
1564 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Remove the Instrument panel & CCB • Refit the CCB & Instrument panel
assembly. assembly.
• Check and ensure the proper functioning
of HVAC unit.

Removal steps:
1. Disconnect the Electrical connectors.
2. Remove the mounting screws.
3. Remove the Actuator
Tools Required

Size Type Quantity

- T20 01

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 1565
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.4.3 Removal:

1. Remove the IP assembly. For additional

information refer to IP R&R section.

2. Remove the CCB assembly. For

additional information refer to CCB R&R
section.

3. Remove the mode actuator mounting

screws using T20 spanner and detach the
mode actuator from HVAC unit.

4. Press the lock and disconnect the

electrical connector.

19.5.4.4 Inspection:
1. Inspect the actuator for mechanical damage.
2. Check and clean the connector pins for sulphation and deposits.

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
1566 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.4.5 Installation:

1. Connect the electrical connector to the

mode actuator.

2. Refit the mode actuator in to HVAC unit

and tighten the mounting screws.

3. Refit the CCB assembly. For additional

information refer to CCB R&R section.

4. Refit the IP assembly. For additional

information refer to IP R&R section.

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 1567
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.5 Fresh/Recirculation Actuator R&R

19.5.5.1 Component Location Index

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
1568 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.5.2 Removal & Assembly Summary

Pre Removal Post Installation

• Remove the Instrument panel • Refit the HVAC unit.

• Remove the Cross Car Beam. • Refit the Cross car beam
• Remove the HVAC unit. • Refit the instrument panel.

Removal steps:
1. Disconnect the electrical connectors.
2. Remove the mounting screws
3. Remove the Actuator.
Tools Required

Size Type Quantity

- Star screw driver 01

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 1569
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.5.3 Removal:

1. Remove the IP assembly. For additional 5. Press the lock and disconnect the
information refer to IP R&R section. electrical connector and unscrew the three
mounting screws and detach the fresh/
2. Remove the CCB assembly. For recirculation actuator from the HVAC unit.
additional information refer to CCB R&R
section.

3. Remove the HVAC unit R&R. For

additional information refer to HVAC unit
R&R section.

4. Detach the blower control unit

separately.

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
1570 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.5.4 Installation:

1. Refit the fresh/recirculation actuator and 5. Refit the IP assembly. For additional
connect the electrical connector and tighten information refer to IP R&R section.
the mounting screws.

2. Refit the blower unit in to the HVAC unit.

3. Refit the HVAC unit R&R. For additional

information refer to HVAC unit R&R section.

4. Refit the CCB assembly. For additional

information refer to CCB R&R section.

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 1571
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.6 Blower Motor R&R

19.5.6.1 Component Location Index

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
1572 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.6.2 Removal & Assembly Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure the proper functioning
of HVAC unit.

Removal steps:
1. Disconnect the electrical connector.
2. Remove the blower motor mounting screws.
3. Remove the blower motor.
Tools Required

Size Type Quantity

- Star screw driver 01

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 1573
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.6.3 Removal:

1. Press the lock and disconnect the blower

motor electrical connector.

2. Remove the blower motor mounting

screws using star screw driver.

3. Separately detach the blower motor from

HVAC unit.

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
1574 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.6.4 Inspection
1. Hand rotate the blower motor and check for any noise due to bearing wear.
2. Check the blower motor fan blade for damage. Replace the blower motor if necessary.

19.5.6.5 Installation:

1. Refit the blower motor into the blower 3. Connect the electrical connector in to the
unit. blower motor.

2. Tighten the blower motor mounting

screws .

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 1575
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.7 Field Effect Transistor (FET) R&R

19.5.7.1 Component Location Index

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
1576 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.7.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
the HVAC Unit.

Removal steps:
1. Disconnect the electrical connector.
2. Remove the FET mounting screws.
3. Remove the FET.
Tools Required

Size Type Quantity

- Star screw driver 01

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 1577
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.7.3 Removal:

1. Disconnect the electrical connector.

2. Using star screw driver loosen and

remove the transistor mounting screws.

3. Remove the terminating transistor.

19.5.7.4 Inspection
1. Visually check the transistor electrical connector. Replace the transistor if necessary.

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
1578 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.7.5 Installation:

1. Align and refit the transistor mounting

screws.

2. Connect the electrical connector.

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 1579
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.8 Blower Resistor R&R

19.5.8.1 Component Location Index

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
1580 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.8.2 Removal & Assembly Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
the blower motor.

Removal steps:
1. Disconnect the electrical connector.
2. Remove the mounting screws.
3. Remove the blower resister.
Tools Required

Size Type Quantity

- Star screw driver 01

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 1581
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.8.3 Removal:

1. Press the lock and disconnect the blower

resister electrical connector.

2. Remove the blower motor mounting

screws using star screw driver.

3. Separately detach the blower resister

from blower control unit.

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
1582 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.8.4 Inspection
1. Visually check the blower resistor electrical connector. Replace the blower resistor if
necessary.

19.5.8.5 Installation:

1. Refit the blower resister into the blower 3. Connect the electrical connector in to the
unit. blower resister.

2. Tighten the blower resister mounting

screws using star screw driver.

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 1583
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.9 Water Drain Hose R&R

19.5.9.1 Component Location Index

19.5.9.2 Removal & Assembly Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
HVAC system.

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
1584 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.9.3 Removal:

1. Remove the HVAC unit water drain hose

which is located in bottom of the HVAC unit

2. Remove the HVAC unit water drain hose

From bottom of the HVAC unit and remove
the hose separately.

19.5.9.4 Inspection
1. Check the water drain hose for damaged. Replace if necessary.

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 1585
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.9.5 Installation:

1. Insert and fix the water drain hose into

the HVAC unit.

2. Insert the other end of the hose in to the

vehicle floor.

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
1586 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.10 Evaporator R&R

19.5.10.1 Component Location Index

19.5.10.2 Removal & Assembly Summary

Pre Removal Post Installation

• position the vehicle on a 2 post/ 4 post lift. • Refit the HVAC assembly.
• Remove IP & CCB assembly. • Refit CCB & IP assembly.
• Recover the refrigerant. • Recharge the refrigerant.
• Remove the HVAC assembly. • Check and ensure proper functioning of
HVAC system.

Tools Required

Size Type Quantity

- Star screw driver 01

- T20 01

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 1587
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.10.3 Removal:

1. Unlock the HVAC unit top housing 4. Separately detach the top housing unit.
mounting clips.

5. Remove the evaporator from HVAC unit.

2. Remove the top housing mounting
screws front side using star screw driver.

3. Remove the top housing mounting

screws rear side using star screw driver.

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
1588 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.10.4 Inspection
1. Inspect the evaporator coil for any damage. Replace if found.
2. Inspect the evaporator coil for free flow. If found any obstruction repair/clean or replace.
3. Inspect the evaporator coil for any foreign particles. Clean if found.

19.5.10.5 Installation:

1. Refit the evaporator in to the HVAC 3. Tighten the top cover mounting screws
housing. front side using star screw driver.

2. Refit the top mounting cover. 4. Tighten the top cover mounting screws
rear side using star screw driver.

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 1589
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Lock the clip and gently press it

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
1590 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.11 Expansion Valve R&R

19.5.11.1 Component Location Index

19.5.11.2 Removal & Assembly Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Recharge the refrigerant.

• Recover the refrigerant. • Check and ensure proper functioning of
HVAC system.

Tools Required

Size Type Quantity

10 mm Deep socket spanner 01

4 mm Allen key 01

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 1591
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.11.3 Removal:

1. Disconnect the negative terminal of 4. Remove the mounting screws on the

battery using 10 mm ring/socket spanner. expansion valve safety cover and detach the
safety cover from the expansion valve.

2. Recover the A/C Gas. For additional

information refer to Refrigerant Recovery 5. Using Allen key remove the expansion
Recycling and Recharging section. valve mounting bolts.

3. Remove the hose mounting bolts fitted

on the expansion valve and detach the
hoses.

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
1592 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Separately detach the expansion valve

from high and low pressure pipes.

Protect the high and low pressure hoses

and expansion valve using suitable
cover, to avoid contamination and
moisture entry.

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 1593
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.11.4 Installation:

1. Refit the expansion valve in to high and 4. Refit the hoses in to the expansion valve
low pressure pipes. and torque tighten the mounting nuts to
specified value.

2. Tighten the expansion valve mounting

bolt using Allen key. 5. Connect battery negative terminal back.

3. Refit the expansion valve safety cover 6. Recharge the A/C Gas. For additional
and tighten the mounting screws. information refer to Refrigerant Recovery
Recycling and Recharging section.

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
1594 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.12 AC Compressor R&R

19.5.12.1 Component Location Index

19.5.12.2 Removal & Assembly Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Refit AC Compressor/Water pump drive

• Recover the refrigerant (A/C Gas). belt.
• Recharge the refrigerant (A/C Gas).
• Remove AC Compressor/Water pump
drive belt. • Check and ensure proper functioning of
HVAC system.

Tools Required

Size Type Quantity

12 mm Socket spanner 01

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 1595
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.12.3 Removal:

1. Remove the Accessory drive belt. For 4. Disconnect the electrical connector and
additional information refer to Auto tensioner remove the mounting bolts and separately
& belt (Alternator/Power Steering) - Replace) detach the AC Compressor from engine.

2. Recover the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section.

3. Remove the high pressure and low

pressure hose fitted on the AC Compressor.

Cover the high and low pressure hoses

with dust caps to avoid entry of air and
Contamination of the refrigerant.

Cover the high and low pressure ports in

the Compressor before removing from
the vehicle to avoid spilling of PAG oil.

Cover the high and low pressure ports in

the compressor with dust caps to avoid
entry of air and contamination of the
refrigerant.

19.5.12.4 Inspection
1. Inspect the compressor for any physical damage.
2. Inspect the clutch pulley for any damage.
3. Inspect the drive belt for any damage.
4. Inspect the connector for any damage.

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
1596 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.12.5 Installation:

1. Refit the AC Compressor and torque

tighten the mounting bolts to specified value.

During installation, fix the new O-ring

into the compressor without any
damage. Damage to the O-ring may
cause A/C refrigerant leakage which
leads to A/C failure.

2. Refit the high and low pressure hoses in

to the AC compressor and connect the
electrical connector.

3. Refit the Accessory drive belt. For

additional information refer to Auto tensioner
& belt (Alternator/Power Steering) - Replace)

4. Recharge the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section

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 1597
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.13 AC Condenser R&R

19.5.13.1 Component Location Index

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
1598 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.13.2 Removal & Assembly Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Recharge the refrigerant (A/C Gas).
• Recover the refrigerant (A/C Gas). • Refit the front bumper with mounting
• Remove the front bumper. bracket.
• Check and ensure proper functioning of
HVAC system.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

13 mm Socket spanner 01

- Flat screw driver 01

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 1599
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.13.3 Removal:

1. Remove the degassing tank. For 6. Remove the mounting nut and detach
additional information refer to degassing tank the two hoses fitted on condenser.
R&R section.

2. Recover the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section.

3. Remove the front bumper. For additional

information refer to Front bumper R&R
section.

4. Remove condenser top cover mounting

bolts using a 10 mm socket spanner and
mounting buttons using star screw driver and
then remove condenser top cover.
7. Remove the condenser assy. mounting
bolts from LHS and RHS.

5. Remove the radiator bracket mounting

bolt.
8. Pull out the condenser assy and
separately detach it.

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
1600 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.13.4 Inspection:
1. Inspect the condenser for any physical damage, leakages etc. Replace if found any.
2. Inspect for any foreign materials on condenser. Clean if found.
3. Check and ensure free flow of condenser.

19.5.13.5 Installation:

1. Gently insert the condenser assembly, 3. Refit the hose in to the condenser
lock the condenser assembly with radiator. assembly and tighten the mounting nut to
specified value.

2. Insert the condenser assembly mounting

bolts and tighten to specified value. 4. Refit the radiator bracket and tighten the
mounting bolt to specified value.

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 1601
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Place condenser top cover in its position

and fasten it with the help of mounting bolts
and buttons. Torque tighten the bolts to
specified torque value.

6. Recharge the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section.

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
1602 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.14 AC High Pressure Hose (Compressor to Condenser) R&R

19.5.14.1 Component Location Index

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 1603
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.14.2 Removal & Assembly Summary

Pre Removal Post Installation

• Recover the AC Refrigerant. • Recharge the Refrigerant.

Removal steps:
1. Remove the mounting nut from compressor.
2. Remove the mounting nut from condenser.
3. Remove the high pressure hose.
Tools Required

Size Type Quantity

- Star screw driver 01

- Flat End Screw Driver 01

10 mm Socket spanner 01

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
1604 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.14.3 Removal:

Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling
equipment to capture the refrigerant whenever the air conditioning System is
discharged.

Always wear eye and hand protection (goggles and gloves) when working with any
Refrigerant or air conditioning system.

Close the high pressure and low pressure refrigerant lines with dust caps to avoid air
entry and/or contamination.

1. Recover the A/C Gas. For additional 3. Remove the high pressure hose
information refer to Refrigerant Recovery mounting nut and remove the high pressure
Recycling and Recharging section. hose from the condenser.

2. Remove the high pressure hose

mounting nut fitted on AC Compressor and
detach the hose.

4. Remove the high pressure hose

separately.

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 1605
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.14.4 Installation:

1. Refit the high pressure hose in to

condenser and tighten the mounting nut.

2. Refit the high pressure hose in to

compressor and tighten the mounting nut.

3. Recharge the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section.

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
1606 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.15 AC High Pressure Hose (Expansion Valve to Compressor) R&R

19.5.15.1 Component Location Index

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 1607
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.15.2 Removal & Assembly Summary

Pre Removal Post Installation

• Recover the AC Refrigerant. • Recharge the Refrigerant.

Removal steps:
1. Remove the mounting nut from Expansion Valve.
2. Remove the mounting nut from compressor.
3. Remove the high pressure hose.
Tools Required

Size Type Quantity

10 mm Socket spanner 01

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
1608 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.15.3 Removal:

Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling
equipment to capture the refrigerant whenever the air conditioning System is
discharged.

Always wear eye and hand protection (goggles and gloves) when working with any
Refrigerant or air conditioning system.

Close the high pressure and low pressure refrigerant lines with dust caps to avoid air
entry and/or contamination.

1. Recover the A/C Gas. For additional 3. Remove the high pressure hose
information refer to Refrigerant Recovery mounting nut and remove the high pressure
Recycling and Recharging section. hose from the compressor.

2. Loosen the high pressure hose mounting

nut and remove the high pressure hose from
the expansion valve.

4. Remove the high pressure hose

separately.

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 1609
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.5.15.4 Installation:

1. Refit the high pressure hose in to

compressor and tighten the mounting nut.

2. Refit the high pressure hose in to

expansion valve and tighten the mounting
nut.

3. Recharge the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section.

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
1610 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.6 Technical Specifications

Description Specification

Compressor

Type Piston

No. Of Cylinders 7

Displacement 130

Condenser

Type Tube and fin

Refrigerant

Type R134a

Quantity 650 ± 20 gms

Boiling Point - 26.1°C

Auto-Ignition Temperature 770°C

Ozone Depletion Level 0

Solubility In Water 0.11% by weight at 25°C

Critical Temperature 252°F or 122°C

Compressor Oil

Type SP10

Quantity 130 ml

Filter Element

Type Particle paper filter

Blower Motor

Rated Voltage 12 V

Rated [email protected] 3650 ± 300 RPM

Outer Diameter 147.1 mm

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 1611
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Description Specification

Heater Core

Type Tube and fin

Make Mahle Behr

Expansion Valve

Type Box Type

Compressor Clutch

Rated Voltage 12 V

Pulley Diameter 132 mm

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
1612 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19.7 Tightening Specifications & Sequence

Descriptions Torque Nm

HVAC MOUNTING 7±1

CONDENSER TOP MOUNTING 6±1

BOLT BRACE COMPRESSOR 35 ± 5

BOLT COMPRESSOR BRACKET 35 ± 5

BOLT AND NUT - COMPRESSOR AND 35 ± 5

BRACKET

BOLT AND NUT – BRACE AND 35 ± 5

COMPRESSOR

BOLT AC COMPRESSOR 35 ± 5

AC PIPES (SUCTION & DISCHARGE) 15±3

HEATER HOSE CLIP TIGHTNING 5±1

AC PIPE IT. ON RD BOTTLE 15 ± 2

AC PIPE CONN. ON EXPANSION VALVE 7±2

AC PIPE FROM COMPRESSOR TO 15 ± 2

CONDESOR

BOTTOM SEAL CONDENSOR PLATE 6±2

AC PIPE HOSE CLAMP MTG. 3 ± 0.5

RECOVERY TANK FIT/ TOP SEAL 5.5 ± 1

CONDENSOR

SEAL CONDENSOR BOTTOM 8±2

AC PIPE SUCTION/DISCHARGE 6±1

CONDENSER STUD/NUT

RD BOTTLE TO EVAPORATOR 15 ± 2
CONNECTION

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 1613
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1614 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20 RESTRAINT SYSTEM

20.1 Description and Operation

Occupant restraints are provided in a vehicle to protect the occupants in case of collision.
Restraints system consists of:
1. Seat belts which are designed for controlled occupant movement during an accident, this
reduces the risk of hard contacts with vehicle interiors.
2. Inflatable system with airbags and seat belt buckles and load limiters which are
designed to further enhance level of occupant protection in accidents.
MAHINDRA PIKUP is equipped with the following airbags:
1. A frontal airbag for the driver ( Located in steering wheel hub).
2. A frontal airbag for the front passenger (Located in passenger side instrument panel).
To minimize the risk of severe injury in the event of a crash, every passenger must always
wear their seat belt. The airbags inflate very quickly with great force. Do not position any part
of your body too close to a airbag, you or especially children could be seriously injured/killed
by a deploying airbag.

• All occupants, including the driver, should always wear their seat belts irrespective
of presence of airbags to minimize the risk of severe injury in the event of a crash.
• Airbags are more effective in reducing injuries when the seat belts are worn.
When an impact of sufficient force occurs, according to the input from crash sensor, the airbag
ECU sends an electrical signal to the airbag module which in turn rapidly ignites the energetic
material and inflates the airbag. The inflated airbag deploys out of steering wheel and
Instrument panel. As the entire deployment of airbag happens in less than a second, in
combination with seat belts, it slows down the driver’s or passengers forward motion, thus
reducing the risk of head and chest injury. The airbags deflate quickly through the ports in the
airbag cushion. Therefore airbag is not a substitute of seat belts. The Airbag can function only
when the ignition key is ‘ON’.

20.1.1 Driver and Passenger Airbag

The restraint system is designed to deploy the front airbags only when an impact which is
sufficiently severe to offer additional protection to the occupants.

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 1615
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

CORRECT SEAT BELT

CORRECT SEAT BELT
POSITIONING
POSITIONING

U3A170073 U3A170074

Front airbags are not intended to deploy in side-impact, rear impact or rollover crashes. In
addition, front airbags will not deploy in frontal crashes which are below the prescribed
deployment threshold where risk of serious injuries is low.

Do not place any objects over the airbag or between the airbag and passenger.

20.1.2 Airbag System Malfunction Lamp

The airbag system malfunction lamp

illuminates when the ignition is ON, and it
turns OFF after about two seconds as self
check confirming normal operations of airbag
system and malfunction lamp.

U3A170075

This SRS ECU monitors airbag modules, airbag sensor, indicator lamp, seat belt pre-tensioner
assemblies, interconnecting wiring and power sources.
If either of the following conditions occur, there is a malfunction of the airbags or seat belt pre-
tensioner.
• The lamp does not glow when the ignition is switched ON or glows beyond two (2) seconds
after switching the ignition ON.
• The lamp comes ON at any other time, even briefly.
• The lamp comes ON intermittently.

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
1616 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Never make any modifications to the vehicle which could affect the performance of
the airbag system. In particular, changes to the vehicle frame, bumpers, bull bar,
front fenders, ride height, suspension, seat belts, interior trim, seats or steering
wheel (especially covers, pads or other trim), could prevent proper deployment of
the airbag.
•

Never try to open or strike the airbag

cover. If the airbag cover is cracked or
damaged in any way, the airbag may not
function as intended.

CORRECT SEAT BELT

POSITIONING

U3A170078

• The driver or front passenger who is too close to the steering wheel or dashboard
can be seriously injured during airbag deployment.
• The front passenger must sit as far back as possible from the dashboard.
• Sitting improperly or out of position can cause occupants to be shifted too close to
a deploying airbag, strike the interior structure or be thrown from the vehicle
resulting in serious injury.

CORRECT SEAT BELT

POSITIONING

CORRECT SEAT BELT

POSITIONING

U3A170076 U3A170077

• Always sit upright with the seat back in an upright position, on the seat cushion
centre with the seat belt on, legs comfortably extended and the feet on the floor.
• All vehicle occupants must be properly restrained using the seat belts.
• All infants and children must be placed in the rear seat of the vehicle in a child
restraint seat and be properly restrained by seat belts.
• Front airbags can injure occupants improperly positioned in the front seats.

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 1617
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Even with airbags, improperly belted and un-belted occupants can be severely
injured when the airbag inflates.
• Do not modify the front seats. Modification of the front seats could interfere with the
operation of the restraint system.

20.1.3 Airbag Inflation/Deployment

The airbag sensors constantly monitor the forward deceleration of the vehicle. If an impact
results in a forward deceleration beyond the designed threshold level, the system triggers the
airbag inflators. This initiates a chemical reaction which quickly fills the airbags with non-toxic
gas.
Upon deployment, tear seams on the pad covers separate under pressure from the expansion
of the airbags. Further opening of the covers allows full inflation of the airbags. A fully inflated
airbag, in combination with a properly worn seat belt, slows the driver's or the passenger's
forward motion, reducing the risk of head and chest injury.
After complete inflation, the airbag immediately starts deflating.
Deployment of the airbags happen in a fraction of a second, producing a loud noise releasing
a ‘white smoke’ and residue along with a non-toxic gas. This does not indicate a fire. This
smoke may remain inside the vehicle for some time, and may cause some minor irritation to
the eyes, skin or breathing.

• Do not modify, remove, strike or open the seat belt pre-tensioner assemblies, airbag
sensor . Failure to follow these instructions may prevent them from activating
correctly, cause sudden operation of the system or disable the system, which could
result in serious injury.
• Do not cover the steering wheel, instrument panel with any object (e.g. dash panel
covers) which may prevent the airbags from inflating properly.
• The airbags inflate with considerable force. While the system is designed to reduce
serious injuries, primarily to the head and chest, it may also cause other, less severe
injuries to the face, chest, arms and hands. These are usually in the nature of minor
burns or abrasions and swelling, but the force of a deploying airbag can also cause
more serious injuries, especially if an occupant's hands, arms, chest or head is in
close proximity to the airbag module at the time of deployment. Sit straight and well
back into the seat. Move the seat as far back as practical to allow room for airbag
inflation, while still allowing the driver to properly operate/drive the vehicle.
• The front passenger should never sit on the edge of the seat, stand near the glove
compartment, rest feet or other parts of the body on the dashboard when the vehicle
is moving.

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
1618 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.4 Child Restraint and Airbag

Never place a rear-facing child restraint in

the front passenger’s seat. If the airbag
deploys, injuries to the child may be fatal.
In addition, do not place front-facing child
restraints in the front passenger’s seat either.
If the front passenger airbag inflates, it could
cause serious or fatal injuries to the child.

CORRECT SEAT BELT

POSITIONING
• Extreme Hazard! Do not use a rear
U3A170094 facing child restraint on a seat
protected by an airbag in front of it.
• Never put a child restraint in the front
passenger’s seat. If the front
passenger airbag inflates, it can cause
serious or fatal injuries.
• Never hold an infant or child on
passengers lap. The infant or child
could be seriously injured in the event
of a crash. All infants and children
should be properly restrained in
appropriate child safety seats or seat
belts in the rear seat.
• Install the child restraint system on
the rear outboard seats, and securely
lock the child restraint system in
position.
• Always Buckle Children (ABC) in the
back seat. It is the safest place for
children of any age to ride.

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 1619
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.5 Airbag Non-Deployment

20.1.5.1 Collision with Utility Poles or Trees

Air bags may not inflate if the vehicle collides

with objects such as utility poles or trees,
where the point of impact is concentrated to
one area and the full force of the impact is
not delivered to the sensors.

20.1.5.2 Under-ride Situations

Running under a truck's tail gate may not

provide the decelerations necessary for
airbag deployment. Just before impact,
drivers often brake heavily. Such heavy
braking lowers the front portion of the vehicle
causing it to “ride” under a vehicle with a
higher ground clearance. Air bags may not
inflate in this “under-ride” situation where
deceleration forces that are detected by
sensors may be significantly reduced by
such “under-ride” collisions.

20.1.5.3 Rear-end Collisions

Frontal air bags are not designed to inflate in

rear collisions, where occupants are moved
backward away from the airbags by the force
of the impact. In this case, inflated air bags
would not be able to provide any additional
benefit.

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
1620 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.5.4 Frontal Impact

Frontal impact beyond 30o range from head-

on to the vehicle will not deploy the airbags.

20.1.5.5 Pot Holes or Stepped Surfaces

Driving into a big pot-hole, stepped surface

or hitting the far side of a hole/incline will not
inflate the airbag.

20.1.5.6 Rollover

Front air bags may not inflate in rollover

accidents where air bag deployment would
not provide protection to the occupants.

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 1621
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.5.7 Frontal Side Swipe Impact

Frontal offset impact to the vehicle may not

provide the deceleration force necessary for
airbag deployment. In an angled collision, the
force of impact may direct the occupants in a
direction where the air bags would not be
able to provide any additional benefit, and
thus the sensors may not deploy any air
bags.

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
1622 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.6 Driver Airbag Module

The driver airbag module is located in the

steering wheel and its function is controlled
by the airbag ECU. A bag within the module
inflates to protect the driver in the event of a
collision severe enough to deploy the
system.
The driver airbag module connects to the
steering column wiring harness via a rotary
coupler called as clock spring. Within the
driver airbag module there is a squib which,
when given the correct current by the airbag
ECU, inflates the airbag by initiating a
chemical reaction. In deployment, the airbag
inflates within a fraction of a second and then
deflate at a controlled rate as the driver body
regions; typically head and chest interact
with airbag. Vents in the airbag control its
deflation

20.1.7 Passenger Airbag Module

The passenger airbag module is located on

LH side of Instrument panel, above the glove
box and its functioning is controlled by the
airbag ECU. A bag within the module inflates
to protect the passenger in the event of a
collision severe enough to deploy the
system.
Within the passenger airbag module is a
squib which, when given the correct current
by the airbag ECU, inflates the airbag by
initiating a chemical reaction. In deployment,
the airbag inflates within a fraction of a
second and then deflates at a controlled rate
as the passenger body regions; typically
head and chest interact with airbag. Vents in
the airbag control its deflation.

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 1623
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.8 Seat Belt Pre-tenioner / Load Limiter

Seat Belt Pre-tenioners

Seat belt pre-tensioner is a device installed
in vehicles to reduce slack that may exist in a
seat belt system at the moment of a frontal
collision. Having the seat belt system snug
allows the supplemental restraint airbag
system to work most effectively. A pre-
tensioner removes the unwanted slack in the
seat belt system and improves the coupling
of the occupant with the vehicle in the event
of a collision.
Load Limiter
Load limiters are provided to limit the seat
belt loads to a pre-defined value. The load
limiter fitted inside the retractor unit is
basically a torsion bar. Whenever the belt
load increases beyond the pre-defined limit,
some energy is dissipated through the seat
belt due to twisting of the torsion bar. The
activation of the load limiter does not depend
on signal from the airbag ECU.

20.1.9 Clock Spring

Clock spring is a spirally wound wire coil

mounted to steering column. It ensures most
reliable contact possible between air bag
module assembly and crash sensor. It also
provides the electrical continuity for airbag,
horn, and infotainment system.

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
1624 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.1.10 Front Crash Sensor

Front crash sensors are acceleration sensors

and are located one each on the RH and LH
side of the front end assembly of the body.
The crash is sensed by the deceleration rate.
Within the sensor, a freely moving object
gets deflected because sudden deceleration.
This in turn changes the system capacitance
which is compared with the capacitance of
the fixed electrodes.

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 1625
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.2 Component Location Index

A. Seat Belt Assembly Co-driver.

B. Second Row Seat Belt Assembly LH.
C. Second Row Twin Buckle Assembly.
D. Second Row Lap with Buckle Assembly.
E. Passenger Airbag Module.
F. Driver Airbag Module.
G. Airbag ECU.
H Driver Seat Belt.
I. Pre-Tensioner Assembly.
J. Second Row Seat Belt Assembly RH.
K. Seat Buckle Assembly Co-Driver Seat.
L. Seat Buckle Assembly Driver Seat.

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
1626 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.3 Care of the System

The restraint system contains components which could be potentially hazardous to the
technician if not serviced and handled correctly. The following guidelines are intended to alert
the technician to potential sources of danger and emphasize the importance of ensuring the
good condition of restraint components fitted to the vehicle.
• Always disconnect the battery first before carrying any operation on restraint components.
• Wait for at least ONE minute after disconnecting the battery before servicing the vehicle to
prevent accidental deployment and personal injury.
• The airbag modules contain extremely flammable components. Contact with water, acid or
heavy metals may produce harmful or explosive compounds. Do not dismantle burn or
bring into contact with electricity.
• Do not expose an airbag module or seat belt pre-tensioner to heat.
• The inflator is intended not to fire below the threshold current. To avoid inadvertent
triggering of the airbag, NEVER apply a current through the squib except with the specified
test equipment and procedures.
• Never dispose the airbag module undeployed without proper instructions as this may result
in possible injury. All deployments must follow special safety instructions. All units should be
activated (deployed) prior to disposal.
• The airbag modules or their components must not be adapted or installed in any other
vehicle other than the specific vehicle for which they are designed and manufactured. Any
attempt to adapt or install airbag modules or their components in any other vehicle can
result in personal injury to the occupants in the event of accidents.
• In order to assure system integrity, it is essential that the restraint system is regularly
checked and maintained so that it is ready for effective operation in the event of a collision.
Carefully inspect restraint components before installation. Do not install a part that shows
signs of being dropped or improperly handled, such as dents, cracks or deformation.
Dropped modules may get damaged.
• Ensure restraint components are not contaminated with oil, grease, detergent or water. It is
essential that restraint components are fitted using the recommended torques.
• Do not install used restraint components from another vehicle. When replacing restraint
parts, only use genuine Mahindra parts.
• It is essential that restraint components are fitted using the recommended torques. Always
use specified earth fixings tightened to the correct torque. Poor earthing can cause
intermittent problems that are difficult to diagnose.
• Do not allow the air bag module assemblies to come into contact with electrical current.
• Never hammer on any restraint component - it might get damaged internally.
• Prior to commencing any test procedure on the vehicle, ensure that only test equipment
approved for the purpose is being utilized and that it is in good working order. Ensure any
harness or connectors are in good condition and any warning lamps are fully functional.
• Only use the diagnostic tool to probe faults in the Airbag system, NEVER use electrical
probing instruments like Multi-meter as the probing current may deploy the airbag.
• Never attach anything to the airbag cover or allow anything to rest on top of the airbag
module.
• Always store airbag module in a dry, cool and secured area.
• Never attempt to modify any splice or repair restraint wiring harness.

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 1627
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Always ensure airbag wiring is routed correctly. Be careful to avoid trapping or pinching the
airbag wiring. Look for possible points of chafing.
• Ensure all airbag harness connectors are mated correctly and securely fastened. Do not
leave the connectors hanging loose or allow restraint components to hang from their
harnesses.
• When using electric welding, first disconnect the all the airbag connectors, ECU and
sensors. If such activities are to be conducted in the vicinity of restraint component then
remove those components also.

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
1628 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4 In Car Repairs

20.4.1 Driver Airbag Module R&R

20.4.1.1 Component Location Index

20.4.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Disconnect the negative terminal from the • Connect the battery negative terminal.
battery and wait for minimum one minute. • Check for airbag warning lamp.

Tools Required

Size Type Quantity

– Star Screwdriver 01

MST 0112AAW0001ST DAB Removal Special Tool 01

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 1629
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.1.3 Removal:

1. Disconnect the battery negative terminal 5. Insert the DAB removal special tool
and wait for about 2 minutes before doing (MST : 0112AAW0001ST) into slot from
any activity on DAB module. upper side of combination switch and push
so that DAB gets unlocked from both that
2. Rotate the steering wheel to 90 degree sides.
both clockwise and anti-clockwise to remove
the steering Upper shroud mounting screws
by using a star screw driver.

6. Gently pull-out the DAB module, using a

small flat end screw driver release the lock
first and then disconnect the DAB squib
3. There are two slots located behind the electrical connector. Also disconnect the horn
steering wheel, where DAB can be removed connector.
using special tool.

7. Remove the DAB module.

4. Rotate the steering wheel to 90 degree
so that both slots can be accessed.

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
1630 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.1.4 Inspection:
1. Inspect the DAB module for any physical damage. Replace if found any.
2. Inspect the DAB connector for any damage.

20.4.1.5 Installation:

1. Rotate and bring the steering wheel into 3. Align the DAB module, gently press with
straight position. both hands to engage the locks.

Ensure wires are routed out of the

snapping zones to avoid damage.

2. Connect DAB squib connector and lock

by pressing the lock inside gently. Also
connect the horn connector.

4. Connect the battery negative terminal,

check for airbag warning lamp on cluster.

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 1631
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.2 Passenger Airbag Module (PAB) R&R

20.4.2.1 Component Location Index

20.4.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Disconnect the negative terminal from the • Refit the Instrument panel.
battery and wait for minimum one minute.
• Connect the battery negative terminal.
• Remove the Instrument panel. • Check for airbag warning lamp.

Tools Required

Size Type Quantity

13 mm Socket spanner 01

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
1632 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.2.3 Removal:

1. Remove the IP assembly. For additional

information refer to IP R&R section.

2. Disconnect the Passenger Airbag

Module (PAB) electrical connector.

3. Using 10 mm socket spanner remove the

Passenger Airbag Module (PAB) mounting
bolts and and crimp the PAB bend legs to
straight and remove the PAB separately from
Instrument panel.

20.4.2.4 Inspection:
1. Inspect the PAB module for any damage. Replace if found any.
2. Inspect the PAB module connector for any damage.
3. Inspect the PAB module trim for any damage.

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 1633
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.2.5 Installation:

1. Insert the PAB module on instrument

panel.

2. Bend the PAB legs and tighten the

mounting bolts to specific torque.

3. Connect the Passenger Airbag Module

(PAB) electrical connector.

4. Refit the IP assembly. For additional

information refer to IP R&R section.

5. Connect battery negative terminal.

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
1634 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.3 Seat Belt Assembly Driver R&R

20.4.3.1 Component Location Index

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 1635
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Refit the B pillar lower trim
• Disconnect the negative terminal of the • Connect the battery negative terminal of
battery. the battery.
• Remove the B pillar lower trim

Removal Steps
1. Remove the seat belt top mounting bolt.
2. Remove seat belt bottom mounting bolt.
3. Detach the seat belt holder.
4. Remove seat belt pre-tensioner electrical connector.
5. Remove the driver seat belt assembly.

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
1636 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

- Small flat end screw driver 01

14 mm Socket spanner 01

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 1637
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.3.3 Removal:

Follow the same procedure for Seat belt assembly Co-driver Removal.

1. Disconnect the battery negative terminal 5. Using a small flat end screw driver pull
and wait for about 1 minutes. the lock first and then gently pull-out and
remove the pre-tensioner electrical
2. Remove the B pillar lower trim. For connector.
additional information refer to B pillar lower
trim R&R section.

3. By using a 14 mm socket spanner,

remove the seat belt bottom mounting bolt.

6. Remove the seat belt assembly.

4. Using a flat end screw driver gently

detach the seat belt holder.

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
1638 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.3.4 Inspection:
1. Inspect the seat belt assembly for any damage. Replace if found any.
2. Inspect the connector for any damage.

20.4.3.5 Installation:

Follow the same procedure for Seat belt assembly Co-driver Installation.

1. Refit the pre-tensioner and seat belt 3. Refit the seat belt holder with the help of
bottom end with the help of mounting bolt. buttons.
Torque tighten the bolt to specified value.

4. Refit the B pillar lower trim.For additional

2. Connect the pre-tensioner electrical information refer to B pillar lower trim R&R
connector, press the lock gently to engage. section.

5. Connect battery negative terminal.

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 1639
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.4 Driver Seat Belt Buckle R&R

20.4.4.1 Component Location Index

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
1640 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.4.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check for proper functioning of seat belt
warning lamp.

Removal Steps
1. Disconnect the seat belt buckle connector.
2. Remove the buckle mounting bolt.
3. Remove the driver seat belt buckle.
Tools Required

Size Type Quantity

14 mm Ring spanner 01

— Sniper 01

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 1641
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.4.3 Removal:

1. Using a 14 mm ring spanner remove the

buckle mounting bolt.

2. Press the lock and disconnect the

electrical connector to buckle.

3. Using a sniper cut the mounting straps

and remove the driver side seat belt buckle
assembly.

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
1642 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.4.4 Installation:

1. Refit the buckle using mounting bolt,

torque tighten the bolt to specified value.

2. Route the buckle wire using mounting

straps.

3. Connect the buckle electrical connector.

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 1643
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.5 Co - Driver Seat Belt Buckle R&R

20.4.5.1 Component Location Index

Tools Required

Size Type Quantity

14 mm Ring spanner 01

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
1644 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.5.2 Removal:

1. Remove the buckle mounting bolt using

14 mm ring spanner and then detach and
remove the co-driver seat belt buckle.

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 1645
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.5.3 Installation:

1. Refit the co-driver seat-belt buckle using

mounting bolt, torque tighten the bolt to
specified value.

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
1646 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.6 Second Row RH Seat Belt Assembly R&R

20.4.6.1 Component Location Index

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 1647
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.6.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Refit the C pillar lower trim
• Remove the C pillar lower trim • Connect the battery negative terminal of
the battery.
• Disconnect the negative terminal of the
battery.

Removal Steps
1. Remove seat belt bottom mounting bolt.
2. Remove the seat belt top mounting bolt.
3. Detach the seat belt holder.
4. Remove seat belt pre tensioner mounting bolt.
5. Remove the Second row seat belt assembly.

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
1648 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Tools Required

Size Type Quantity

14 mm Socket spanner 01

- Flat end screw driver 01

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 1649
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.6.3 Removal:

Follow same removal procedure for LH seat belt assembly.

1. Remove the C pillar lower trim. For

additional information refer to C pillar lower
trim R&R section.

2. Using a flat end screw driver detach the

seat belt holder.

3. Remove the rear seat belt pre tensioner

mounting bolt using 14 mm socket spanner.

4. Remove the second row RH seat belt

assembly.

20.4.6.4 Inspection:
1. Inspect the seat belt assembly for any damage. Replace if found any.

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
1650 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.6.5 Installation:

Follow same installation procedure for LH seat belt assembly.

1. Refit the belt pre tensioner using

mounting bolt. Torque tighten the bolt to
specified value.

2. Refit the seat belt holder.

3. Refit the C pillar lower trim. For

additional information refer to C pillar lower
trim R&R section.

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 1651
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.7 Second Row seat Lap and Buckle Assembly R&R

20.4.7.1 Component Location Index

Tools Required

Size Type Quantity

14 mm \ 13 mm Socket spanner 01

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
1652 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.7.2 Removal:

1. Using the 13 mm socket spanner remove

the rear seat top mounting bolts and fold the
seat.

2. Using a 14 mm socket spanner remove

the mounting bolt and then gently pull-out
and remove the second row lap and buckle
assembly.

Pull down and remove the second row

lap and buckle assembly.

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 1653
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.7.3 Installation:

1. Position and Refit the second row lap

and buckle assembly with the help of
mounting bolt. Torque tighten the bolt to
specified value.

2. Refit the rear seat top mounting bolts,

Torque tighten the bolts to specified value.

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
1654 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.8 Second Row Seat Twin Buckle Assembly R&R

20.4.8.1 Component Location Index

Tools Required

Size Type Quantity

- Star screw driver 01

14 mm \ 13 mm Socket spanner 01

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 1655
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.8.2 Removal:

1. Using 14 mm socket spanner remove

the mounting bolt and then gently pull-out
and remove the buckle assembly.

Pull down and remove the second row

lap and buckle assembly.

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
1656 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.8.3 Installation:

1. Position and Refit the buckle assembly

with the help of mounting bolt. Torque tighten
the bolt to specified value.

2. Refit the rear seat top mounting bolts,

Torque tighten the bolts to specified value.

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 1657
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.9 Airbag ECU R&R

20.4.9.1 Component Location Index

Tools Required

Size Type Quantity

10 mm Socket spanner 01

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
1658 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.9.2 Removal:

1. Disconnect battery negative terminal.

2. Remove the centre console. For

additional information refer to CCB R&R
section.

3. Open the lock and disconnect airbag

ECU connector.

U2A200081

4. Using a 10 mm socket spanner remove

the airbag ECU mounting bolts, remove the
earth cable and then remove the airbag ECU.

x3

U2A200082

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 1659
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.4.9.3 Inspection:
1. Inspect the airbag ECU for any damage, replace if found any.
2. Inspect airbag ECU connectors for any damage.

20.4.9.4 Installation:

1. Refit the earth cable and refit the airbag

ECU with the help of mounting bolts. Torque
tighten the bolts to specified value.

x3

U2A200082

2. Connect the airbag ECU connector and

engage the lock.

U2A200081

3. Refit the centre console. For additional

information refer to CCB R&R section.

4. Connect the battery negative terminal.

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
1660 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

20.5 Tightening Specifications

SR. PART/ASSEMBLY OPERATION Qty TORQUE (N-m)

NO.

1 Seat belt MTG frond Top/Bottom LH/ 1 37.5±5

RH

2 Seat belt MTG Rear Top/Bottom LH/ 1 37.5±5

RH

3 Driver seat MTG on floor 1 47.5±7.5

4 Co-Driver seat MTG on floor 1 47.5±7.5

5 Driver Seat belt Buckle Assembly 1 37.5±6

fitment

6 Co-Driver Seat belt Buckle 1 37.5±6

Assembly fitment

7 Passenger airbag bracket to CCB 2 18±3

bracket

8 Rear seat bracket mounting 3 25±5

9 Rear seat bottom mounting 4 47.5±7.5

10 Airbag ECU mounting 3 8±2

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 1661
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1662 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21 INSTRUMENT PANEL

21.1 Description and Operation

The instrument panel is mounted in A-pillar channel located near the front doors with corner
mounting bolts and fixed in the cross car beam with center mounting bolts. The instrument
panel not only offers utility but also enhances the visual appeal of the interiors. The centre
console located between driver and co - driver seat. The instrument panel also forms a
housing for the wiring looms, diagnostic connector, Body control module (MBFM), fuse box,
HVAC components like evaporator unit and heater core along with the blower and the vent
system. The cluster is mounted at the RHS of the instrument panel. The glove boxes are
provided at the LHS of the instrument panel.

21.2 INSTRUMENT CLUSTER OVERVIEW

21.2.1 Instrument Cluster

A Tachometer / RPM Gauge F Mode Button

B Temperature Gauge G Odometer
C Trip meter H Gear Indicator
D Fuel Gauge I Set Button
E Speedometer

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 1663
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.2.2 Warning Lamps Overview

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
1664 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.2.3 Warning Lamps

The phenomenon of warning lamps flashing momentarily when ignition is turned ON is called
pre-check. This is self check done by the cluster at every ignition ON.

Lamp
Sym- Warning Lamp/ Lamp
Pre- Action/Remarks
bol Tell Tale Status
check
Either one of below conditions:-
1) Park brake might be engaged
Parking Brake ON/
Continuous- 2) Brake fluid level might be low
Brake Fluid Low Yes ly ON Contact Authorized Mahindra Dealer
Warning Lamp
immediately for assistance if the lamp
is not turning OFF even after
checking the above conditions
Indicates left turn lamp is blinking
Slow Blinking: Normal operation
Slow or Fast
Left Turn Indicators No Blinking Fast Blinking: One /more left turn
lamp bulb has fused. Have the bulb
replaced
Indicates water in fuel filter. Drain the
Water in Fuel Filter Continuous- water from filter or contact an
Warning Lamp Yes ly ON Authorized Mahindra Dealer for
assistance
Slow Blinking: Vehicle armed and
Immobilizer system active
Slow or Fast Fast Blinking: Once the ignition is
Security Lamp No Blinking turned OFF, security lamp will blink at
fast rate frequency indicating vehicle
is secured against unauthorized start
of engine
Continuous- There is a potential malfunction in the
ENGINE ! Check Engine For about 3 ly ON or engine system, contact an Authorized
Lamp sec Blinking Mahindra Dealer immediately.
High Coolant Continuous- Engine temperature very high.
Temperature No ly ON or Contact an Authorized Mahindra
Warning Lamp Blinking Dealer immediately
Indicates right turn lamp is blinking
Slow Blinking: Normal operation
Right Turn Slow or Fast
No Blinking Fast Blinking: One /more turn signal
Indicators
lamp bulb has fused. Have the bulb
replaced

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 1665
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Lamp
Sym- Warning Lamp/ Lamp
Pre- Action/Remarks
bol Tell Tale Status
check
Head Lamp High Continuous-
No Indicates head lamp high beam is ON
Beam Indicator ly ON

Indicates malfunction of the ABS

Continuous-
ABS Warning Lamp For about 3 system. Contact an Authorized
sec. ly ON
Mahindra Dealer immediately.
Indicates malfunction of the airbag
Airbag Warning For about Continuous-
system. Contact an Authorized
Lamp 4.5 sec. ly ON
Mahindra Dealer immediately.

Cruise Control Continuous-

Yes ly ON Indicates vehicle is in Cruise mode.
Indicator

Door Ajar Warning Continuous- Indicates one or more doors are

Lamp No ly ON open.

Front Fog Lamp Continuous-

No Indicates front fog lamp is ON.
Indicator ly ON

Indicates driver seat belt not

Seat Belt Warning Continuous- fastened. If tell tale is not turning OFF
Lamp No ly ON even after fastening the driver seat
belt, contact an Authorized Mahindra
Dealer for assistance.

Low Fuel Warning Continuous- The fuel level in the fuel tank is low.
Lamp No ly ON Re-fuel immediately to a avoid empty
tank.
Continuously ON: Engine is in auto
stop mode
START Continuous-
A Blinking: Stop/Start is about to stop
Start/Stop Lamp No ly ON or
STOP the engine
Blinking
Fast Blinking: Stop/Start is inhibited
due to unhealthy battery conditions
Continuous-
Malfunction Lamp ly ON till Continuous- There is a potential malfunction
(OBD) Engine ly ON related to emission control system.
Starts
Continuous-
Battery Charging ly ON till Continuous- Indicates malfunction in the charging
Warning Lamp Engine ly ON system.
Starts

Low Engine Oil Continuous-

Pressure Warning ly ON till Continuous- Indicates engine oil pressure is low.
Engine ly ON
Lamp
Starts

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
1666 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Lamp
Sym- Warning Lamp/ Lamp
Pre- Action/Remarks
bol Tell Tale Status
check
Continuous- Indicates a malfunction in the starting
Glow Plug Indicator For about 2
seconds ly ON system.

Indicates malfunction of the AMT

! AMT warning lamp For about 3
sec.
Continuous-
ly ON
system. Contact an Authorized
Mahindra Dealer immediately

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 1667
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.3 Component Location Index

21.3.1 Refer below illustration for Instrument Panel

A. Side Vents B. Side Defrost Vents

C. Front Passenger Airbag D. HVAC Controls

E. Infotainment System F. Center Vents

G. Steering Controls H. Instrument Cluster

I. Horn/Driver Airbag J. Steering Wheel

K. Light Stalk L. Steering Controls-cruise

M. Clutch, Brake, Accelerator pedal N. Parking Brake

O. 4WD Shift switch P. Rear AC Vents

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
1668 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Q. Can/Bottle Holder R. 12 V Power Socket

S. Gear Sifter Lever T. Glove Box

21.4 Service Tips and Precautions

To protect the instrument panel and adjacent areas:
• Ensure the availability of sufficient work space before removing or installing the instrument
panel.
• Care should be taken not to damage and scratch the instrument panel when removing and
installing fasteners within the vehicle.

While removing or installing the instrument panel, protect the seats and carpets
from damage.

– Disconnect battery before carrying out any work on instrument panel.

– Protect the modules, connectors, and wiring from dirt, heat, static electricity and
moisture.

While removing or installing the instrument panel, ensure that the instrument panel
is not scratched or damaged.

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 1669
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5 In Car Repairs

21.5.1 Centre Console R&R

21.5.1.1 Component Location Index

21.5.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of
Center console assembly.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

— Star screw driver 1

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
1670 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.1.3 Removal:

1. Disconnect the negative terminal of 5. Pull out the top tray and disconnect the
battery using 10 mm ring/socket spanner. electrical connector.

While attempting to remove the top tray,

ensure that the tray lock is not damaged.

2. Remove the Audio unit. For additional

information refer to Audio unit R&R section.

3. Pull out the top tray from the centre

console.
6. Remove the side mounting screws using
star screw driver from LHS and RHS side.

4. Rotate the gear lever knob in anti-

clockwise direction and remove the knob
from the gear lever.

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 1671
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Remove the top mounting screws using 10. Disconnect the electrical connector and
star screw driver. separately detach the centre console from
instrument panel.

Carefully detach the floor console

without any scratches or damage.

8. Using 10 mm socket spanner remove the

center console rear mounting bolts.

11. Using screw driver pull out the wiring

harness from rear duct assembly.

9. Pull out the centre console.

12. Unscrew the duct assy floor console

flower mounting screws and detach the duct
assy from centre console.

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
1672 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Unscrew the rear duct assy flower 16. Unscrew the bezel assy parking lever
mounting screws and detach the rear duct flower mounting screws and detach the bezel
assy from centre console. assy parking lever from centre console.

14. Unscrew the bezel assy air vent flower

mounting screws and detach the bezel assy
air vent from centre console.

15. Unscrew the bottle holder flower

mounting screws and detach the bottle
holder from centre console.

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 1673
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.1.4 Installation:

Fix all the parts properly and do not over tighten the parts screws, over tighten will
lead to damage the threads.

1. Refit the bezel assy parking lever in to 3. Refit the bezel assy air vent in to centre
centre console and tighten the flower console and tighten the flower mounting
mounting screws. screws.

2. Refit the bottle holder in to centre 4. Refit the rear duct assy in to centre
console and tighten the flower mounting console and tighten the flower mounting
screws. screws.

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
1674 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the duct assy floor console in to 7. Before fixing the centre console connect
centre console and tighten the flower the electrical connector.
mounting screws.

8. Fix the centre console in to the

6. Refit the wiring harness in to rear duct instrument panel.
assy.

Install the centre console properly into

the instrument panel. Carefully install
without scratching the driver and co-
driver seats.

9. Refit the centre console rear mounting

bolts, torque tighten the bolts to specified
value.

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 1675
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

10. Refit the top mounting screws. 13. Rotate the gear lever knob in clockwise
direction and tighten the knob.

11. Refit and tighten the side mounting

screws on LH and RH side. 14. Gently press the top tray in to the centre
console.

12. Connect the electrical connector of top

tray. 15. Refit the Audio unit. For additional
information refer to Audio unit R&R section.

16. Connect battery negative terminal.

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
1676 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.2 Glove Box R&R

21.5.2.1 Component Location Index

21.5.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper operation of
glove box.

Tools Required

Size Type Quantity

- Star screw driver 1

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 1677
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.2.3 Removal:

1. Open the glove box and unlock the side

locks using screw driver.

2. Using star screw driver remove the glove

box mounting screws from inside the glove
box.

3. Remove the glove box from instrument

panel.

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
1678 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.2.4 Installation:

While installing the lower glove box, ensure that the glove box is fixed properly.

Before installing the glove box check the side locks condition.

1. Refit the glove box in to the instrument 2. Refit the glove box mounting screws.
panel correctly.

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 1679
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Lock the glove box side locks and check

the operation.

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
1680 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.3 Instrument Panel R&R

21.5.3.1 Component Location Index

21.5.3.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of IP
assembly.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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 1681
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.3.1.3 Removal:

1. Disconnect the negative terminal of 9. Remove the hood lock from instrument
battery using 10 mm ring/socket spanner. panel.

2. Remove the Combination switch. For 10. Remove the side trim cover from
additional information refer combination instrument panel.
switch R&R section.

3. Remove the HVAC control panel. For

additional information refer to HVAC control
panel R&R section.

4. Remove the Instrument Cluster. For

additional information refer to Cluster R&R
section.

5. Remove the A-piller upper trim (Both RH

& LH). For additional information refer to A-
piller upper trim R&R section.

6. Remove the Center console. For 11. Using 10 mm socket spanner remove
additional information refer to Center console the instrument panel mounting bolts on either
R&R section. sides LH and RH.

7. Remove the Glove Box. For additional

information refer to Glove Box R&R section.

8. Remove the Passenger Airbag. For

additional information refer to Passenger
Airbag R&R section.

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
1682 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Using 10 mm socket spanner remove 15. Using 10 mm socket spanner remove
the instrument panel center mounting bolt the instrument panel bottom mounting bolts
inside the audio unit. on either sides LH and RH.

13. Using 10 mm socket spanner remove 16. Using 10 mm socket spanner remove
the instrument panel mounting bolt inside the the instrument panel mounting bolt on cluster
glove box. centre side.

14. Disconnect the Airbag ECU electrical 17. Using 10 mm socket spanner remove
connector. the instrument panel mounting bolt on driver
end.

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 1683
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

18. Using 10 mm socket remove the 21. Unscrew the adapter centre flower
instrument panel mounting bolt below the mounting screws both LHS, RHS and detach
steering assembly. the adapter centre from the instrument panel.

19. Pull out the instrument panel and 22. Unscrew the air vent flower mounting
separately detach it from cross car beam. screws both LHS, RHS and detach the air
vent from the instrument panel.

20. Unscrew the adapter centre flower

mounting screws both LHS, RHS and detach 23. Unscrew the centre demist duct flower
the adapter centre from the instrument panel. mounting screws from the instrument panel.

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
1684 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24. Unscrew the demist duct flower 27. Unscrew the centre vent flower
mounting screws both LHS, RHS from the mounting screws both LHS, RHS and detach
instrument panel. the centre vent from the instrument panel.

25. Separately detach the demist duct from 28. Unscrew the centre bezel assy flower
the instrument panel. mounting screws and detach the centre bezel
assy from the instrument panel.

26. Unscrew the duct centre flower

mounting screws both LHS, RHS and detach
the duct centre from the instrument panel.

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 1685
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.3.4 Installation:

1. Refit the centre bezel assy and tighten 4. Refit the demist duct in to the instrument
the flower mounting screws of instrument panel.
panel.

5. Tighten the demist duct flower mounting

2. Refit the centre vent and tighten the screws both LHS, RHS of instrument panel.
flower mounting screws both LHS, RHS of
instrument panel.

6. Tighten the centre demist duct flower

mounting screws of instrument panel.
3. Refit the duct centre and tighten the
flower mounting screws both LHS, RHS of
instrument panel.

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
1686 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit the air vent and tighten the flower 10. Carefully fit the instrument panel in to
mounting screws both LHS, RHS of the cross car beam.
instrument panel.

11. Refit the instrument panel mounting bolt

8. Refit the duct outboard and tighten the below steering assembly, torque tighten the
flower mounting screws both LHS, RHS of bolt to specified value.
instrument panel.

12. Refit the instrument panel mounting bolt

9. Refit the adapter centre and tighten the on driver door side, torque tighten the bolt to
flower mounting screws both LHS, RHS of specified value.
instrument panel.

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 1687
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

13. Refit the instrument panel mounting 16. Connect the Airbag ECU electrical
bolts on either sides of cross car beam, connector.
torque tighten the bolts to specified value.

17. Refit the instrument panel mounting bolt

14. Refit the instrument panel mounting bolt inside the glove box, torque tighten the bolt to
on cluster centre, torque tighten the bolt to specified value.
specified value.

18. Refit the instrument panel mounting bolt

15. Refit the instrument panel mounting on inside the audio unit, torque tighten the bolt
either sides of center console, torque tighten to specified value.
the bolts to specified value.

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
1688 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

19. Refit the instrument panel side trim. 24. Refit the HVAC control panel. For
additional information refer to HVAC control
panel R&R section.

25. Refit the Combination switch. For

additional information refer combination
switch R&R section.

26. Refit the Cluster. For additional

information refer to Cluster R&R section.

27. Refit the Center console. For additional

information refer to CCB R&R section.

28. Refit the Glove Box. For additional

20. Refit the hood lock on the instrument information refer to Glove Box R&R section.
panel.

21. Connect battery negative terminal.

22. Refit the Passenger Airbag. For

additional information refer to Passenger
Airbag R&R section.

23. Refit the A-piller upper trim (Both RH &

LH). For additional information refer to A-
piller upper trim R&R section.

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 1689
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.4 Cross Car Beam R&R

21.5.4.1 Component Location Index

21.5.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the Instrument panel assembly.
• Remove the Instrument panel assembly.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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
1690 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.4.3 Removal:

1. Remove the Instrument panel. For 5. Remove the steering column mounting
additional information refer to IP R&R bracket nuts and bolts fitted on CCB.
section.section.

2. Using 10 mm socket spanner remove the

fuse box mounting bolts fitted on CCB.

6. Remove the ground connection

mounting bolts fitted on body.

3. Using 10 mm socket spanner remove the

MBFM mounting bolts fitted on CCB.

4. Disconnect all the MBFM electrical

connectors.

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 1691
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Unclip all the wiring harness locks and 9. Remove the mounting bolts from RHS of
disconnect the CCB wiring harness along the cross car beam mounted in A-Pillar
with fuse box. channel.

10. Remove the mounting bolts from LHS

of the cross car beam mounted in A-Pillar
While attempting to remove the cross channel.
beam, pull out the wiring harness and
disconnect the electrical connectors
from the cross beam.

8. Remove the cross car beam mounting

bolts fitted on HVAC unit

11. Remove the cross car beam mounting

bolt fitted on body.

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
1692 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

12. Remove the cross car beam mounting

bolt fitted on body.

13. Separately detach the cross car beam.

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 1693
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.4.4 Installation:

1. Refit the cross car beam into the 4. Tighten the mounting bolts from LHS of
mounting holes provided in the vehicle. the cross car beam mounted in A-Pillar
channel.

2. Tighten the cross car beam mounting

bolt fitted on body. 5. Tighten the mounting bolts from RHS of
the cross car beam mounted in APillar
channel.

3. Tighten the cross car beam mounting

bolt fitted on body.
6. Tighten the cross car beam mounting
bolt fitted on HVAC unit.

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
1694 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Clip all the wiring harness locks and 10. Connect the electrical connectors and
connect the CCB wiring harness along with tighten the MBFM mounting bolts fitted on
fuse box. CCB.

8. Tighten the ground connection mounting 11. Tighten the fuse box mounting bolts
bolt fitted on body. fitted on CCB.

9. Tighten the steering column mounting 12. Refit the Instrument panel. For
bracket nuts and bolts fitted on CCB. additional information refer to IP R&R
section.

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 1695
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.5 Instrument Cluster R&R

21.5.5.1 Component Location Index

21.5.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the hood instrument cluster.
• Turn the ignition OFF. • Check and ensure proper functioning of
• Remove the hood instrument cluster. Instrument cluster.

Tools Required

Size Type Quantity

- Star screw driver 1

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
1696 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.5.3 Removal:

1. Remove the rubber.

2. Remove instrument cluster 2 mounting

screws using star screw driver.

3. Pull out instrument cluster gently.

4. Disconnect electrical connector from

instrument cluster and remove instrument
cluster.

21.5.5.4 Inspection:
• Check for any damage or crack, replace if found.

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 1697
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.5.5 Installation:

1. Connect electrical connector on

instrument cluster.

2. Position the instrument cluster on IP and

mount it with the help of 2 screws.

3. Refit the rubber.

4. Odometer reading need to be written if

Instrument cluster is replaced with a new
one. For additional information refer
Instrument cluster diagnostic manual.

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
1698 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.6 MBFM R&R

21.5.6.1 Component Location Index

21.5.6.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit driver panel.
• Disconnect the battery negative terminal. • Connect battery negative terminal.
• Remove driver panel. • Do clock setting, power window learning
etc.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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 1699
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.6.1.3 Removal:

1. Turn off the ignition.

2. Disconnect negative terminal of the

battery.

3. Remove the Steering column lower trim.

4. Remove MBFM mounting bolts using 10

mm socket spanner.

5. Disconnect all electrical connectors from

MBFM and remove the MBFM.

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
1700 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.6.1.4 Inspection:
• Inspect the connectors for any damage.
• Check for any damage, replace if found.

21.5.6.1.5 Installation:

1. Connect all electrical connectors on 3. Refit the steering column lower trim.
MBFM.

4. If the MBFM is new carry out

2. Position MBFM on CCB, mount it with
the help of mounting bolts, torque tighten the • RKE learning. For additional information
bolts to specified value. refer MBFM diagnostic manual.
• TPMS learning. For additional information
refer to TPMS learning procedure.

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 1701
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.7 Crash Sensor R&R

21.5.7.1 Component Location Index

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
1702 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.7.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Connect battery negative terminal.
• Disconnect the battery negative terminal. • Refit front grill.
• Remove front grill.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

- Star screw driver 1

- Flat end screw driver 1

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 1703
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.7.3 Removal:

1. Remove front grill. For more information

refer to Front grill R&R section.

2. Disconnect LH front crash sensor

electrical connector.

3. Using a 10 mm socket spanner, loosen

the mounting bolt and detach and remove
front crash sensor from front cross member.

21.5.7.4 Inspection:
• Check sensor for any damage, replace if found.

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
1704 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.5.7.5 Installation:

1. Position both LH & RH front crash sensor

in its position, mount it with the help of bolt
and torque tighten to specified values.

2. Connect electrical connector.

3. Refit front grill. For more information

refer to Front grill R&R section.

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 1705
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

21.6 Torque Specifications & Sequence

Descriptions Torque (Nm)

CCB FITMENT/CCB BRACKET FITMENT 22±4

PAB SUB ASSY 18±3

PAB MTG ON CCB 18±3

IP MTG BRACKET 8±2

FITMENT OF REST PAD OVER THE DASH 4.5 ± 0.5

PANEL

CLUSTER FIT, COMBI SW. & HVAC 2 ± 0.5

CONTROL PANEL

CENTRE CONSOLE ASSY 6.5 ± 1.5

MBFM 2.5 ± 0.5

CRASH SENSOR MOUNTING 8+2

4W WIRING HARNESS 9±2

WIRING MTG. ON JUNCTION BOX 5±1

ALL EARTHING MOUNTING 9±2

ECU FITMENT 6.5±1.5

HORN FITMENT 15 ± 3

FUSE BOX BRKT MTG. 45 ± 7

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
1706 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22 DOORS,BONNET & TAIL GATE

22.1 Description and Operation

In Mahindra PIKUP doors, tailgate and bonnet assembly are hinged with the vehicle body.
Doors are used for entering and exiting the vehicle & Tailgate is used for entering and exiting
the cargo. The doors can be opened to provide access to the opening, or closed to secure.
Engine compartment is secured by bonnet assembly.
Rear doors are equipped with child lock.

22.2 Component Location Index

22.2.1 Refer below illustration for Doors.

A. Bonnet Assembly C. Rear Door

B. Front Door D. Tail Door

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 1707
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.3 Outside Rear View Mirror

Integrated exterior rear view mirrors on both

the sides facilitate maximum rear
View information to the driver. Both the
ORVM’s are hinged and can be manually
folded or unfolded. This avoids hindrances in
narrow areas and parking slots. Make sure
that you fully engage the mirror in its support,
while folding or unfolding.

22.4 Tip-Tap ORVM Adjustment

Tip Tap ORVM’s can be adjusted by hand in

the direction as indicated by the arrows.
Adjust the mirror as required to bring the rear
traffic vision as desired.

22.5 Manual (Joystick) ORVM Adjustment (if equipped)

Manual ORVM’s can be adjusted by the

joystick provided on the ORVM trim. Adjust
the joy stick as required to bring the rear
traffic vision as desired.

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
1708 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.6 Power Window (if equipped)

The quadruple switch controls the window

winding functions of all doors of the vehicle. It
also houses a child safety switch that
enables/disables power window operation of
rear doors when operated independently
from the respective door. Power windows
can be operated only when the ignition is
“IGN” position. The quadruple power window
switch is located on the driver door trim / floor
console depending on the variant.
Passengers can also raise or lower their
respective window glasses individually by the
separate switches provided on each of the
door trim pads.
To lower/raise the window glass push/pull the
respective power window switch.

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 1709
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.7 Power Window Lock Switch

A power window lock switch is provided in

the quadruple switch bank which toggles the
operation of rear passenger power window
switches.

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
1710 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8 In Car Repairs

22.8.1 Outside Rear View Mirror (ORVM)

22.8.1.1 Component Location Index

22.8.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the ORVM inner trim.
• Remove the ORVM inner trim. • Check and ensure proper functioning of
ORVM.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

10 mm Socket spanner 01

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 1711
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.1.3 Removal:

1. Open the front driver side door and 4. Using a star screw driver, remove the
remove the two mounting clips. door trim inner handle mounting screw.

2. Using a star screw driver loosen the two 5. Gently pull the door trim and disconnect
screws and pull the outside rear view mirror the electrical connector.
cover.

6. Remove the outside rear view mirror

3. Using 10 mm socket spanner loosen and from front door.
remove the ORVM mounting bolts.

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
1712 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.1.4 Inspection:
1. Inspect the ORVM for any physical damage.
2. Inspect the ORVM mirror for fading.
3. Inspect the ORVM trim for colour fading.

22.8.1.5 Installation:

1. Open the front driver door and refit the 3. Tighten the inner handle mounting screw
mirror in correct position. cover on the door trim.

2. Connect the electrical connector. 4. Refit the ORVM mounting bolts.

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 1713
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit the outside rear view mirror cover.

6. Tighten the two screws and finally put the

clip.

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
1714 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.2 Front Door R&R

22.8.2.1 Component Location Index

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 1715
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Connect the front door harness electrical
• Disconnect the front door harness connector.
electrical connector. • Check and ensure smooth operation of
door assembly.
• Check and ensure power window
functioning.
• Do Striker adjustment if required.

Tools Required

Size Type Quantity

- Hammer 01

12 mm Socket spanner 01

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
1716 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.2.3 Removal:

1. Remove the two A pillar lower trim 4. Using a 12mm ring spanner remove the
mounting clips. door hinges mounting bolts.

2. Press the lock and disconnect the two 5. Detach the front door electrical connector
front door electrical connectors from the A- rubber from the A-pillar and separately
pillar. remove the door.

3. Using hammer remove the door checker

locator pin.
Front door electrical connectors can be
easily accessed by removing the A-Pillar
trim.

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 1717
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.2.4 Installation:

1. Insert the electrical connector rubber into 4. Connect the two front door electrical
A-pillar. connectors into A-pillar.

2. Refit the door hinges and tighten the 5. Refix the A pillar lower trim mounting
door hinges mounting bolts. clips further press and refit the beading.

3. Refit the door checker locator pin and

hammer it.
Align and fix the front door properly.
Check the front door open and close
operation after align the front door.

Before installing the A-Pillar lower trim

check the mounting clips condition.
When installing the A-Pillar lower trim
insert the locator.

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
1718 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.3 Front Door Window Glass R&R

22.8.3.1 Component Location Index

22.8.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the inner and outer weather strip.
• Remove the inner and outer weather strip • Check and ensure proper functioning of
. door window operation.

Tools Required

Size Type Quantity

- Star screw driver 01

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 1719
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.3.3 Removal:

1. Remove the front door trim. For 5. Carefully remove the window glass from
additional information refer to Front Door the door.
Trim R&R section.

2. Remove the inner and outer weather

strip from the front door.

To avoid scratching or breaking of the

window glass, carefully place the window
3. Raise the power window glass upward to glass on a secure area.
half closed position.

4. Using star screw driver remove the two

window glass mounting screws.

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
1720 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.3.4 Installation:

1. Carefully insert the window glass into the 3. Tighten the two window glass mounting
door. screws.

2. Fix the window glass into the groove

provided in the window regulator.
Do not over tighten the window glass
mounting screws to avoid the damage of
window glass.

4. Gently press the inner and outer weather

strip on the front door.

Align the window glass properly and

tighten the window glass. Check the
window glass operation before fixing the
door trim.

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 1721
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.4 Door Outer Handle R&R

22.8.4.1 Component Location Index

22.8.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the front door trim.
• Remove the front door trim. • Check and ensure proper functioning of
door lock and unlock mechanism.

Tools Required

Size Type Quantity

- Star screw driver 01

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
1722 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.4.3 Removal:

1. Remove the respective door trim. For 5. Detach the front door key barrel.
additional information refer to Front Door
Trim R&R section.

2. Fully raise the front door window glass.

3. Unlock the lock and detach the link

connected to door outer handle and key
barrel.

6. Pull out door handle from the door.

4. Using star screw driver remove the

mounting screw connected to key barrel.

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 1723
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.4.4 Installation:

1. Match the door handle to the front door 4. Fit the lock connected to door outer
slot and push forward. handle and key barrel.

2. Fit the key barrel and press it.

3. Using star screw driver tighten the

mounting screw.

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
1724 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.5 Front Door Inner Handle

22.8.5.1 Component Location Index

22.8.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the front door trim.
• Remove the front door trim. • Check and ensure proper functioning of
door mechanism and inner handle
operation

Tools Required

Size Type Quantity

- Star screw driver 01

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 1725
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.5.3 Removal:

1. Remove the respective door trim. For

additional information refer to Front Door
Trim R&R section.

2. Using star screw driver loosen the

mounting screw.

3. Detach the cable connected to inner

handle and separately remove the inner
handle.

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
1726 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.5.4 Installation:

1. Fit the two cables provided in the inner

handle slot.

2. Tighten the mounting screw and check

the inner handle function.

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 1727
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.6 Rear Door Window Glass

22.8.6.1 Component Location Index

22.8.6.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the inner and outer weather strip.
• Remove the inner and outer weather strip • Check and ensure proper functioning of
. door window operation.

Tools Required

Size Type Quantity

- Star screw driver 01

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
1728 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.6.3 Removal:

1. Remove the respective door trim. For 5. Detach the quarter glass from rear door.
additional information refer to Front Door
Trim R&R section.

2. Remove the runner beading.

6. Lift the glass to half closed position and

unlock the lock fitted on the glass.

3. Remove the 2 no’s top door channel

mounting screw using star screw driver.

7. Detach the door channel from rear door.

4. Using a 10 mm socket spanner remove

the door channel mounting bolt.

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 1729
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

8. Carefully remove the glass from rear

door.

To avoid scratching or breaking of the

window glass, carefully place the window
glass in a secure area.

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
1730 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.6.4 Installation:

1. Carefully insert the glass into the rear 3. Rotate the lock in clockwise direction and
door. lock the glass.

2. Refit the channel door on the rear door.

Align the window glass properly and

tighten the window glass. Check the
window glass operation before fixing the
door trim.

4. Refit the quarter glass on rear door.

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 1731
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit and tighten the door channel

mounting bolt.

6. Refit and tighten the top door channel

mounting screw.

7. Gently fix the runner beeding.

Do not over tighten the window glass

mounting screws to avoid the damage of
window glass.

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
1732 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.7 Tail Gate R&R

22.8.7.1 Component Location Index

22.8.7.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the tailgate handle shield (cover)
• Remove the tailgate handle shield (cover) mountings.
mountings . • Refit the tail gate latch.
• Remove the tail gate latch. • Check and ensure smooth operation of
door assembly.

Tools Required

Size Type Quantity

- Star screw driver 01

10mm Socket spanner 01

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 1733
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.7.3 Removal:

1. Using star screw driver remove tailgate 4. Disengage the tailgate stay rope from the
handle shield (cover) mounting screws. tail door.

2. Remove tailgate latch 'T'40 bolts. 5. Using a 10 mm socket spanner remove

the tail gate hinges mounting bolt.

3. Using a 10 mm socket spanner remove

tailgate handle mounting bolts. 6. Using 10 mm socket spanner remove the
tail gate alignment mounting bolts.

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
1734 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Remove tail gate assembly.

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 1735
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.8.7.4 Installation:

1. Align and fix the tail assembly. 4. Engage the stay rope on the tail door.

2. Refit and torque tighten the tail gate 5. Refit the tailgate handle, torque tighten
alignment mounting bolts. the mounting bolts to specified value.

3. Refit and torque tighten the tail gate 6. Refit the tailgate latch, torque tighten the
hinges mounting bolts. mounting bolts to specified value.

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
1736 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit the tailgate handle shield (cover).

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 1737
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

22.9 Torque Specifications

Location Torque Nm

DOOR CHECK ARM MOUNTING 4.5 ± 0.5

OUTER DOOR HANDLE 1.3 ± 0.5

DOOR LATCH 6.5 ± 1.5

REAR DOOR SPEAKER 9±2

TAIL DOOR CHECK ARM 22± 5

DOOR STRIKER MTG. SCREW FRT LH/RH 31 ± 4

DOOR STRIKER MTG. SCREW LH/RH 31 ± 4

TAIL DOOR LATCH 25 ± 5

STRIKER FITMENT 25 ± 5

BACK DOOR SWITCH ACTUATOR 3.5 ± 0.5

DOOR STRIKER PRE TORQUE 20 ± 5

TAILGATE HANDLE 8±2

DOVETAIL MALE MTG. 6.5 ± 1.5

DOVETAIL FEMALE MTG. ON BODY 11 ± 2

STAY ROPE 25 ± 5

HOOD LATCH MTG. ON FRT PANEL 20 ± 3

SCOOP MOUNTING ON BONNET 4 ± 0.5

TAIL DOOR STRIKER FITMENT 25 ± 5

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
1738 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23 SEATS

23.1 Description and Operation

The seats are designed based on modern ergonomics to suit the drivers and passengers
comfort level as top priority. The seats are provided with all necessary adjustments to enhance
the passenger’s comfort.

23.1.1 Sitting in correct position — Driver Seat

• Never adjust the driver's seat while the vehicle is in motion. The seat may
unexpectedly move and cause the driver to unintentionally operate the accelerator
or brake, or turn the steering wheel, causing loss of control of the vehicle, an
accident or serious personal injury. Adjust the driver's seat only when the vehicle is
not in motion.
• Never put objects under the seats. They may interfere with the seat-lock mechanism
or unexpectedly activate the seat position adjusting lever, causing the seat to
suddenly move, resulting in loss of control of the vehicle, an accident or serious
personal injury.
• While adjusting the seat, do not put your hands under the seat or near the moving
parts. This may lead to injuries.

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 1739
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.1.2 Front Seat Slide

Move the seat forward or backward by lifting

the adjustment lever located under the seat
front and release once the desired position is
reached.

While adjusting the seat, make sure the

latch engages fully and the seat is locked
firmly in the desired position. An
unlocked seat may move in a sudden
stop or collision, causing injury to the
person in that seat. Push and pull on the
seat to be sure it is locked.

23.1.3 Front Seat Recline

To adjust the seat back, lift the lever located

on the outboard side of the seat, lean back,
and release the lever at the desired position.
To return the seat back, lift the lever, lean
forward, and release the lever.

The seat belts provide maximum

protection in a frontal or rear collision
when the occupants are sitting up
straight and well back in the seats. If you
are reclined, the lap belt may slide past
your hips and apply restraint forces
directly to the abdomen, or the shoulder
strap may contact your neck. The more
the seat is reclined, the greater the risk of
serious injury.
When returning the rear-reclined seat
back to its upright position, make sure
you support seat back while operating
the lever.

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
1740 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.1.4 Driver Seat Height Adjust (If Equipped)

Lift/Push the seat height adjustment lever

located on the outboard side of the driver
seat to raise/lower the seat. Adjust the seat
height such that you can depress the clutch
pedal completely.

It is recommended to adjust the seat

height only when vehicle is stationary.

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 1741
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.1.5 Head Restraint

The head restraint comprises of the padded

portion which contacts your head and is
inserted/locked in receptacles on the top of
the seat back.
Your vehicle seats are equipped with head
restraints which are vertically adjustable.
The purpose of these head restraints is to
restrain rearward motion of the head in a
collision.
Always align top of the head restraint with the
top of your head or as close to it as possible.
To raise or lower the head restraint, press the
lock knob and pull or push the restraint up or
down.
The head restraint can be pulled out
completely by depressing the locking button
while pulling the restraint out. To install, align
the head restraint shafts over the holes on
the seat top and push the restraint straight
down till you hear the lock click.
Keep the seat back as upright as possible so
the headrest is behind, not beneath, and
almost touching your head.

Head restraints are designed to support

the head, not the back of the neck. The
restraint must be positioned correctly to
restrain rearward movement of the head
in a collision. An incorrectly adjusted
head restraint increases the risk of
serious injury in the event of a collision.

Never drive with the head restraints not

properly adjusted, head restraints
removed or inserted in a flipped
condition. With no support behind your
head, your neck could be seriously
injured in a collision.
Adjust the head restraint so that the top of
the head restraint is above the centre line of
the head. An incorrectly adjusted head
restraint increases the risk of serious injury in
the event of a collision.

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
1742 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Do not drive, or carry passengers with the

head restraints removed from occupied
seats. The absence of a correctly adjusted
head restraint increases the risk of serious
injury in the event of a collision. Never adjust
the head restraints while the vehicle is in
motion.

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 1743
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.2 Component Location Index

23.2.1 Refer below illustration for Seating System

A. Co - Driver Seat
B. Driver Seat
C. Second Row Seats

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
1744 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3 In Car Repairs

23.3.1 Driver Seat R&R

23.3.1.1 Component Location Index

23.3.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment and
operation of seat recliner, slide etc.

Tools Required

Size Type Quantity

16 mm Socket spanner 01

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 1745
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.1.3 Removal:

Move the seat backwards or forward by lifting the towel bar located under the seat
front in-order to access seat mounting bolts.

1. Press the lock and pull out the head 3. Using 16 mm socket spanner loosen and
restrain from Co - driver seat. remove the front side mounting bolts of Co -
driver seat.

2. Press the lock and disconnect the

electrical connectors from the driver seat. 4. Using 16 mm socket spanner loosen and
remove the rear side mounting bolts of Co -
driver seat and separately detach the seat.

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
1746 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.1.4 Inspection:
1. Check for any damages.
2. Check for seat sagging.
3. Check for proper functionality of recliner.
4. Check for any damages on seat trims.

23.3.1.5 Installation:

While mounting the seat, take care not to crush floor wiring harness.

1. Refit the Co- driver seat in correct 3. Press the lock and connect the electrical
position and torque tighten the mounting connector of the driver seat.
bolts on rear side of Co - driver seat.

4. Press the lock and install the head

2. Similarly refit the front side mounting restrain.
bolts torque tighten the same to specified
value.

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 1747
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.2 Co — Driver Seat R&R

23.3.2.1 Component Location Index

23.3.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment and
operation of seat recliner, slide etc.

Tools Required

Size Type Quantity

16 mm Socket spanner 01

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
1748 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.2.3 Removal:

Move the seat backwards or forward by lifting the towel bar located under the seat
front in-order to access seat mounting bolts.

1. Press the lock and pull out the head 3. Using a 16 mm socket spanner loosen
restrain from driver seat. and remove the rear side mounting bolts from
driver seat and separately detach the driver
seat.

2. Using a 16 mm socket spanner loosen

and remove the driver seat front side
mounting bolts.

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 1749
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.2.4 Inspection:
1. Check for any damages.
2. Check for seat sagging.
3. Check for proper functionality of recliner.
4. Check for any damages on seat trims.

23.3.2.5 Installation:

While mounting the seat, take care not to crush floor wiring harness.

1. Refit the driver seat in correct position 3. Press the lock and install the head
and torque tighten front side mounting bolts restrain.
to specified value.

2. Similarly refit the rear side mounting

bolts, torque tighten the same to specified
value.

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
1750 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.3 Second Row Seat R&R

23.3.3.1 Component Location Index

23.3.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment.

Tools Required

Size Type Quantity

16 mm Socket spanner 01

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 1751
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.3.3 Removal:

1. Using 16 mm socket spanner loosen and 4. Using 16 mm socket spanner loosen and
remove second row RH seat front mounting remove second row LH seat rear mounting
bolt. bolt.

2. Using 16 mm socket spanner loosen and 5. Using 13 mm socket spanner loosen and
remove second row RH seat rear mounting remove second row top side mounting bolts.
bolt.

6. Detach the Seat belt Buckle with Lap &

3. Using 16 mm socket spanner loosen and Twin buckle from seat & Carefully remove the
remove second row LH seat front mounting second row seat.
bolt.

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
1752 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.3.3.4 Inspection:
1. Check for any damages.
2. Check for seat sagging.
3. Check for any damages on seat trims

23.3.3.5 Installation:

While mounting the seat, take care not to crush floor wiring harness.

1. Position the second row seat and attach 4. Refit the second row LH seat front
the Seat belt Buckle with Lap & Twin buckle mounting bolt, torque tighten the bolt to
on seat. specified value.

2. Refit the second row top side mounting

bolts, torque tighten the bolts to specified
value.

5. Refit the second row RH seat rear

mounting bolt, torque tighten the bolt to
specified value.

3. Refit the second row LH seat rear

mounting bolt, torque tighten the bolt to
specified value.

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 1753
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit the second row RH seat front

mounting bolt, torque tighten the bolt to
specified value.

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
1754 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

23.4 Torque Specifications

Descriptions Torque Nm

SEAT BELT TOP MOUNTING LH/RH 37.5 ± 5

SEAT BELT BOTTOM MOUNTING LH/RH 37.5 ± 5

SEAT BELT MOUNTING FRONT BOTTOM 37.5 ± 5

RH

SEAT BELT MOUNTING REAR BOTTOM 37.5 ± 5

RH

DRIVER AND CO - DRIVER SEAT BUCKLE 37.5 ± 6

MOUNTING LH/RH

DRIVER SEAT MOUNTING ON FLOOR 47.5 ± 7.5

CO - DRIVER SEAT MOUNTING ON 47.5 ± 7.5

FLOOR

REAR SEAT BRACKET MTG 25 ± 5

SEAT LATCH MTG M10 40 ± 7

SEAT LATCH MTG M8 22 ± 3

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 1755
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1756 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24 INTERIOR TRIMS

24.1 Description and Operation

24.1.1 Interior Trims

A. Roof liner F. B-pillar upper trim

B. Speaker cover G. A-pillar lower trim
C. C-pillar upper trim H. Front door trim
D. C-pillar lower trim I. B-pillar lower trim
E. A-pillar upper trim J. Rear door trim

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 1757
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2 In Car Repairs

24.2.1 Driver Sun Visor R&R

24.2.1.1 Component Location Index

24.2.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment and
operation of driver side sun visor.

Tools Required

Size Type Quantity

— Star screw driver 01

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
1758 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.1.3 Removal:

1. Open the driver sunvisor.

2. Using a star screw driver loosen and

remove the sunvisor support bracket
mounting screws.

3. Using a star screw driver loosen and

remove the sunvisor mounting screws.

4. Separately remove the driver sun visor.

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 1759
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.1.4 Installation:

1. Refit the driver sun visor mounting

screws. Torque tighten the screws to
specified value.

2. Refit the support bracket with the help of

mounting screw. Torque tighten the screw to
specified value.

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
1760 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.2 Co - Driver Sun Visor R&R

24.2.2.1 Component Location Index

24.2.2.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment and
operation of co-driver side sun visor.

Tools Required

Size Type Quantity

— Star screw driver 01

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 1761
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.2.3 Removal:

1. Open the co-driver sunvisor.

2. Using a star screw driver loosen and

remove the sunvisor mounting screws.

3. Gently detach from support bracket and

remove the co-driver side sunvisor.

4. Remove support bracket mounting screw

using star screw driver and then gently pull-
out and remove the support bracket.

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
1762 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.2.4 Installation:

1. Refit the support bracket with the help of

mounting screw. Torque tighten the screw to
specified value.

2. Insert the sunvisor on support bracket

first and then mount the sunvisor on other
side with the help of mounting screws.
Torque tighten the screws to specified value.

3. Close the co-driver side sunvisor.

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 1763
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.3 A-Pillar Upper Trim R&R

24.2.3.1 Component Location Index

24.2.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of A-
• Open the front door. pillar upper trim.

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
1764 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.3.3 Removal:

1. Remove the A-pillar door beading.

2. Gently pull out the A-pillar upper trim.

3. Separate the A-pillar upper trim.

24.2.3.4 Inspection:
1. Inspect the A-pillar upper trim for any damage/crack/cut etc. Replace if found any.
2. Inspect the A-pillar upper trim mounting legs for crack/bend etc.

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 1765
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Inspect the A-pillar upper trim fasteners for any damage. Replace the fasteners if found
any damage.

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
1766 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.3.5 Installation:

1. Fit the A-Pillar upper trim and gently

press it.

• Take sufficient care not to damage the

A-pillar upper trim mounting legs
while installation.
• Ensure proper engagement of A-pillar
upper trim fasteners and mounting
legs.

2. Fit the A-Pillar door beading and gently

press it.

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 1767
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.4 A-Pillar Lower Trim R&R

24.2.4.1 Component Location Index

24.2.4.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Ensure proper fitment of A-pillar lower
• Open the respective side front door. trim.

Tools Required

Size Type Quantity

— Long flat end screw driver 01

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
1768 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.4.3 Removal:

1. Remove the A-pillar door beading. 4. Remove the ‘A’ pillar lower trim
separately.

2. Using the flat screw driver pull out the ‘A’

pillar lower trim.

3. Remove the mounting clips from ‘A’ pillar

lower trim.

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 1769
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.4.4 Inspection:
1. Inspect the A-pillar lower trim for any damage/crack/cut etc. Replace if found any.
2. Inspect the A-pillar lower trim fasteners for any damage. Replace the fasteners if found
any damage.
3. Inspect the A-pillar lower trim mounting legs for crack/bend etc.

24.2.4.5 Installation:

Before installing the A-Pillar lower trim check the locator condition.

1. Fix the A-pillar lower trim and gently 2. Fix the mounting clips on A-pillar lower
press it. trim and press it.

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
1770 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Refix the A-Pillar door beading.

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 1771
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.5 B-Pillar Upper Trim R&R

24.2.5.1 Component Location Index

24.2.5.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of B-
pillar upper trims and also the door
• Open respective side front and rear doors.
beadings.

Tools Required

Size Type Quantity

14 mm Ring spanner 01

— Long flat end screw driver 01

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
1772 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.5.3 Removal:

1. Remove the B-pillar door beadings from 4. Using a flat/wedge screw driver remove
front door side and rear door side. the two mounting clips.

2. Open the cap and using 14 mm ring 5. Gently pull out the B-pillar trim.
spanner remove the mounting bolt from top
of the seat belt.

3. Separately detach the seat belt from B-

pillar trim.

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 1773
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.5.4 Inspection:
1. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any.
2. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found
any damage.

24.2.5.5 Installation:

1. Fix the B-pillar upper trim and press it. 2. Fix the mounting clips on B-pillar upper
trim and press it.

When installing the B-Pillar upper trim

check the locator condition and insert
the locator in correct position.

3. Refit the seat belt on B-pillar upper trim.

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
1774 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Refit the seat belt top mounting bolt

torque tighten the bolt to specified value.

5. Refix the B-pillar front and rear door

beadings.

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 1775
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.6 B-Pillar Lower Trim R&R

24.2.6.1 Component Location Index

24.2.6.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of B-
pillar lower trim.

Tools Required

Size Type Quantity

– Long flat screw driver 01

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
1776 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.6.3 Removal:

1. Before removing the B-pillar lower trim 4. Using a flat/wedge screw driver remove
remove the B-pillar upper trim. For additional the seat belt from B-Pillar lower trim.
information refer to B - Pillar Upper Trim R&R
section.

2. Using a flat/wedge screw driver pull out

the B-Pillar lower trim.

5. Separately detach the B-pillar lower trim.

3. Remove the mounting clips from the B-

pillar lower trim.

24.2.6.4 Inspection:
1. Inspect the B-pillar lower trim for any damage/crack etc. Replace if found any.
2. Inspect the B-pillar lower trim fasteners for any damage. Replace the fasteners if found
any damage.

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 1777
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.6.5 Installation:

1. Refit the seat belt on B-pillar lower trim. 3. Refix the B-pillar front and rear door
beadings.

When installing the B-Pillar lower trim

check the mounting clip condition and
insert the locator in correct position.

2. Refit the B-pillar lower trim and gently

press it and then fix the mounting clips.

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
1778 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.7 Front Scuff Plate R&R

24.2.7.1 Component Location Index

24.2.7.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of front
scuff plate.
• Open the respective side front door.

Tools Required

Size Type Quantity

– Star screw driver 01

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 1779
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.7.3 Removal:

1. Using star screw driver remove the front

scuff plate mounting screws.

2. Remove the front scuff plate.

24.2.7.4 Inspection:
1. Inspect the scuff plate for any damage/crack. Replace if found.
2. Inspect the fasteners for any damage. Replace the fasteners if found any damage.

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
1780 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.7.5 Installation:

1. Refit the front scuff plate mountings

screws tighten the same to specified value.

• When installing the front scuff plate fix

the plate in correct mounting position.
• Check front scuff plate plastic
mounting locks.

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 1781
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.8 Rear Scuff Plate R&R

24.2.8.1 Component Location Index

24.2.8.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of rear
scuff plate.
• Open the respective side rear door.

Tools Required

Size Type Quantity

– Star screw driver 01

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
1782 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.8.3 Removal:

1. Using star screw driver remove the rear

scuff plate mounting screws.

2. Separately detach the rear scuff plate.

24.2.8.4 Inspection:
1. Inspect the scuff plate for any damage/crack. Replace if found.
2. Inspect the fasteners for any damage. Replace the fasteners if found any damage.

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 1783
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.8.5 Installation:

1. Refit the rear scuff plate mountings

screws tighten the same to specified value.

• When installing the rear scuff plate fix

the plate in correct mounting position.
• Check rear scuff plate plastic
mounting locks.

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
1784 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.9 C-Pillar Upper Trim R&R

24.2.9.1 Component Location Index

24.2.9.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of C-
pillar upper trim.

Tools Required

Size Type Quantity

14 mm Combination spanner 01

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 1785
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.9.3 Removal:

1. Using 14 mm combination spanner

loosen and remove the top mounting bolt and
separately detach the second row seat belt.

2. Pull out the door beading.

3. Remove the C-pillar upper trim mounting

clips.

4. Gently pull out the C-pillar upper trim.

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
1786 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.9.4 Inspection:
1. Inspect the C-pillar upper trim for any damage/crack etc. Replace if found any.
2. Inspect the C-pillar upper trim fasteners for any damage. Replace the fasteners if found
any damage.

24.2.9.5 Installation:

1. Refix the C-pillar upper trim and gently 3. Refit the seat belt top mounting bolt,
press the mounting clips. torque tighten the same to specified value.

2. Refit the door beading.

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 1787
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.10 C-Pillar Lower Trim - R&R

24.2.10.1 Component Location Index

24.2.10.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of C-
• Remove the respective side C-pillar upper pillar lower trim.
trim. • Refit the respective side C-pillar upper
trim.

Tools Required

Size Type Quantity

— Long flat screw driver 01

14 mm Socket spanner 01

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
1788 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.10.3 Removal:

1. Remove the C-pillar upper trim. For

additional information refer to C-Pillar Upper
Trim R&R section.

2. Using 14 mm combination spanner

loosen and remove the seat belt bottom
mounting bolt and separately detach the
second row seat belt.

3. Using flat end screw driver gently pull out

the C-pillar lower trim.

24.2.10.4 Inspection:
1. Inspect the C-pillar lower trim for any damage/crack etc. Replace if found any.
2. Inspect the C-pillar lower trim fasteners for any damage. Replace the fasteners if found
any damage.

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 1789
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.10.5 Installation:

1. Refit the C-pillar lower trim and gently

press it.

2. Refit the seat belt bottom mounting bolt

torque tighten the bolt to specified value.

3. Refit the C-pillar upper trim. For

additional information refer to C-Pillar Upper
Trim R&R section.

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
1790 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.11 Front Door Trim R&R

24.2.11.1 Component Location Index

24.2.11.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of front
• Open the respective side front door. door trim.

Tools Required

Size Type Quantity

— Star screw driver 01

— Flat end screw driver 01

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 1791
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.11.3 Removal:

1. Open the driver side door and by using a 4. Using star screw driver remove the door
star screw driver remove the outside rear switch bezel mounting screw.
view mirror cover mounting screws.

5. Remove the door switch bezel.

2. Remove the outside rear view mirror
cover.

6. Press the lock and disconnect the

electrical connectors from power window
3. Using star screw driver, remove the inner switch.
handle mounting screw.

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
1792 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Disconnect the electrical connector from

puddle lamp.

8. Gently pull out the door trim from the

front door.

24.2.11.4 Inspection:
1. Inspect the door inner trim for any damage/crack etc. Replace if found any.
2. Inspect the door inner trim mounting fasteners for any damage. Replace the fasteners if
required.
3. Inspect the door inner trim mounting legs for any damage/bend etc.

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 1793
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.11.5 Installation:

1. Connect the puddle lamp electrical 4. Refit the door switch bezel mounting
connector. screw.

2. Align and refit the door trim and gently 5. Refit the inner handle mounting screw.
press it.

6. Refit the outside rear view mirror cover.

3. Connect the power window switch
electrical connector.

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
1794 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Refit the outside rear view mirror cover

mounting screws.

• Carefully install the door trim panel without damaging the clips. Damaged clips may
cause rattling noise from the door.
• Fix the cables properly without damaging the cable locks, damage of cable locks
will not operate properly.

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 1795
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.12 Roof Liner R&R

24.2.12.1 Component Location Index

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
1796 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.12.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit all the grab handles.
• Remove all the grab handles. • Refit LH & RH A-pillar upper trims.
• Remove both sunvisors. • Refit LH & RH B-pillar upper trims.
• Remove LH & RH A-pillar upper trims. • Refit LH & RH C-pillar upper trims.
• Remove LH & RH B-pillar upper trims. • Refit Overhead console.
• Remove LH & RH C-pillar upper trims. • Refit High Mount Stop lamp.
• Remove Overhead console. • Refit speaker cover LH & RH.
• Remove High Mount Stop lamp. • Refit both sunvisors.
• Remove speaker cover LH & RH.

Tools Required

Size Type Quantity

— Flat end screw driver 1

— Star screw driver 1

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 1797
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.12.3 Removal:

1. Remove driver side sunvisor. For 9. Open the sun glass holder and by using
additional information refer to Driver side screw driver remove the over head console
sunvisor R&R section. mounting screws.

2. Remove co-driver side sunvisor. For

additional information refer to Co-driver side
sunvisor R&R section.

3. Remove all the grab handles. For

additional information refer to Grab handle
R&R section.

4. Remove RH & LH A-pillar upper trims.

For additional information refer to A-pillar
upper trim R&R section.

5. Remove RH & LH B-pillar upper trims.

For additional information refer to B-pillar
upper trim R&R section.

6. Remove LH & RH C-pillar upper trims.

For additional information refer to C-Pillar
Upper Trim R&R section.

7. Remove High Mount Stop lamp. For

additional information refer to High Mount
Stop lamp R&R section.

8. Remove the speaker covers of both LH &

RH.
10. Pullout the overhead console and
disconnect the roof lamp electrical connector.

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
1798 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

11. Using a flat end screw driver remove

roof liner mounting push buttons and gently
remove the roof liner.

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 1799
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.12.4 Inspection:

Inspect the roof liner for any damages.

24.2.12.5 Installation:

1. Align and position the roof liner. 4. Refit the over head console mounting
screws and close the sun glass holder.
2. Mount the roof liner using push buttons.

3. Connect the roof lamp electrical

connector and refit the over head console.

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
1800 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refit speaker covers.

6. Refit High Mount Stop lamp. For

additional information refer to High Mount
Stop lamp R&R section.

7. Refit all the grab handles. For additional

information refer to Grab Handle R&R
section.

8. Refit LH & RH A-pillar upper trims. For

additional information refer to A-Pillar Upper
Trim R&R section.

9. Refit LH & RH B-pillar upper trims. For

additional information refer to B-Pillar Upper
Trim R&R section.

10. Refit LH & RH C-pillar upper trims. For

additional information refer to C-pillar upper
Trim R&R section.

11. Refit driver side sunvisor. For additional

information refer to Driver side sunvisor R&R
section..

12. Refit co-driver side sunvisor. For

additional information refer to Co - Driver
Sunvisor R&R section.

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 1801
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.13 Inner Grab Handle - R&R

24.2.13.1 Component Location Index

24.2.13.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of
handle.

Tools Required

Size Type Quantity

— Star screw driver 01

— Flat end screw driver 01

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
1802 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.13.3 Removal:

1. Using flat end screw driver open the grab

handle mounting screw cover.

2. Using star screw driver remove the grab

handle mounting screw.

3. Separately detach the grab handle from

roof.

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 1803
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.2.13.4 Installation:

1. Refix the grab handle on roof liner and

tighten the mounting screws.

2. Refix the grab handle cover.

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
1804 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

24.3 Tightening Specifications

Descriptions Torque (NM)

GRAB HANDLE MTG. 4.5 ± 0.5

SUNVISOR MTG. LH 4.5 ± 0.5

SCUFF PLATE 4.5 ± 0.5

SCUFF PLATE BACK DOOR 3 ± 0.5

LOWER DRIVER PANEL 2.5 ± 0.5

PULL HANDLE MTG. RH 3.5 ± 0.5

CONSOLE Mounting FRT BRKT 3.5 ± 0.5

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 1805
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1806 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25 EXTERIOR TRIMS

25.1 Component Location Index

25.1.1 Refer below illustration for Exterior Trims

A. Front Grill.

B. Front Bumper Mesh.

C. Bezel Fender.

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 1807
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.1.2 Component Location Index

25.1.2.1 Refer below illustration for Exterior Trims

A. Front Fender Cladding.

B. Foot Step Assembly.

C. Rear Splash Shield.

D. Anti Skid Pad.

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
1808 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2 In Car Repairs

25.2.1 Front Bumper Mesh R&R

25.2.1.1 Component Location Index

25.2.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and ensure proper fitment of front
bumper mesh .

Tools Required

Size Type Quantity

— Small flat end screw driver 01

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 1809
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.1.3 Removal:

1. Using a flat end screw driver unlock the

bumper mesh bottom clips.

2. Using a flat end screw driver unlock the

bumper mesh top clips.

3. Gently pull out the front bumper mesh

from bumper assembly.

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
1810 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.1.4 Inspection:
1. Check for any damages or crack in the bumper mesh.

25.2.1.5 Installation:

1. Mount the bumper mesh correctly in to

the bumper assembly.

2. Using flat end screw driver lock the top

and bottom clips.

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 1811
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.2 Front Splash shield R&R

25.2.2.1 Component Location Index

25.2.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift. • Check and ensure proper fitment of front
splash shield.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

10 mm Socket spanner 01

— Nose plier 01

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
1812 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.2.3 Removal:

1. Remove the splash shield mounting

clips.

2. Using 10 mm socket spanner loosen and

remove the mounting bolt and separately
detach the splash shield.

25.2.2.4 Inspection:
1. Check for any damages or crack in splash shield.

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 1813
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.2.5 Installation:

1. Align and refit the splash shield mounting

bolt.

2. Refit the splash shield mounting clips

and gently press it.

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
1814 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.3 Foot Step Assembly R&R

25.2.3.1 Component Location Index

25.2.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a 2 post lift/ 4 Post • Check and ensure proper fitment.
lift.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

13 mm Socket spanner 01

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 1815
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.3.3 Removal:

1. Using a 13 mm socket spanner remove

the foot step plate mounting bolts.

2. Using a 13 mm socket spanner remove

the reinforcement assembly sill side
mounting bolts.

3. Separately remove the foot step

assembly.

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
1816 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.3.4 Inspection:
1. Check for any damages or crack in foot step.

25.2.3.5 Installation:

1. Align and refit the foot step assembly. 3. Refit the foot step plate mounting bolts,
torque tighten the bolts to specified value.

2. Refit the reinforcement assembly sill side

mounting bolt, torque tighten the bolts to
specified value..

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 1817
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.4 Bezel Fender R&R

25.2.4.1 Component Location Index

25.2.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift/ 4 Post • Check and ensure proper fitment.
lift.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

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
1818 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.4.3 Removal:

1. Remove the side marker lamp. For

additional information refer to side marker
lamp R&R section.

2. Using a flat/wedge screw driver gently

pull out the bezel fender.

3. Separately detach the bezel fender.

25.2.4.4 Inspection:
1. Check for any damages on mounting clips.

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 1819
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.4.5 Installation:

Before installing the bezel fender check the mounting clip condition.

1. Align and refit the bezel fender in its

position and gently press it.

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
1820 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.5 Rear Splash Shield Cover R&R

25.2.5.1 Component Location Index

25.2.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift/ 4 Post • Check and ensure proper fitment of rear
lift. splash shield

Tools Required

Size Type Quantity

— Small flat end screw driver 01

10mm Socket spanner 01

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 1821
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.5.3 Removal:

1. Using a 10 mm socket spanner remove 4. Using a flat end screw driver remove the
the splash shield cover mounting bolts. splash shield mounting clips and separately
detach the splash shield.

2. Using a flat end screw driver remove the

mounting clips and separately remove the
splash shield.

3. Using a 10 mm socket spanner remove

the splash shield mounting bolts and
separately remove the splash shield cover.

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
1822 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.5.4 Inspection:
1. Check for any damages or crack in splash shield.

25.2.5.5 Installation:

1. Refit the splash shield cover, torque 3. Refit the splash shield cover, torque
tighten the mounting bolts to specified value. tighten the mounting bolts to specified value.

2. Refit the splash shield mounting clips on 4. Refit the splash shield mounting clips on
the cover. the cover.

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 1823
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.6 Rear Bumper Anti Skid Pad - R&R

25.2.6.1 Component Location Index

25.2.6.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 post lift/ 4 Post • Check and ensure proper fitment of rear
lift. bumper anti skid pad.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

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
1824 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.2.6.3 Removal:

1. Using a flat end screw driver remove the

anti-skid pads from the top of rear bumper
assembly.

25.2.6.4 Inspection:
1. Inspect anti-skid pad for any crack or damage.

25.2.6.5 Installation:

1. Align and gently press and refit the anti-

skid pad on the rear bumper assembly.

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 1825
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

25.3 Torque Specifications & Sequence

Location Torque Nm

TAIL DOOR CHECK ARM 22 ± 5

PLENUM APPLIQUE 1 ± 0.25

FRONT BUMPER CENTER BRKT 4.5 ± 0.5

SCOOP MOUNTING ON BONNET 4 ± 0.5

REGISTRATION PLATE MOUNTING 2.5 ± 0.5

REAR VIEW MIRROR PATCH RH 2.5 ± 0.5

REAR VIEW MIRROR MTG. RH 6.5 ± 1.5

FRONT GRILL MTG. 2.5 ± 0.5

CLADDING MIDDLE DOOR 3 ± 0.5

FRONT MUD FLAP FIT 1.5 ± 0.5

REAR MUD FLAP FIT 4.5 ± 0.5

SKI RACK CAP MTG. 1.2 ± 0.3

SKI RACK CAP MTG. ON BODY 10 ± 2

GAS STRUT MOUNTING BRACKET CC 25±5

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
1826 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26 INTERIOR LIGHTING

26.1 Description and Operation

Interior lamps comprise of roof lamps, (Front and Rear) and ignition key ring illumination.
These lamps can be used for an illuminated entry. In auto mode, the roof lamps (courtesy
lamps) and ignition key ring illuminate when any of the doors are opens. Once all doors are
closed, the interior lamps switch OFF.

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 1827
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.1.1 Front Courtesy/Map Reading

The front courtesy lamp is located in the roof

console above the front seats. The courtesy
lamp can be switched on using the middle
switch (B) on the lamp. The right/left map
reading lamps for the driver/front passenger
are located adjacent to the courtesy lamp
and can be individually switched ON/OFF by
the Map reading lamp switches (A & C).
Do not leave the courtesy/map reading
lamp in permanent ON mode. This will
drain your vehicle battery.

A -Roof Lamp Switch B1- Permanent ON

B - Map Reading Lamp (LH) B2 - Permanent OFF
C - Map Reading Lamp (RH) B3 - Door/Auto Mode Do

Front Courtesy Lamp — Auto Mode Operation

This is applicable to front row courtesy lamp only. The courtesy lamp switch (A) has three
operation modes to choose
B1. The courtesy lamp remains permanently ON in this position irrespective of the door open
status
B2. The courtesy lamp remains permanently OFF in this position
B3. The courtesy lamp remains in AUTO mode in this position. The operation of the courtesy
lamp in Auto mode is as follows;
• Courtesy lamp switches ON, dims and goes OFF after 10 sec delay during RKE unlock
• Courtesy lamp switches ON, dims and goes OFF after 10 sec delay, once vehicle stops and
ignition turned OFF
• Courtesy lamp switches ON when any of the doors is/ are open
• Courtesy lamp switches ON when UNLOCK is pressed on RKE (with ignition in key out)
enabling ease of entry
• Courtesy lamps dim and go OFF after 10 sec delay upon closing of all doors or with ignition
turned ON
• Courtesy lamps dim and go OFF immediately on RKE lock after all doors are closed
• If any of the doors are not closed properly, then the courtesy lamps switch OFF
automatically after a preset duration
• Courtesy lamps go OFF with ignition ON and all doors closed properly

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
1828 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.1.2 Second Row Courtesy Lamp

The second row courtesy lamp is located on

the roof above the second row seats. The
courtesy lamp can be switched ON by the
middle switch on the lamp.

26.1.3 Puddle Lamps

The Puddle lamps are provided at the bottom

of the front doors. They are switched ON
automatically when either of the front doors
are opened. This illuminates the ground
below the respective door thereby assisting
in a safe entry and exit.

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 1829
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.2 Component Location Index

26.2.1 Refer below illustration for Interior Lighting

A. Front Courtesy/ Front Roof Lamp

B. Rear Roof Lamp

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
1830 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3 In Car Repairs

26.3.1 Front Courtesy/Map Reading Lamp R&R

26.3.1.1 Component Location Index

26.3.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
Front Courtesy/Map Reading Lamp
• Turn the ignition OFF.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

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 1831
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.1.3 Removal:

1. Turn the ignition OFF. 4. Disconnect the electrical connectors and

remove the front courtesy lamp.
2. Disconnect the negative terminal of
battery using 10 mm ring/socket spanner.

3. Insert a wedge/flat screw driver in the

roof to press the lock and then pull out the
front courtesy lamp.

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
1832 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.1.4 Inspection:

1. Check the mounting clips condition to

avoid rattling and falling down.
2. Inspect the bulb conditions.

26.3.1.5 Installation:

1. Connect the front courtesy lamp 3. Connect battery negative terminal.

electrical connectors.

2. Align the front courtesy lamp and press

gently to fix.

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 1833
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.2 Second Row Courtesy Lamp R&R

26.3.2.1 Component Location Index

26.3.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
Second Row Courtesy Lamp
• Turn the ignition OFF.

Tools Required

Size Type Quantity

10 mm ring/socket spanner 01

— wedge/flat screw driver 01

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
1834 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.2.3 Removal:

1. Disconnect the negative terminal of 3. Disconnect the electrical connectors

battery using 10 mm ring/socket spanner. from second row courtesy lamp.

2. Insert a wedge/flat screw driver in the

roof to press the lock and then pull out the
second row courtesy Lamp. In case of front roof lamp failure, replace
the front roof lamp assembly.

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 1835
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.2.4 Installation:

1. Connect the connector and Insert the 2. Insert the second row courtesy lamp side
roof lamp side locks into roof console trim. locks into roof console trim and gently press
it.

3. Connect battery negative terminal.

Before installing the assembly overhead
console lamp, check the mounting clips
condition to avoid rattling and falling
down.

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
1836 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.3 Roof Lamp Bulb R&R

26.3.3.1 Component Location Index

26.3.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
rear roof lamp
• Turn the ignition OFF.

Tools Required

Size Type Quantity

— Small flat end screw driver 01

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 1837
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.3.3 Removal:

1. Disconnect the negative terminal of

battery using 10 mm ring/socket spanner.

2. Insert a wedge/flat screw driver in the

gap between roof liner and rear roof lamp to
press the lock and then pull out the rear roof
lamp.

3. Gently expand the bulb holding legs and

remove the bulb.

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
1838 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.3.4 Installation:

1. Carefully expand the bulb mounting legs

and insert the bulb, release the legs to fix the
bulb.

2. Align the roof lamp and press gently to

mount.

3. Connect battery negative terminal.

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 1839
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.4 High Mount Stop Lamp R&R

26.3.4.1 Component Location Index

26.3.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
high mount stop lamp.
• Turn the ignition OFF.

Tools Required

Size Type Quantity

10 mm Ring/Socket spanner 01

— Star screw driver 01

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
1840 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.4.3 Removal:

1. Disconnect the negative terminal of

battery using 10 mm ring/socket spanner.

2. Using star screw driver remove the high

mount stop lamp mounting screws.

3. Disconnect the electrical connector and

separately detach the high mount stop lamp.

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 1841
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.4.4 Installation:

1. Connect the electrical connector of high

mount stop lamp.

Mount the high mount stop lamp properly

into the correct position.

2. Refit the high mount stop lamp and

tighten the screws.

3. Connect battery negative terminal back.

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
1842 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.5 Puddle Lamp R&R

26.3.5.1 Component Location Index

26.3.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat horizontal • Refit the Front door trim.
surface. • Check for power window operation.
• Remove the Front door trim.

Tools Required

Size Type Quantity

- Flat end screw driver 1

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 1843
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.5.3 Removal:

1. Remove the respective side door trim.

For additional information refer to Front Door
Trim R&R section.

2. Pull out the door trim and disconnect the

electrical connector from puddle lamp.

3. Using wedge or flat screw driver

separately detach the puddle lamp from door.

Carefully remove the puddle from the door, failure to follow this instruction will lead to
damage the door painting and puddle lamp.

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
1844 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

26.3.5.4 Installation:

1. Connect the electrical connector to

puddle lamp.

2. Attach the puddle lamp to the door.

3. Refit the door trim. For additional

information refer to Front Door Trim R&R
section.

• Carefully install the door trim panel without damaging the clips. Damaged clips may
cause rattling noise from the door.
• Fix the cables properly without damaging the cable locks, damage of cables locks
will not operate properly.

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 1845
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1846 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27 EXTERIOR LIGHTING

27.1 Description & Operation

Exterior lamps comprise of Front head lamps, Front day time running /position lamps, Front
fog lamps, Side turn signal lamps & Rear tail lamps.

27.1.1 Follow-Me Home (FMH) with Rain Light Sensor (RLS)

This feature helps the driver and passengers to easily get out of the vehicle during poor light
conditions. The head lamp low beam is turned ON for about 20 seconds, assisting the
passengers to find their way unless cancelled by the UNLOCK signal from the RKE.
To enable FMH;
• Ignition transition from ON to OFF
• Park lamp is OFF
• Ignition key is out
• Driver door open within 3 mins from KEY OUT
• Head lamp would turn ON only if the ambience light is found dark by the light sensor
To extend FMH;
• The first RKE LOCK command will be used for locking all doors
• Successive RKE LOCK commands will be used for toggling the current status of the head
lamp low beam
• Each time FMH is extended, the head lamp low beam will be kept/turned on for the next 20
seconds
To disable FMH
• Park lamp transition from OFF to ON
• Ignition off to any other states
• FMH ON 20 seconds expires
With FMH mode ON, if the UNLOCK signal is received twice from RKE; the feature gets
deactivated and cannot be extended further. Also, the doors are unlocked and vehicle the
disarmed.

27.1.2 Follow-Me Home (FMH) Non RLS

This feature helps the driver and passengers to easily get out of the vehicle during poor light
conditions. The head lamp low beam is turned ON for about 20 seconds, assisting the
passengers to find their way unless cancelled by the UNLOCK signal from the RKE.
To enable FMH;
• Ignition transition from ON to OFF
• Park lamp is OFF
• Ignition key is out
• Double press RKE LOCK
• Head lamp low beam will turn ON for 20 seconds unless cancelled by the UNLOCK signal

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 1847
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

To extend FMH;
• The first RKE LOCK command will be used for locking all doors
• Successive RKE LOCK commands will be used for toggling the current status of the head
lamp low beam
• Each time FMH is extended, the head lamp low beam will be kept/turned on for the next 20
seconds
• If no extension is provided for 3 mins, FMH will get expired
To disable FMH
• Park lamp transition from OFF to ON
• Ignition off to any other states
• FMH ON 20 seconds expires
• Max time of 3 mins has elapsed and no extension of FMH
With FMH mode ON, if the UNLOCK signal is received twice from RKE; the feature gets
deactivated and cannot be extended further. Also, the doors are unlocked and vehicle
disarmed.

27.1.3 Lead Me to Vehicle (LMV)(if equipped)

LMV is the feature that switches the head lamp ON in low beam for 20 sec helping the
passengers to reach the parked vehicle safely and comfortably at night.
To enable FMH;
• Ignition key is out
• Park lamp is OFF
• Press UNLOCK button on the RKE (press twice for non RLS equipped version)
• System will unlock all doors and disarm the vehicle followed by head lamp turning ON for 20
sec

If FMH has already expired, LMV would turn ON in the 1st RKE unlock press, else LMV
would be activated for the 2nd RKE unlock press.
When LMV is activated for the 1st press, magic lamp will be initiated followed by head
lamp ON for LMV.
To extend FMH;
• Successive UNLOCK commands received from RKE is used for toggling the current status
of the head lamp low beam.
• Each time LMV is extended the low beam will be kept/turned on for next 20 seconds.
To disable FMH
• LMV ON 20 seconds expires
• Driver door is open (for RLS variant only)
• Ignition off to any other states
• LOCK command is received from RKE
• Park lamp is switched ON

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
1848 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

With FMH mode ON, if the UNLOCK signal is received twice from RKE; the feature gets
deactivated and cannot be extended further. Also, the doors are unlocked and vehicle
disarmed.

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 1849
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.2 Component Location Index

27.2.1 View 1:

A. Head Lamp

B. Fog Lamp

C. Side Marker Lamp

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
1850 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.2.2 View 2:

A. High Mount Stop Lamp

B. Number Plate Lamp

C. Tail Lamp

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 1851
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.3 Care of the System

27.3.1 All Light, Horn, Wipers & Washer - Check

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 right side turn
signal lamps with chime indicating your
intention of turning towards right
• After you have completed your right turn,
the stalk will automatically return to the
neutral position. Both the right turn lamp
and the right turn signal lamp switch OFF
LEFT TURN INDICATOR
• For inspection, push the lighting control
stalk anti-clockwise (to stop position A) to
indicate a left turn. The instrument cluster
arrow lamp pointing towards the left
flashes along with the left side turn signal
lamps with chime indicating your intention
of turning towards left.

LAMPS OFF
• For inspection, rotate the outer rotary
switch on the lighting control stalk aligning
the ‘dot’ on the switch to ‘O’ on the stalk to
switch OFF all lamps.

PARKING LAMPS ON
• For inspection, rotate the outer rotary
switch on the lighting control stalk aligning
the ‘dot’ on the switch to the ‘1st détente’
position on the stalk to switch ON the
parking lamps.

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
1852 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

HEAD LAMP ON
• For inspection, rotate the outer rotary
switch on the lighting control stalk aligning
the ‘dot’ on the switch to the ‘2nd détente’
position on the stalk to switch ON the
head lamps.

HEAD LAMP HIGH BEAM/LOW BEAM

A Low B High
Beam 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.

HEAD LAMP FLASH

• For inspection, pull the lighting control
stalk (from the head lamp low beam
position) towards the steering wheel to
instantaneously flash the head lamp high
beam.
• The head lamp flash works even when the
head lamp is OFF.

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 1853
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

FOG LAMPS OFF

• Align the inner rotary switch on the lighting
control stalk to the fog lamp off ‘dot’ on the
inner fixed stalk as shown to switch OFF
the fog lamps.

FRONT FOG LAMPS ON

• To inspect the front fog lamps, switch ON
the ignition and the parking lamps. Turn
the inner rotary switch on the lighting
control stalk to align to the fog lamp
symbol on the inner fixed stalk as shown.
• The front fog lamp indicator in the
instrument cluster indicates the operation
status.

HAZARD WARNING LAMP

• For inspection, press the switch in. All the
turn signal lamps flash. To turn OFF, press
the switch again.

ROOF LAMPS
The Roof lamp switch has three operation
modes to choose from;
• The lamp remains permanently ON in this
position irrespective of the door open
status.
• The lamp remains permanently OFF in
this position.
• The lamp remains in AUTO mode in this
position.

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
1854 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

WIPER CONTROL STALK

A Flick Wipe (MIST)

B Off

C Intermittent (INT)

D Low Speed (LO)

E High Speed (HI)

1. Wiper Off
For inspection, move the wipe stalk in
neutral position (B). Wiper remains
OFF.
2. Flick-Wipe (Mist)
For inspection, push the wipe control
stalk to position A for a flick-wipe, hold
to operate the wipe continuously
(simultaneously lift the wiper stalk
towards the steering wheel to operate
the wash). The stalk automatically
comes back to position B when
released.
3. Intermittent (INT) Mode
For inspection, push down the stalk
down to position C. In the INT mode,
the wiper operates on preset intervals.
4. Low Speed Wiping
For inspection, push the wipe control
stalk up to the position D to operate the
wiper at a fixed low speed.
5. High Speed Wiping
For inspection, push the wiper control
stalk up to position E to operate the
wiper at a fixed high speed.

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 1855
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

FRONT WIPE/WASH
• For inspection, pull/lift the wiper control
stalk towards the steering wheel from any
position to activate the front wipe/wash
function. Washer fluid is sprayed on the
front windshield and the wipers wipe the
windshield 3 times after the washer spray
is stopped and wipe once after 4 sec. Hold
the stalk in position for continuous spray
of washer fluid.

HORN
• For inspection, press the pad on the
steering wheel to sound the horn. The
horn functions even when the ignition has
been switched OFF.

HIGH MOUNTED STOP LAMP

• For inspection, Press the brake pedal and
the high mounted stop lamp will illuminate.

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
1856 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

REVERSE LAMP
• For inspection, Engage the reverse gear
and the reverse lamp will illuminate.

• Inspect All lights, Horns, Wiper and washers first at 10,000 kms or 6 Months
(Distance Covered in km / Months in service whichever is earlier) and then every
regular service.

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 1857
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.3.2 Head Lamp Aiming

Tools Required

Size Type Quantity

5 mm Socket spanner 01

- Star screw driver 01

Preliminary Activities/Conditions
1. Vehicle & head lamp aiming equipment placed on the same level surface.
2. Check and ensure all four tyre pressures as per specification.
3. Head lamp levelling switch position is on zero (0).
4. Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10
meters/ 3 meters which is the distance from starting point of front tyre to the
aiming board as shown in illustration below)
Head lamp Alignment by Visual Method.
Refer below illustration for “L= 10 Meters”.

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
1858 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Refer below illustration for “L= 3 Meters”.

Refer the below illustration for the head lamp adjustment arrangement -

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 1859
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Refer the below illustration for the head lamp aiming board dimensions -

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
1860 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.3.2.1 LOW BEAM SETTING PROCEDURE:

Refer below illustration for the head lamp low beam cut off Pattern:

1. Using a 5 mm socket spanner, rotate the 2. Using a star screw driver, rotate the
adjusting screw on motor to vary the low adjusting screw to vary the low beam cut-off
beam cut-off pattern in vertical direction. pattern in horizontal direction.
● Clockwise rotation – Downwards.. ● Clockwise rotation – Left side.
● Anti-clockwise rotation – Upwards.. ● Anti-clockwise rotation – Right side.

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 1861
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

3. Check the function of system, by

operating the switch from '0' to '3' and
observe the cutoff pattern movement in
downward direction accordingly.

• As far as possible High beam setting (horizontal/ vertical) should not to be

disturbed..
• Since the high beam spreads out, it is very difficult to identify the center/ Hot spot.
Hence it is not recommended to change the aim of high beam unless otherwise
warranted by an accident repair or front end damage.

• Inspect head lamp aiming first at 10,000 kms or 6 Months (Distance Covered in km /
Months in service whichever is earlier) and then every regular service and do the
adjustment only if required.

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
1862 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4 In Car Repairs

27.4.1 Head Lamp R&R

27.4.1.1 Component Location Index

27.4.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Turn the ignition OFF. • Check and ensure proper functioning of
• Position the vehicle on a flat surface. head Lamp.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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 1863
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.1.3 Removal:

1. Disconnect the negative terminal of 4. Press the lock and disconnect the two
battery using 10 mm ring/socket spanner. head lamp electrical connectors and remove
the head lamp assembly from the vehicle.

2. Remove the front bumper. For additional

information refer to Front Bumper R&R
section.

3. Using 10 mm socket spanner loosen and

remove the head lamp mounting bolts and
remove the head lamp assembly.

27.4.1.4 Inspection:
1. Inspect the head lamp for any damage, crack and glass fading.
2. Inspect the bulbs.

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
1864 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.1.5 Installation:

1. Connect the two head lamp electrical 3. Connect battery negative terminal.
connectors and fit the head lamp assembly
into the vehicle.

4. Refit the front bumper. For additional

information refer to Front Bumper R&R
section.
Mount the head lamp properly into the 5. After installation check the head lamp
correct position. operation.
2. Refit the head lamp mounting bolts,
torque tighten the bolts to specified value.

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 1865
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.2 Fog Lamp R&R

27.4.2.1 Component Location Index

27.4.2.2 Removal & Installation Summary

Pre removal Post Installation

• Turn the ignition OFF. • Check and ensure proper functioning of
fog lamp.
• Position the vehicle on a flat surface.

Tools Required

Size Type Quantity

10 mm Socket spanner 1

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
1866 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.2.3 Removal:

1. Using 10 mm socket spanner remove the 4. Using 10 mm socket spanner remove the
negative terminal of battery. LH side bumper mounting bolt.

2. Remove the splash shield mounting 5. Slightly pull out the bumper and
clips. disconnect the fog lamp connector.

3. Using 10 mm socket spanner remove the 6. Using a star screw driver loosen and
mounting bolt and separately detach the remove the fog lamp mounting screws and
splash shield. separately detach the fog lamp from bumper.

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 1867
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.2.4 Inspection:
1. Inspect the fog lamp assembly for any damage/crack.
2. Inspect the glass for fading.
3. Inspect the bulbs.

27.4.2.5 Installation:

1. Refit the fog lamp on to the bumper, 3. Refit the LH side bumper mounting bolt,
torque tighten the mounting screws to torque tighten the bolt to specified value.
specified value.

4. Refit the splash shield mounting bolt.

2. Connect the electrical connector of fog
lamp.

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
1868 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Refix the splash shield mounting clips

and gently press it.

6. Connect battery negative terminal.

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 1869
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.3 Side Marker Lamp R&R

27.4.3.1 Component Location Index

27.4.3.2 Removal & Installation Summary

Pre removal Post Installation

• Turn the ignition OFF. • Check and ensure proper functioning of
side marker lamp.
• Position the vehicle on a flat surface.

Tools Required

Size Type Quantity

10 mm Ring/ Socket spanner 1

— flat \wedge screw driver 1

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
1870 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.3.3 Removal:

1. Disconnect the negative terminal of

battery using 10 mm ring/socket spanner.

2. Remove the side marker lamp using flat

\wedge screw driver.

3. Disconnect the electrical connector and

separately detach the side marker lamp.

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 1871
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.3.4 Inspection:
1. Inspect the Side Marker lamp for any damage/crack.
2. Inspect the glass for fading.
3. Inspect the bulb.

27.4.3.5 Installation:

1. Connect the electrical connector of side 3. Connect battery negative terminal.

marker lamp.

2. Insert the side marker lamp on to the

fender and gently press it.

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
1872 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.4 Registration Plate Lamp R&R

27.4.4.1 Component Location Index

27.4.4.2 Removal & Installation Summary

Pre removal Post Installation

• Turn the ignition OFF. • Check and ensure proper functioning of
Registration plate lamp.
• Position the vehicle on a flat surface.

Tools Required

Size Type Quantity

— Star screw driver 1

10 mm Socket spanner 1

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 1873
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.4.3 Removal:

1. Disconnect the negative terminal of 4. Gently remove the registration lamp from
battery using 10 mm ring/socket spanner. rear bumper.

2. Disconnect the registration lamp

electrical connectors from LH & RH side.

3. Using a small star screw driver loosen

and remove the registration lamps (LH & RH)
mounting screws.

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
1874 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.4.4 Inspection:
1. Inspect the registration lamp for any damage/crack.

27.4.4.5 Installation:

1. Refit the registration lamps on the rear 3. Connect battery negative terminal.
bumper assembly, torque tighten the
mounting screws to specified value.

2. Connect the LH & RH registration lamps

electrical connectors.

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 1875
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.5 Tail Lamp R&R

27.4.5.1 Component Location Index

27.4.5.2 Removal & Installation Summary

Pre removal Post Installation

• Turn the ignition OFF. • Check and ensure proper functioning of
Tail lamp.
• Position the vehicle on a flat surface.

Tools Required

Size Type Quantity

— Star screw driver 1

10 mm Socket spanner 1

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
1876 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.5.3 Removal:

1. Disconnect the negative terminal of 4. Using a 10 mm socket spanner remove

battery using 10 mm ring/socket spanner. the tail lamp mounting nuts.

2. Using a star screw driver remove the tail 5. Detach the tail lamp.
lamp cover mounting screws.

3. Remove the electrical connector.

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 1877
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.4.5.4 Inspection:
1. Inspect the tail lamp assembly for any physical damage/crack etc.
2. Inspect the glass for fading.
3. Inspect the bulb.
4. Inspect the tail lamp assembly mounting legs for any damage/crack.
5. Inspect the connectors for proper fitment.

27.4.5.5 Installation:

1. Align and refit the tail lamp. 3. Refit the electrical connector.

2. Refit the tail lamp, torque tighten the 4. Refit the tail lamp cover, torque tighten
mounting nuts to specified value. the mounting screws to specified value.

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
1878 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

5. Connect battery negative terminal.

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 1879
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.5 Technical Specifications

27.5.1 Bulb Specification

Lamp Bulb Wattage No. of Bulbs per Vehicle

Head Lamp - Low Beam H7 55W 2

Head Lamp - High Beam / H7 55W / 15W 2

DRL

Front Turn Signal Lamp 21W 2

Side Turn Signal Lamp 5W 2

(Fender)

Static Bending Lamp * H1 55W 2

Front Position Lamp * LED* / 5W LED* / 2

High Mount Stop Lamp LED* / 10W LED* / 2

Brake Lamp LED* LED*

Rear Turn Signal Lamp 16W 2

Rear Position Lamp LED* LED*

Reversing Lamp 16W 2

Front Fog Lamp * 35W 2

Rear License Plate Lamp 5W 2

Interior Lamps Bulb 10W 1

Puddle Lamps * LED* LED*

* select models only, subject to LED serviceability

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
1880 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

27.6 Torque Specifications

Location Torque Nm

Head Lamp 6± 1

Fog Lamp 3 ± 0.5

High mount stop lamp 4± 0.5

Tail Lamp & Reflector 3 ± 0.5

Tail Lamp mounting 3±1

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 1881
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1882 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28 IN CAR ENTERTAINMENT

28.1 Description and Operation

28.1.1 Level 1 Audio Infotainment System

S.NO. Function/Description

1 Disc Eject

2 Setup button

3 Phone

4 ID3 Tag Display

5 Equalizer Setting

6 Preset station Memory Buttons

7 Power ON/OFF Mute/ Volume control

8 Repeat function (RPT)

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 1883
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

S.NO. Function/Description

9 Random Function (RDM)

10 Directory UP (D+)

11 Directory down(D-)

12 Auto Select

13 Call Reject / Seek down / track down / FF

14 Call Accept / Seek Up / Track Up / RW

15 BAND control (BAND)

16 Source Selector

17 Red colour DISC IN Indicator

18 IR Receiver

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
1884 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.1.2 Level 3 Audio Infotainment System

S.NO Function/Description

1 Power On/Off / Volume / Mute

2 Tune Up/Down / AST / Selector / Enter

3 Home Button

4 Navigation Button

5 Seek Up / Bt Call Button

6 Seek Down / Bt End Button

7 Equalizer Button (Equalizer)

8 Info – Car Info Display Mode

9 Phone Book Button (Phone Book / Pairing)

10 Radio Button

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 1885
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

S.NO Function/Description

11 Eject Button (DVD/Disc Eject)

12 Indicator For Disc-In (Red Colour)

13 Window For IR Receiver

FEATURES
AM/FM tuner
• Auto Seek with RDS
• 18-FM and 12-AM manual preset store
CD- AUDIO/VIDEO, DVD, USB, iPod
• Supports CDDA, MP3, WMA9 ,Divx,MPEG4
• Browsing
• Random / Repeat
Aux Audio Input
Bluetooth
• Hands Free
• Phone Book Access
• Music Streaming
Audio adjustments
• Bass, Treble, Balance, Fade
• Normal, Classic, Pop, Jazz, Rock
• Mahindra Modes

28.2 Component Location Index

28.2.1 Refer below illustration for In-car Entertainment

A. Infotainment Unit

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
1886 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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 1887
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.3 Service Tips and Precautions

To avoid risk of damage and/ or fire, observe the following precautions:
• To avoid short circuits, never insert metallic objects (for instance coins or metallic tools) into
the unit.
• Pay attention not to let the unit fall down, nor beat the device strongly. Glass and other
internal components of the unit may get damaged, making it non-operative.
• If the LCD (Liquid Crystal Display) is damaged or broken as a result of a crash, never touch
the liquid crystal fluid inside it. The liquid crystal fluid may be harmful to your health. If the
liquid gets in contact with the body or clothes, wash it promptly with water and soap and
seek medical help.
• If you notice that the unit is releasing smoke or strange smell, promptly disconnect the
supply and identify the cause.
• Do not place 8 cm (3 inches) compact discs into the CD opening. If you try to place into the
device an 8 cm CD with its adaptor, it may separate from the CD and damage the unit.
Cleaning of the unit
If the front panel of this unit is dirty, clean it with a dry cloth or slightly soaked in water. If the
front panel is too dirty, clean it with a cloth moistened with neutral soap and then repeat the
prior operation.

• Do not use any cleaning spray with this unit, as that can affect its mechanical parts.
• If you clean the front panel with a rough cloth or using a volatile liquid like solvent or
alcohol, that may scratch the surface or erase some characters.

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
1888 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4 In Car Repairs

28.4.1 Infotainment Unit R&R

28.4.1.1 Component Location Index

28.4.1.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Refit the centre bezel assembly.
• Remove the centre bezel assembly. • Check and ensure proper functioning of
Infotainment unit.

Tools Required

Size Type Quantity

— Flat screw driver 01

— Star screw driver 01

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 1889
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.1.3 Removal:

1. Insert a wedge/flat screw driver and 4. Using a star screw driver remove the
carefully remove the central bezel from the infotainment unit mounting screw and
instrument panel. separately detach the unit.

2. Disconnect the electrical connectors 5. Pull the Infotainment unit forward and
from the central bezel. disconnect the electrical connectors from
Infotainment unit and separately detach it
from instrument panel.

3. Separately detach the central bezel from

Instrument panel.

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
1890 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Always pull the central bezel carefully from the bottom side to avoid the damage of
central bezel and the central bezel locks.
• Store the removed Infotainment unit in a dust free environment. Avoid direct
sunlight, excessive heat or humidity.
• Press the Power ON/OFF button on the face plate to Turn ON/OFF the audio system.

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 1891
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.1.4 Inspection:
1. Inspect the unit for any damage.
2. Inspect the connectors for any damage.

28.4.1.5 Installation:

1. Connect all the electrical connector of 3. Connect all the electrical connector to
audio unit and insert the infotainment unit in central bezel.
to the instrument panel.

4. Gently press the central bezel on to

2. Refit the Infotainment unit. instrument panel.

• While installing the central bezel, ensure that the wiring harness is routed properly.
• Properly route the audio unit wiring harness to avoid the short circuit and
malfunction.

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
1892 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.2 GPS Antenna R&R

28.4.2.1 Component Location Index

28.4.2.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
GPS Antenna function.
• Turn the ignition OFF.

Tools Required

Size Type Quantity

— Flat screw driver 01

— Star screw driver 01

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 1893
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.2.3 Removal:

1. Insert a wedge/flat screw driver and 4. Using a star screw driver remove the
carefully remove the central bezel from the infotainment unit mounting screw and
instrument panel. separately detach the unit.

2. Disconnect the electrical connectors 5. Pull the Infotainment unit forward and
from the central bezel. disconnect the GPS antenna electrical
connector & other connectors from
infotainment unit and separately detach it
from instrument panel.

3. Separately detach the central bezel from

Instrument panel.

6. Remove the Instrument panel. For

additional information refer to IP R&R
section.

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
1894 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Remove the GPS Antenna from demist

duct bracket.

28.4.2.4 Inspection:
1. Inspect the antenna for any damage.
2. Inspect the connectors for any damage.

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 1895
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.2.5 Installation:

1. Refit the GPS antenna on demist duct 5. Connect all the electrical connector to
bracket. central bezel.

2. Refit the Instrument panel. For additional 6. Gently press the central bezel into
information refer to IP R&R section. instrument panel.

3. Connect all the electrical connector of

GPS antenna & others of audio unit and
Insert the audio unit on to the instrument
panel.

• While installing the central bezel,

ensure that the wiring harness is
routed properly.
4. Refit the Infotainment unit. • Properly route the audio unit wiring
harness to avoid the short circuit and
malfunction.

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
1896 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.3 Front Door Speaker R&R

28.4.3.1 Component Location Index

28.4.3.2 Removal & Installation Summary

Pre removal Post Installation

• Position the vehicle on a flat surface. • Refit the front door trim.
• Remove the front door trim. • Check and ensure proper functioning of
speaker.

Tools Required

Size Type Quantity

— Star screw driver 01

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 1897
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.3.3 Removal:

1. Remove the front door trims. For

additional information refer to Front Door
Trim R&R section.

2. Using a star screw driver remove

speaker unit mounting screws.

3. Disconnect the electrical connectors of

front door speaker and separately detach the
speaker from door.

• Do not connect speaker leads to any inputs on external amplifiers, this will cause
damage to the internal amplifier of this unit.
• Follow the same procedure for removing front door speaker (LHS).

28.4.3.4 Inspection:
1. Inspect the speaker for any physical damage. Replace if found.
2. Inspect the connector for any damage.

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
1898 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.4.3.5 Installation:

1. Connect the electrical connector to front

door speaker.

2. Refit the speaker unit, torque tighten the

mountings to specified value.

3. Refix the door trims. For additional

information refer to Front Door Trim R&R
section.

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 1899
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

28.5 Tightening Specifications

Description Torque (NM)

SPEAKER MTG. 3.5 ± 0.5

REAR DOOR SPEAKER 3.5 ± 0.5

SPEAKER ON FRONT DOOR 3.5 ± 0.5

BACK DOOR SPEAKER 3.5 ± 0.5

AUDIO 2 ± 0.25

ANTENNA MOUNTING 3± 0.5

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
1900 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29 BUMPERS

29.1 Description and Operation

Bumper is designed to absorb impact in a collision and protect body of vehicle & pedestrians
from severe damage in minor collisions.

29.1.1 Refer below illustrations for front bumper exploded view:

A. Front Bumper.
B. RH Fog Lamp.
C. Appron Front Bumper Lower.
D. Mesh Front Bumper.
E. LH Fog Lamp.

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 1901
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.1.2 Refer below illustrations for rear bumper exploded view:

A. Rear Bumper.
B. Rear Bumper Anti skid pad.

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
1902 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.2 Component Location Index

29.2.1 Refer below illustration for front bumper layout

A. Front Bumper Grill.

B. Front Bumper Assembly.

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 1903
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.2.2 Refer below illustration for rear bumper layout

A. Rear Bumper Assembly.

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
1904 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3 In Car Repairs

29.3.1 Front Bumper Grill R&R

29.3.1.1 Component Location Index

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 1905
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of front
bumper grill.
• Open the bonnet.

Removal steps:
1. Remove front bumper grill top mounting screws.
2. Remove front bumper grill.
Tools Required

Size Type Quantity

- Small flat end screw driver 01

- Small star screw driver 01

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
1906 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.1.3 Removal:

1. Remove front grill top mounting screws

by unscrewing the screws using star screw
driver and then pulling it up with the help of
small flat end screw driver.

2. Unlock the bottom clips and remove the

front bumper grill.

Take sufficient care not to damage the

mounting legs while removal.

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 1907
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.1.4 Inspection:
1. Inspect front grill lower mounting legs for any damage/ bend/ crack. Replace if found any.
2. Inspect front grill for any damage.

29.3.1.5 Installation:

1. Match and lock front bumper grill bottom

mounting clips.

2. Mount front grill with the help of mounting

screws on the top.

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
1908 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.2 Front Bumper Assembly R&R

29.3.2.1 Component Location Index

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 1909
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check for proper fitment.

• Open the bonnet.

Removal steps:
1. Remove front bumper assembly top mountings.
2. Remove front bumper assembly mounting bolts.
3. Remove front bumper assembly mountings on LH wheel arch.
4. Remove front bumper assembly mountings on RH wheel arch.
5. Remove front bumper assembly bottom mounting buttons.
6. Remove front bumper assembly main mounting nuts.
7. Remove front bumper assembly.
Tools Required

Size Type Quantity

- Star screw driver 01

10 mm Socket spanner 01

- Flat end screw driver 01

13 mm Tubular spanner 01

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
1910 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.2.3 Removal:

1. Remove front bumper grill assembly. For 4. Remove front bumper RH mounting bolt
additional information refer Front Bumper and buttons on wheel arch with the help of 10
Grill R&R section. mm socket spanner and flat end screw driver.

2. Remove bumper top mounting screws by

unscrewing the screws using star screw
driver and then pulling it up with the help of
small flat end screw driver.

5. Remove front bumper LH mounting bolt

and buttons on wheel arch with the help of 10
mm socket spanner and flat end screw driver.

3. Using 10 mm socket spanner, remove

the bumper top mounting bolts.

6. Remove front bumper bottom mounting

buttons with the help of flat end screw driver.

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 1911
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using 13 mm tubular spanner remove

front bumper main mounting nuts and washer
located behind the bumper.

8. Disconnect fog lamp electrical connector

(If applicable) on both the side.

9. Remove the front bumper assembly.

29.3.2.4 Inspection:
1. Inspect front bumper for any crack or damage.
2. Inspect the fog lamps for any damage.

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
1912 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.2.5 Installation:

1. Place the front bumper in its position. 4. Refit front bumper bottom mounting
buttons.

2. Connect fog lamp electrical connectors

on both sides (If applicable). 5. Refit LH & RH bumper mounting bolt and
buttons on wheel arch, torque tighten the bolt
to specified value.

3. Refit front bumper main mounting nuts

with washer, toque tighten the nuts to
specified value.

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 1913
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Refit bumper top mounting bolts, torque

tighten the bolts to specified value.

7. Plug in front bumper top mounting

screws.

8. Refit front bumper grill assembly. For

additional information refer Front Bumper
Grill R&R section.

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
1914 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.3 Rear Bumper Assembly R&R

29.3.3.1 Component Location Index

29.3.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of rear
bumper assembly.

Tools Required

Size Type Quantity

- Flat end screw driver 1

10 mm/ 13 mm Socket spanner 1

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 1915
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.3.3 Removal:

1. Using a flat end screw driver remove the 4. Using a 10 mm socket spanner loosen
anti-skid pads from the top of rear bumper and remove the bumper bracket bolts from
assembly. chassis (LH & RH).

2. Disconnect the registration lamp 5. Using a 13 mm socket spanner loosen

electrical connectors from LH & RH side. and remove the bumper center mounted
bolts.

3. Using a small star screw driver loosen

and remove the registration lamps (LH & RH) 6. Using a 13 mm socket spanner loosen
mounting screws. and remove the RH side bumper mounting
bolts.

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
1916 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

7. Using a 13 mm socket spanner loosen

and remove the LH side bumper mounting
bolts.

8. Remove the rear bumper assembly from

the vehicle.

29.3.3.4 Inspection:
1. Inspect rear bumper for any crack or damage.

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 1917
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.3.3.5 Installation:

1. Position and align the rear bumper 3. Refit the rear bumper center mounting
assembly on the vehicle. bolts, torque tighten the bolts to specified
value.

2. Refit the rear bumper LH & RH mounting

bolts, torque tighten the bolts to specified 4. Refit the rear bumper LH & RH bracket
value. mounting bolts on chassis.

5. Refit the registration lamps on the rear

bumper assembly, torque tighten the
mounting screws to specified value.

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
1918 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

6. Connect the LH & RH registration lamps

electrical connectors.

7. Refit the anti-skid pad on the rear

bumper assembly.

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 1919
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

29.4 Tightening Specifications & Sequence

Location Torque Nm

Rear bumper structure Mounting chassis 45 ± 5

Rear bumper Mounting on structure 25 ± 5

End Cap Rear Bumper 2.5 + 0.5

Rear bumper reinforcement screw 2.5 + 0.5

Rear bumper Mtg. Bracket 22 + 3

Front bumper mounting on chassis 32.5 ± 6

Front grill mounting 2.5 ± 0.5

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
1920 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30 WIPERS & WASHERS

30.1 Description and Operation

A windscreen wiper or windshield wiper is a device used to remove rain and debris from a
windscreen or windshield.
Wiper consists of an arm, pivoting at one end and with a long rubber blade attached to the
other. The blade is swung back and forth over the glass, pushing water from its surface.

30.1.1 Front Nozzle

In the front, a single nozzle with twin

adjustable washer jets is provided on the
hood. Using a pin, the eye ball jets can be
adjusted precisely for direction.Always direct
the washer jet to hit middle of the windshield.
This will enable the wiper blade to wipe the
complete width of the windshield.

30.1.2 Washer Tank and Washer Motor

The fluid reservoiris located in the engine

compartment inside the LH fender.
In very cold weather conditions, fill the
reservoir with washer fluid premixed with
anti-freeze. Windshield washers is equipped
with electric motors, mounted on reservoir
itself.
The motor pumps fluid at high pressure,
which is sprayed in to windshield at greater
velocity and pressure with the help of nozzle
arrangement. Nozzle arrangement increases
the velocity and pressure of the fluid.

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 1921
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.1.3 Front Wiper Arms/Blade

The drive output arm is revolved or moved

back and forth by the operation of the wiper
motor, the force of this movement is
transmitted by the linkage, to the linkage
pivots, to which the wiper arms and blades
are attached. As the linkage pivots are forced
to rotate, the arms and blades move on the
windshield in a predetermined arc.

30.1.4 Wiper Control Stalk

The wipe/wash function can be activated

only when the ignition is in “IGN” position
A Flick Wipe (MIST)
B Off
C Intermittent (INT)
D Low Speed (LO)
E High Speed (HI)
Wiper Off
The wipe function is OFF when the wipe
control stalk is in neutral position (B). Wiper
remains OFF.
Flick-Wipe (Mist)
Push the wipe control stalk to position A for a
flick-wipe, hold to operate the wipe
continuously (simultaneously lift the wiper
stalk towards the steering wheel to operate
the wash). The stalk automatically comes
back to position B when released.

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
1922 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

Intermittent (INT) Mode

Intermittent (INT) wiping is selected when the
wipe control stalk is pushed down to position
C. In the INT mode, the wiper operates on
preset intervals.
Low Speed Wiping
Push the wipe control stalk up to the position
D to operate the wiper at a fixed Low speed.
High Speed Wiping
Push the wiper control stalk up to position E
to operate the wiper at a fixed high speed.

30.1.5 Auto Wipe (if equipped)

The auto wipe button is located in the switch

bank under the HVAC controls.
Press the button to enable the auto wipe;
• Front wiper will wipe once to indicate the
entry into Automatic mode.
• Front wiper will wipe according to the rain
intensity.
Keeping the Wiper in Low / High speed will
deactivate the Auto mode.

30.1.6 Wipe/Wash

Pull/Lift the wiper control stalk towards the

steering wheel from any position to activate
the front wipe/wash function. Washer fluid is
sprayed on the front windshield and the
wipers wipe the windshield 3 times after the
washer spray is stopped and wipe once after
4 sec. Hold the stalk in position for
continuous spray of washer fluid.

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 1923
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.2 Component Location Index

30.2.1 Refer below illustration for front wiper assembly layout.

A. Front LH Wiper Arm Mounting Nut.

B. Front Wiper Link assembly.
C. Wiper motor mounting bolt.
D. Front Wiper Assembly Bracket.
E. Front wiper motor.
F. Front RH Wiper Arm Mounting Nut.

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
1924 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.2.2 Refer below illustration for wiper washer assembly layout.

A. Filler Cap.
B. Filler Hose.
C. Washer Tank.
D. Front Washer Motor.

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 1925
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.3 Care of the System

30.3.1 Windshield Washer Fluid Top-up

1. Top up the windshield washer reservoir

as and when required. The reservoir supplies
washer fluid to front.

In very cold weather conditions, fill the

reservoir with washer fluid premixed with
antifreeze.

• If wiper washer is operated when

vehicle is under 4.5ºC, use washer
fluid with anti-freeze protection.
Failure to use washer fluid with anti-
freeze protection in cold weather
could result in impaired windshield
vision and increase the risk of injury
or accident.

30.3.2 Checking the Wiper Blades

Lift the wiper arm from its position. Expose

the blade lip for inspection. Clean the wiper
blade lips with water applied with a soft
sponge. If the wiper blade is not wiping the
glass satisfactorily or is worn-out, cut,
cracked or bulging, then replace it.

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
1926 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4 In Car Repairs

30.4.1 Front Wiper Blade R&R

30.4.1.1 Component Location Index

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 1927
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.1.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper functioning of
wipers.

Removal steps:
1. Press the lock.
2. Pull the wiper blade downwards.
3. Remove wiper blade.

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
1928 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.1.3 Removal:

• While attempting to remove the front wiper blade, ensure that the wiper arm is at the
park position and the ignition switch is in OFF position.

1. Lift the front wiper arms to raise the wiper

blade, until the wiper arm hinge is moved to
the centre position.

2. Press the wiper blade retaining lock, and

pull down the wiper blade through the wiper
arm as shown in illustration.

• Do not allow the wiper arm to spring back against the glass without the wiper blade
in place. It may lead to the damage of the windshield glass.

30.4.1.4 Inspection:
1. Check wiper blade for any damage, bent. Replace if found any.

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 1929
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.1.5 Installation:

1. Insert the wiper blade to the arm, and

lock into the slot by gently pulling the wiper
blade upward.

• Make sure that the wiper blade

retaining locks fit and engage
properly.

2. Lower the wiper arm to the original

position.

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
1930 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.2 Front Wiper Rubber R&R

30.4.2.1 Component Location Index

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 1931
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.2.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the wiper blade

• Remove the wiper blade • Check and ensure proper functioning of
wiper.

Removal steps:
1. Remove wiper blade.
2. Remove wiper blade rubber.
Tools Required

Size Type Quantity

- Cutting plier 01

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
1932 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.2.3 Removal:

1. Remove front wiper blade. For additional

information refer to front wiper blade R&R
section.

2. Using a cutting plier, grip the wiper

rubber along with steel bead on locking side
and pull outwards for unlocking.

• Wiper rubber has got 2 sides, on one

side the rubber is getting locked on
metal support as shown in illustration,
rubber needs to be pulled from that
side using a cutting plier for removing.

3. Hold the end of the rubber and pull until

the tabs are free of the metal support.

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 1933
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.2.4 Installation:

1. Carefully insert the new wiper rubber on 3. To engage the wiper blade lock, hold the
wiper blade from one end. wiper rubber together with the metal bead
and pull outwards as shown in illustration.

• As shown in illustration, the rubber

end which has groove open till end
need to be inserted from one end.
• Always use new wiper rubber.

• Make sure that the wiper rubber

retaining locks fit and engage
properly.

4. Refit front wiper blade. For additional

2. Push the wiper rubber and engage all information refer to front wiper blade R&R
metal supports. section.

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
1934 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.3 Front RH Wiper Arm R&R

30.4.3.1 Component Location Index

30.4.3.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the wiper blade

• Remove the wiper blade • Check and ensure proper functioning of
wiper.

Tools Required

Size Type Quantity

13 mm Socket spanner 01

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 1935
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.3.3 Removal:

1. Remove front RH wiper blade. For

additional information refer to front wiper
blade R&R section.

• While attempting to remove the front

wiper arm, ensure that the wiper arm is
at the park position and the ignition
switch is in OFF position.

2. Pull out the wiper arm mounting nut

plastic cover.

3. Loosen and remove front RH wiper arm

mounting nut with the help of a 13 mm socket
spanner and then detach and separate wiper
arm assembly.

30.4.3.4 Inspection:
1. Check front wiper arm for any bend, crack or damage

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
1936 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.3.5 Installation:

1. Place the RH wiper arm in its position.

2. Insert mounting nut and torque tighten to

specified value.

3. Plug in the cover.

4. Refit front RH wiper blade. For additional

information refer to front wiper blade R&R
section.

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 1937
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.4 Front LH Wiper Arm R&R

30.4.4.1 Component Location Index

30.4.4.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the wiper blade

• Remove the wiper blade • Check and ensure proper functioning of
wiper.

Tools Required

Size Type Quantity

13 mm Socket spanner 01

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
1938 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.4.3 Removal:

1. Remove front LH wiper blade. For

additional information refer to front wiper
blade R&R section.

• While attempting to remove the front

wiper arm, ensure that the wiper arm is
at the park position and the ignition
switch is in OFF position.

2. Pull out the wiper arm mounting nut

plastic cover.

3. Loosen and remove front LH wiper arm

mounting nut with the help of a 13 mm socket
spanner and then detach and separate wiper
arm assembly.

30.4.4.4 Inspection:
1. Check front wiper arm for any bend, crack or damage

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 1939
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.4.5 Installation:

1. Place the LH wiper arm in its position.

2. Insert mounting nut and torque tighten to

specified value.

3. Plug in the cover.

4. Refit front LH wiper blade. For additional

information refer to front wiper blade R&R
section.

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
1940 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.5 Plenum Applique R&R

30.4.5.1 Component Location Index

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 1941
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.5.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Check and ensure proper fitment of front
wiper cowl.
• Open the bonnet.

Removal steps:
1. Remove plenum applique mounting buttons.
2. Remove the plenum applique.
Tools Required

Size Type Quantity

- Flat end screw driver 01

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
1942 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.5.3 Removal:

1. Remove the front LH wiper arm. For

additional information refer to front Wiper
arms R&R section.

2. Remove the front RH wiper arm. For

additional information refer to front Wiper
arms R&R section.

3. Using a flat end screw driver, remove

plenum applique mounting buttons.

4. Remove the plenum applique.

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 1943
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.5.4 Inspection:
1. Check plenum applique for any damage, crack and degradation. Replace if found.

30.4.5.5 Installation:

1. Place the plenum applique in its position.

2. Insert plenum applique mounting

buttons.

3. Refit the front LH wiper arms. For

additional information refer to front wiper
arms R&R chapter.

4. Refit the front RH wiper arms. For

additional information refer to front wiper
arms R&R chapter.

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
1944 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.6 Front Wiper Assembly R&R

30.4.6.1 Component Location Index

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 1945
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.6.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the plenum applique.

• Open the bonnet. • Check and ensure proper functioning of
• Remove the plenum applique. wiper mechanism.

Removal steps:
1. Loosen wiper link mounting nuts.
2. Remove wiper assembly bracket mounting bolts.
3. Remove wiper assembly.
Tools Required

Size Type Quantity

24 mm Open end spanner 01

13 mm Socket spanner 01

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
1946 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.6.3 Removal:

1. Remove the front LH wiper arms. For 7. Using a 24 mm open end spanner,
additional information refer to Front Wiper LH loosen and remove wiper link mounting nuts
arm R&R section. and washers.

2. Remove the front RH wiper arms. For

additional information refer to Front Wiper
RH arm R&R section.

3. Remove Plenum Applique. For additional

information refer to front Plenum Applique
R&R section.

4. Remove front wiper cowl beading. For

additional information refer to front wiper
cowl R&R section.

5. Press the lock and disconnect front wiper

motor electrical connector.

8. Remove wiper assembly bracket

mounting bolts using 13 mm socket spanner.
6. Remove the caps on wiper link mounting
nuts.

9. Detach wiper linkage from both slots on

either side and remove the front wiper
assembly.

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 1947
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.6.4 Inspection:
1. Check linkages for any bend, damage.
2. Check for easy movement of linkages.
3. Check motor for any damage.

30.4.6.5 Installation:

1. Insert wiper assembly link on both sides 2. Insert front wiper assembly mounting
in to slot, tighten it with the help of washer bracket bolts and torque tighten to specified
and mounting nut. value.

3. Insert the caps back.

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
1948 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

4. Connect front wiper motor electrical

connector.

5. Refit the front wiper LH arm. For

additional information refer to Front Wiper LH
arm R&R section.

6. Refit the front wiper RH arm. For

additional information refer to Front Wiper
RH arm R&R section.

7. Refit front wiper cowl beading. For

additional information refer to front wiper
cowl R&R section.

8. Refit Plenum Applique. For additional

information refer to Plenum Applique R&R
section.

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 1949
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.7 Front Wiper Motor R&R

30.4.7.1 Component Location Index

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
1950 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.7.2 Removal & Installation Summary

Pre Removal Post Installation

1. Position the vehicle on a flat surface. • Refit the front wiper assembly.
2. Remove the front wiper assembly. • Check and ensure proper functioning of
wiper mechanism.

Removal steps:
1. Remove link mounting nut.
2. Remove wiper motor mounting bolts.
3. Remove the wiper motor.
Tools Required

Size Type Quantity

12 mm Socket spanner 01

10 mm Socket spanner 01

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 1951
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.7.3 Removal:

1. Remove the front wiper assembly. For

additional information refer to Front Wiper
assembly R&R section.

2. Remove link assembly mounting nut with

the help of 12 mm socket spanner.

3. Remove the wiper motor mounting bolts

with the help of 10 mm socket spanner and
detach wiper motor separately.

30.4.7.4 Inspection:
1. Check the motor for any damage. Replace if found any.
2. Check for burning. Replace if found.

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
1952 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.7.5 Installation:

1. Mount motor back on bracket with the

help of mounting bolts and torque tighten the
bolts to specified value.

2. Position the link assembly on motor

shaft, insert mounting nut and tighten to
specified torque value.

3. Refit the front wiper assembly. For

additional information refer to Front Wiper
assembly R&R section.

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 1953
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.8 Front Washer Nozzle R&R

30.4.8.1 Component Location Index

30.4.8.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the intercooler duct.

• Remove the intercooler duct. • Check and ensure proper functioning of
front washer nozzles.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

- Flat end screw driver 01

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
1954 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.8.3 Removal:

1. Remove intercooler duct. For additional

information refer to rear intercooler duct R&R
section.

2. Disconnect front washer nozzle tube.

3. Press the locks and detach nozzle from

hood.

30.4.8.4 Inspection:
• Check nozzle for any damage or blockage in orifice.

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 1955
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.8.5 Installation:

1. Refit nozzle back on hood.

2. Connect the washer nozzle tube.

• Ensure that the tube is fixed properly.

3. Refit intercooler duct. For additional

information refer to rear intercooler duct R&R
section.

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
1956 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.9 Wiper Washer tank R&R

30.4.9.1 Component Location Index

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 1957
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.9.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a flat surface. • Refit the LH fender.

• Remove the LH fender. • Check and ensure proper functioning of
front wiper & washer.

Tools Required

Size Type Quantity

10 mm Socket spanner 01

13 mm Socket spanner 01

13 mm Ring spanner 01

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
1958 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.9.3 Removal:

1. Remove LH fender. 5. Loosen washer tank bottom bracket

mounting nut using 13 mm ring spanner and
2. Detach the filler neck by removing its remove washer tank assembly.
mounting nut with the help of 10 mm socket
spanner.

3. Disconnect washer motor electrical • Never use petroleum-based cleaners

connectors and outlet tubes. or solvents in the washer system.

4. Remove washer tank mounting bolt

using 13 mm socket spanner.

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 1959
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.9.4 Inspection:
1. Inspect the washer tank for any damage or crack.
2. Inspect the washer motor O-rings for any damage.

30.4.9.5 Installation:

1. Place the washer tank in its position, 3. Connect washer motor tubes and
torque tighten bottom mounting nut to connectors back.
specified value.

4. Mount filler neck using mounting nut and

2. Insert mounting bolt and torque tighten to torque tighten the nut.
specified value.

5. Refit LH fender.

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
1960 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.10 Wiper Washer Motor R&R

30.4.10.1 Component Location Index

30.4.10.2 Removal & Installation Summary

Pre Removal Post Installation

• Position the vehicle on a 2 pot/ 4 post lift. • Refit the Front Wiper Washer tank.
• Remove the Front Wiper Washer tank. • Fill washer fluid and check and ensure
there is no leakage from tank through
motor fitment area.

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 1961
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.10.3 Removal:

1. Remove the Front Wiper Washer tank.

For additional information refer to Front
Wiper Washer tank R&R section.

2. Disconnect wiper motor electrical

connector and water outlet hose from both
front and rear washer motor.

3. Pull and remove the front washer motor

from the washer tank.

• Carefully remove the washer motor

without damaging the O-rings.
• While removing the washer motor
from the washer tank, drain the water
from the washer tank.

30.4.10.4 Inspection:
1. Inspect the washer tank for any damage or crack.
2. Inspect the washer motor O-rings for any damage.

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
1962 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.4.10.5 Installation:

1. Refit the front wiper washer motor.

2. Connect wiper motor electrical connector

and water outlet hose to both front and rear
washer motor.

3. Refit the Front Wiper Washer tank. For

additional information refer to Front Wiper
Washer tank R&R section.

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 1963
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.5 Specifications & Wear Data

Component Description Specification

Wiper Motor Type Tandem wiping with direct

mounting wiper

Front Wiper Motor Rated voltage 12 V

Operating voltage range 10 V – 15 V

Washer Tank Capacity 3.2±10% Liters

Washer Motor Type Electric Motor

Operating voltage 12 V

Operating voltage range 10 V - 15 V

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
1964 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

30.6 Tightening Specifications & Sequence

Location Torque Nm

W/S washer tank mounting 11 ± 2

W/S washer tank neck mounting 2.5 ± 0.5

Front wiper motor mounting 15 ± 2

Front wiper motor check nut 12 ± 2

Front wiper arm mounting 11 ± 2

Windshield water bottle fit inside fender 15 ± 3

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 1965
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

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
1966 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

31 CHASSIS

31.1 Chassis — Side View

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 1967
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

31.2 Chassis — Top View

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
1968 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

31.3 Under Body Inspection

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 1969
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.
Repair Manual MAN-00591
MAHINDRA PIKUP E2 E4 LHD MAY - 2018/Rev 1

• Inspect the Differential, propeller shafts, drive shafts, body mounting bolts, engine mounting
bolts, suspension mounting bolts for any damage at every 10000 kms / 6Months.

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
1970 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2018 Mahindra & Mahindra Ltd.