Mahindra Genio DC BS-IV User Manual

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution © 2011 Mahindra & Mahindra Ltd.
39
705-MAT-0029 : 0.50 hrs
POWER STEERING BELT – REPLACE
Power Steering Belt Type: 3PK, 815mm, GATES make.
 If the belt is loose then it will give belt noise. If tightened excessively then it
can cause the power steering pump failure.
 Power Steering Pump Drive Belt tension to be check at 5000, 20000, and then
at every 20000kms.and adjust (if required)
 Power Steering Pump Drive Belt replacement interval is at every 100000kms.
B
[B] - Power Stg. Pump mounting on Engine
[C] - Power Stg. Pump drive belt position
C
A
3
4
1
2
POWER STEERING PUMP DRIVE BELT – REPLACE
Refer illustrations shown.
1. Remove NVH cover, Fan and Shroud.
2. Loosen pump fixing bolts 1 & 2 and loosen the lock nut 3 in sketch [A].
3. Remove power steering pump drive belt.
4. Refer belt tensioning procedure while refitting steering pump drive belt.
5. Check belt tension, correct if required.
Procedure for belt tensioning:
1. Loosen pump fixing bolts 1 & 2 And Loosen the Lock Nut 3
2. Screw tension bolt 4 as shown in fig to tighten the belt by appropriate amount.
3. Check tension value, should be between 200 – 230 Hz, if found less, screw in clockwise
direction, if found more than 235Hz unscrew in anticlockwise direction.
4. Final set value, New Belt: 255 - 260 Hz; & Used/ Stabilized Belt: 215 – 225 Hz.
5. Tighten the fixing Bolts 1, 2 & 3 to 25 N-m.

Mahindra Genio DC BS-IV Specifications

General

Brand	Mahindra
Model	Genio DC BS-IV
Category	Automobile
Language	English

Summary

ABOUT THE MAINTENANCE MANUAL

Maintenance Schedule Overview

Outlines operations to be carried out at specified intervals. Includes Adjust, Inspect, Replace, Clean.

Standard Operating Procedures (SOP)

Explains each maintenance operation step-by-step with codes, man-hours, tools, and lubricants.

Check Sheets

Lists operations for technicians to perform during scheduled maintenance service.

GOOD WORKSHOP PRACTICES

Attire and Dress

Guidelines for technician's clothing and personal protective equipment.

Vehicle Protection

Procedures to protect vehicle components during maintenance operations.

Safety Precautions

Essential safety measures to follow during vehicle maintenance and repairs.

Parts and Tools Handling

Preparation and handling of tools, parts, and replacement items.

Removed Parts Handling

Proper procedures for managing parts that have been removed from the vehicle.

LSPV Spring Warning

Important caution regarding the LSPV spring when lifting the vehicle on a 2-post lift.

MAINTENANCE SCHEDULE

Engine Maintenance

Covers maintenance items related to the vehicle's engine.

Brake System Maintenance

Maintenance procedures for the vehicle's braking system.

Suspension System Maintenance

Maintenance for the vehicle's suspension components.

Steering System Maintenance

Maintenance procedures for the steering system.

Electrical System Maintenance

Maintenance for the vehicle's electrical components.

Tyre Maintenance

Maintenance related to vehicle tires.

MAINTENANCE PROCEDURES INDEX

Engine Oil Replacement

Procedure for replacing the engine oil.

Engine Oil Level Check

Procedure for checking the engine oil level.

Engine Oil Filter Replacement

Procedure for replacing the engine oil filter.

Coolant Replacement

Procedure for replacing the coolant.

Transmission Oil Replacement

Procedure for replacing transmission oil.

Differential Oil Replacement

Procedure for replacing rear differential oil.

Brake Pads/Calipers Check

Procedure for checking front and rear brake pads and calipers.

Wheel Alignment

Procedure for performing wheel alignment.

Tyre Pressure Check & Adjust

Procedure to check and adjust tyre pressure.

Headlamp Aiming/Alignment

Procedure for adjusting headlamp aiming.