MAN-00131 - SCORPIO m2DiCR - Maintenence Manual

MAINTENANCE MANUAL
SCORPIO
MAN-00131
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
Rev1 – MAY 2011
www.teknetmahindra.com
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS.
© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without
the written permission of Mahindra & Mahindra Ltd.
About the Maintenance Manual
The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying out
maintenance operations in a Mahindra Scorpio m2DiCR vehicle. Carrying out the periodic maintenance
operations, as specified, is crucial for safe and trouble-free operation of the vehicle.
The recommended maintenance schedule /operations are published in the owner’s handbook.
This manual covers the correct method of carrying out the maintenance operations, using the correct
process/procedures, tools, parts and lubricants. The manual consists of –
Maintenance Schedule – The maintenance schedules outlines the operations to be carried out a
specified interval. These operations are Adjust (A), Inspect & Correct (I), Replace (.R), Clean (C). The
maintenance periods are specified in Kilometers (Kms).
Standard Operating Procedures (SOP) – Each maintenance operation is coded by a operation code
– 706-MAT-xxxx. Here 706 stands for the model family code, MAT indicating it is a maintenance
operation and xxxx the operation number.
Each maintenance operation is explained step-by-step, in the SOP section of the manual. The man-hours
required to complete the operation is also mentioned along with the operation code. The correct grade of
lubricants /coolants to be used, torque values, special tools are also mentioned wherever applicable.
Check Sheets – Check sheets for each service list outs the operation which need to be carried out by
the technician, when the vehicles report for scheduled maintenance service. These check sheets need to be
attached to the Repair order.
Job Description Repair Time {Manhours}
Repair Code Torque Specified
Lubricant Quantity Tool Specified
Lubricant Recommended
This chart is only a sample.
Good Workshop Practices
Attire/Dress
Always wear clean uniform

Wear safety shoes
Wear gloves, when required
Wear belt cover
Vehicle Protection
Put seat cover, fender cover, steering wheel cover, before starting the operations.
Safety
When working with 2 or more persons, be sure to check safety for one another
When working with engine running, make sure to provide ventilation for exhaust fumes in the
workshop
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear
appropriate safety gear and take extra care not to injure yourself or others.
When jacking up the vehicle, be sure to support the specified location with a safety stand.
When lifting up the vehicle, use appropriate safety equipment.
Parts and tools
Before starting operation, prepare tool stand, MST, Gauges, oils and parts for replacement.
Removed Parts
Place removed parts in a separate box to avoid mixing them up with new parts or contaminating
new parts.
For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new
ones as instructed in the manual
Retain the removed parts for customer inspection, if requested.
IMPORTANT
Mahindra SCORPIO m2DiCR is fitted with LSPV (Load Sensing Pressure Regulating Valve)
in the brake circuit. Hence it is imperative that the LSPV spring is disconnected before
lifting the vehicle on a 2-post lift. Failure to do so can lead to elongation of the spring,
disturbing the LSPV settings, leading to different braking characteristics.
Ensure to re-connect the LSPV spring and measure the fitted length after lowering the
vehicle from the 2-post lift.
Maintenance Manual MAN-00131
SCORPIO m2DiCR MAY 2011/Rev 1
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
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
706 - MAT-xxxx
Operation
Operation Name and Description Page No.
Code
ENGINE OIL - REPLACE 706-MAT-0010 3
ENGINE OIL - LEVEL CHECK 706-MAT-0020 4
ENGINE OIL FILTER - REPLACE 706-MAT-0030 5
TAPPET CLEARANCE – INSPECT & ADJUST 706-MAT-0031 6
ACCESSORY DRIVE BELT & ROLLER – INSPECT (WATER PUMP
706-MAT-0032 7
& ALTERNATOR)
ACCESSORY DRIVE BELT & ROLLER – REPLACE (WATER PUMP
706-MAT-0033 9
& ALTERNATOR)
ACCESSORY DRIVE BELT – INSPECT (AC COMPRESSOR) 706-MAT-0034 10
ACCESSORY DRIVE BELT – REPLACE (AC COMPRESSOR) 706-MAT-0035 11
ACCESSORY DRIVE BELT – INSPECT (POWER STEERING) 706-MAT-0036 12
ACCESSORY DRIVE BELT – REPLACE (POWER STEERING) 706-MAT-0037 13
COOLANT - INSPECT 706-MAT-0130 14
COOLANT - REPLACE 706-MAT-0140 15
AIR FILTER ELEMENT - REPLACE 706-MAT-0150 16
FUEL FILTER ELEMENT (PRIMARY) – REPLACE 706-MAT-0151 17
CLUTCH FLUID - LEVEL & LEAK 706-MAT-0190 19
CLUTCH FLUID - REPLACE 706-MAT-0200 20
TRANSMISSION OIL - REPLACE 706-MAT-0210 21
DIFFERENTIAL OIL (REAR) - REPLACE 706-MAT-0230 22
REAR WHEEL BEARINGS - LUBRICATE 706-MAT-0260 23
TYRE ROTATION 706-MAT-0270 24
PROPELLER SHAFT - GREASING 706-MAT-0221 25
BRAKE FLUID - LEVEL & LEAK 706-MAT-0290 26
BRAKE FLUID - REPLACE 706-MAT-0300 27
BRAKE PADS/ CALIPERS - CHECK 706-MAT-0310 29
BRAKE DRUM AND LINING - CHECK 706-MAT-0320 30
PARKING BRAKE OPERATION - CHECK & ADJUST 706-MAT-0330 31
FRONT SUSPENSION BUSHES- INSPECT 706-MAT-0360 32
FRONT SUSPENSION ARM- INSPECT 706-MAT-0370 32
REAR SUSPENSION BUSHES- INSPECT 706-AMT-0380 33
REAR SUSPENSION LINK- INSPECT 706-MAT-0381 33
POWER STEERING FLUID - LEVEL & LEAK 706-MAT-0390 34
WHEEL ALIGNMENT * 706-MAT-0420 35
BATTERY ELECTROLYTE LEVEL - CHECK 706-MAT-0430 39
BATTERY SPECIFIC GRAVITY - CHECK 706-MAT-0440 40
ALL LIGHTS, HORNS, WIPERS & WASHERS - CHECK 706-MAT-0450 41
HEAD LIGHT AIMING - CHECK & ADJUST 706-MAT-0460 44
HVAC FILTER - CLEAN 706-MAT-0470 47
TYRE PRESSURE - CHECK & ADJUST 706-MAT-0490 48
BODY MOUNTING BOLTS FOR TIGHTNESS - CHECK & ADJUST 706-MAT-0500 49
EXHAUST PIPE MOUNTINGS & DAMAGE / LEAKAGE - CHECK 706-MAT-0510 50
2
706-MAT-0010:0.30 hrs.
ENGINE OIL – REPLACE
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
 Oil Sump drain plug 01 22 mm 27.5 ± 2.5
Engine oil – MAXIMILE PREMIUM
Capacity – 7.0 Lit
Oil Drain & Refill –

1. Open the oil filler cap.
2. Put the oil collecting tray below the sump, loosen & remove the oil sump drain plug.
Allow the oil to drain for 15 min.
3. Fit the drain plug with a new gasket/ washer. Torque tightens the Drain Plug –Torque
27.5 ± 2.5 Nm.
4. Fill fresh oil as per the recommended quantity and specification.
5. Refit the oil filer cap & check the oil level as per procedure (706-MAT-0020).
 Park the vehicle on level ground/2 post lift* /4 post lift

 Engine should be hot while draining the oil.
 Engine oil to be replaced at 5000, 15000 & then at every 10000kms.
 If the activity is done on a 2 post lift, ensure that the LSPV spring is
disconnected before lifting the vehicle. After lowering, re-connect the LSPV
spring and ensure that the setting height is correct.
3
706-MAT-0020:0.05 hrs.
ENGINE OIL – LEVEL & LEAK - INSPECT
MAX
MIN
Oil Level Check –

1. Pull out the dip stick gauge and wipe it clean with a cloth/paper.
2. Insert the dip stick gauge into the dip stick guide fully till the end.
3. Pull out the dip stick slowly and check for the oil level between Maximum and
Minimum level - if found below, top up with recommended oil.
4. Start the engine and check for oil leakage/ seepage at –
 Oil sump & crankcase joint.
 Oil sump drain plug.
 Oil filter joint.
 Ensure that the vehicle is parked on level ground/2 post lift/4 post lift.
disconnected before lifting the vehicle. After lowering, re-connect the LSPV
spring and ensure that the setting height is correct.
 Ensure that the engine is not running.
4
706-MAT-0030:0.20 hrs.
ENGINE OIL FILTER– REPLACE
m2DiCR – Engine Oil Filter – Dismantled
Oil filter Removal –

Refer illustrations.
1. Remove the oil filter by unscrewing it in anti-clockwise direction, using an oil filter
wrench.
2. Check the oil cooler stud for tightness – Torque 27.5 ± 2.5 Nm.
3. Smear a layer of fresh engine oil on the oil filter “O” ring
4. Fit the oil filter & turn it clockwise till the “O” ring touches to oil cooler face.
5. Turn the filter another 3/4th turn by hand.
6. Check for Oil leakage/ seepage at –
 Oil pan & crankcase joint
 Oil pan Drain Plug.
 Oil filter joint.
 Oil cooler joint
 Never use a wrench/spanner to tighten the oil filter.

 Engine oil filter element to be replaced first at 5000kms, 15000kms and then at
every 10000kms.
 If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected
before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure
that the setting height is correct.
5
706-MAT-0031:0.50 hrs.
TAPPET CLEARANCE – INSPECT & ADJUST
m2DiCR – Engine Tappet Clearance Adjust
TAPPET CLEARANCE – INSPECT & ADJUST.
Refer illustration shown.
1. Remove oil filler cap & then Rocker Arm Cover with Gasket.
2. Adjust the tappet clearance as per the following procedure …
 Bring no.1 piston at TDC. Ensure no 4 cylinder Rockers at dancing /rocking position.
 Adjust the tappet clearance of 1st cylinder both Inlet & Exhaust valves as per
specifications*.
 Turn the engine 1800 further in the direction of engine rotation (2 ndcylinder Rockers at
dancing / rocking position). Adjust tappet of 3rd cylinder valves as per specifications*.
 Turn the engine 1800 further in the direction of engine rotation (1st cylinder Rockers at
dancing / rocking position). Adjust tappet of 4th cylinder valves as per specifications*.
 Turn the engine 1800 further in the direction of engine rotation (3rd cylinder Rockers at
dancing / rocking position). Adjust tappet of 2nd cylinder valves as per specifications*.
3. Ensure the tightening Rocker Screw Nut to 20 ± 2 Nm
4. Ensure metallic sleeve in gasket & gasket position in groove.
 The tappet clearance to be check first at 15000 kms & adjust at every 20000kms.
6
706-MAT-0032:0.15 hrs.
ACCESSORY DRIVE BELT & ROLLER – INSPECT
(Water Pump/Alternator Drive Belt – Gates 4PK)
ACCESSORY DRIVE BELT TO BE

CHECK FOR –
Refer illustrations below.
1. Abrasion
2. Cracking
3. Improper Install
4. Uneven Rib Wear
5. Misalignment
6. Chunk-out
7. Gravel penetration
8. Pilling
ACCESSORY DRIVE BELT - LAYOUT
Refer illustrations shown.

1. Abrasion – Each side of belt appears shiny or glazed. In advanced stages, fabric becomes
exposed.
2. Cracking – Small, yet visible cracks along the length of a rib or ribs.
3. Improper Install – A belt rib begins separating from the joined strands. If left unattended,
the cover will often separate, causing the belt to loosen.
4. Uneven Rib Wear – 5. Misalignment –

Refer illustration shown. Refer illustration shown.
Belt shows damage to the side with Sidewalls of the belt may appear glazed or the
the possibility of breaks in the tensile edge cord may become frayed and ribs removed.
cord or rough edged ribs. A thumping A noise may result. In severe cases, the belt can
noise may also be heard when jump off the pulley.
running.
7

6. Chunk Out – Pieces or chunks of rubber material have broken off from the belt. When
chunk-out has occurred, a belt can fall at any moment.
7. Gravel Penetration – Small pinholes are visible on the backside of the belt. Bumps may be
visible and the fabric around the holes can be frayed.
8. Pilling – Belt material is sheared off from the ribs and builds up in the belt grooves.
 Water Pump–Alternator drive belt is 4PK type and it is recommended to be

Inspect first at 5000kms & then at every 15000 kms. It is to be replaced at every
75000kms.
 Recommended Belt Tension value is – 140 + 5 /114 + 5 Hz (New/Used)
 Check belt tension at the point shown as green dot in above illustration.
8
706-MAT-0033:0.30 hrs.
ACCESSORY DRIVE BELT & ROLLER – REPLACE
(Water Pump/ Alternator Drive Belt - Gates 4PK)
Water Pump-Alternator Drive Belt
Alternator stay rod & nuts for

drive belt tightening.
WATER PUMP-ALTERNATOR DRIVE BELT – REPLACE

1. Remove Fan, shroud and NVH cover.
2. Loosen the nut [1] on the Alternator stay rod.
3. Loosen the nut [2] on other side of stay rod.
4. Move Alternator assembly towards engine side to loosen the belt tension.
5. Take out the Water pump-Alternator drive belt.
 Assembly procedure is reverse to the removal of drive belt.
 Check and adjust Water pump-Alternator drive belt tension.
 Water Pump–Alternator drive belt is 4PK type and it is recommended to be

replaced at every 75000kms.
 Recommended Belt Tension value is – 140 + 5 /114 + 5 Hz (New/Used)
9
706-MAT-0034:0.10hrs.
ACCESSORY DRIVE BELT – INSPECT
(AC Compressor Drive Belt–Gates/ Rolunds AVX 13V)
Water Pump -
Alternator Drive Belt
Steering Pump Drive Belt

AC Compressor Drive Belt
AC COMPRESSOR DRIVE BELT TO BE INSPECTED FOR – Refer illustration.
1. Cracking
2. Chunk-out
1. Cracking – Small, yet visible cracks along the length of a rib or across the belt groove.
 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at

every 10000kms.
 AC Compressor drive belt is recommended to be replaced at every 45000kms.
 Recommended value for AC Compressor drive belt Tension is –
190 + 5/160 + 5 Hz (New/Used)
10
706-MAT-0035:0.60hrs.
ACCESSORY DRIVE BELT – REPLACE
(AC Compressor Drive Belt- Gates/ Rolunds AVX 13V)

AC Compressor stay
bracket & nut to adjust belt
tension
AC COMPRESSOR DRIVE BELT – REPLACE

2. Remove Water pump-Alternator drive belt. (Refer:706-MAT-0033)
3. Loosen the lock nut on the AC Compressor stay bracket.
4. Move Compressor assembly towards engine to loosen the belt tension.
5. Take out the AC Compressor drive belt.
 Check and adjust Water Pump-Alternator drive belt tension.
 Check and adjust AC Compressor drive belt tension.
every 10000kms. Replace belt first at 45000 kms & then at every 30000 kms.
 AC Compressor drive belt is recommended to be replaced at every 40000kms.
 Recommended value for AC Compressor drive belt Tension is –
190 + 5/160 + 5 Hz (New/Used)
11
706-MAT-0036:0.10hrs.
ACCESSORY DRIVE BELT – INSPECT
(Power Steering Drive Belt- Rolunds AVX 10V)
Water Pump -
Alternator Drive Belt
Steering Pump Drive Belt

POWER STEERING DRIVE BELT TO BE INSPECTED FOR – Refer illustration.
1. Cracking
2. Chunk-out
1. Cracking – Small, yet visible cracks along the length of a rib or across the belt groove.

 Recommended value for Power Steering drive belt is –
210 + 5/175 + 5 Hz (New/Used)
12
706-MAT-0037:0.90hrs.
ACCESSORY DRIVE BELT – REPLACE
(Power Steering Drive Belt- Rolunds AVX 10V)
Steering Pump stay bracket with

slot for belt tension bolt & nut
POWER STEERING DRIVE BELT – REPLACE

2. Remove Water pump-Alternator drive belt. (Refer :706-MAT-0033)
3. Remove AC Compressor drive belt. (Refer :706-MAT-0035)
4. Loosen the nut on the Steering Pump stay bracket.
5. Move Steering Pump assembly towards engine to loosen the belt tension.
6. Take out the Power Steering Pump drive belt.
 Check and adjust Water Pump-Alternator drive belt tension.
 Check and adjust AC Compressor drive belt tension.
 Check and adjust Steering Pump drive belt tension.

 Recommended value for Power Steering drive belt is – 210+5/175+5Hz
(New/Used)
13
706-MAT-0130:0.05hrs.
COOLANT LEVEL & LEAK – INSPECT
Coolant – MAXIMILE Coolant. Capacity – 7.5 Liters.
Coolant Level & Leak - Inspect 1
.....MAX........
.
…MIN…...
COOLANT LEVEL - INSPECT

1. Check the coolant level when the engine is cold.

2. Check the coolant level in the recovery tank – it should be between MAX and MIN marks. If
below MIN, top it up with Maximile Coolant.
3. Check the coolant level in the radiator and top up if found less. Use MAXIMILE Coolant
directly from the container to top up. Maximile Coolant is pre-mixed and hence do not
dilute it with water.
4. Check for evidence of leakage at Water pump hose, Oil cooler hose. Radiator top and
bottom hoses and HVAC heater hoses.
 Never remove the radiator cap when the engine is hot.

 Never mix MAXIMILE coolant with water. Maximile coolant is premixed.
14
706-MAT-0140 :0.60hrs.
COOLANT – REPLACE
DRAIN COCK
ON RADIATOR
Coolant – MAXIMILE Coolant. Capacity – 7.5 Liters.

COOLANT – REPLACE
Refer illustration.
1. Open the radiator cap [1]
2. Remove the drain plug on the Engine block and Radiator.
3. Drain the coolant and collect in drain tray.
4. Refit the drain plugs & fill new coolant in radiator
5. Check all the hoses & clips for leakage and correct fitment.
6. Start the engine and run at approx. 1200rpm for 2-3 min.
7. Check coolant level in radiator and add coolant as per requirement.
8. Fill coolant in the coolant recovery tank up to MAX level
9. Refit the radiator cap.
10. Start the engine and run at approx. 1200rpm for 2-3 min.
11. Check coolant level in radiator and coolant recovery tank and add as required
 Never remove the radiator cap when the engine is hot.

 Never mix MAXIMILE coolant with water. Maximile coolant is premixed.
15
706-MAT-0150:0.25hrs.
AIR FILTER ELEMENT - REPLACE
Nut/ Bolt description Quantity Spanner Torque Value – Nm.

Nos. Size
 Air filter top cover allen bolt 07 6 mm 4.5 ± 0.5
 Hose clamps – air cleaner to 02 11 mm. 2.5 ± 0.5
manifold 02 11 mm. 4.5 ± - 0.5
Air Intake Assembly – Dismantled
AIR FILTER ELEMENT – REPLACE. Refer illustration shown above –
1. Open the clean and dirty sides hose clip & remove the hose.
2. Open the Air cleaner Top cover bolts.
3. Remove the Air filter element along with grates and clean the bottom bowl.
4. Separate the top as well as bottom grates and replace the air filter element; assemble the
grates & put the assembly back in place. Position the new element properly. Take care of
lug projections.
5. Assemble the top cover & tighten the top cover bolts diagonally.
6. Assemble the clean hose on the air cleaner outlet-Air Mass Sensor neck and tighten the
hose clip.
 Do not clean the air filter element.

 Replace Air filter element at 40000 kms or early if required.
before lifting the vehicle & re-connect the LSPV spring and ensure that setting
height is correct after job complete.
16
706-MAT-0151:0.20hrs.
FUEL FILTER ELEMENT – REPLACE
Scorpio m2DiCR is fitted with single Fuel filter
unit with paper type cartridge.
Put the tray below before attending removal of

the fuel filter assembly.
Remove the fuel inlet and outlet hoses from

fuel filter.
NOTE:
1. Both hoses are quick fix type connectors.
2. Ensure correct fitment of fuel inlet & outlet

hoses during installation. Refer ‘IN’ & ‘OUT’
arrow marks embossed on filter top cover
plate.
Remove the filter top cover with help of ‘Torx’

tool.
NOTE:
‘Torx’ type screw driver or ratchet can be used
for removal & refitting of Torx screws fitted on
top cover.
17
Remove the fuel filter upper cover.
Use flat screw driver to remove the top cover.
Remove top cover along with fuel filter

cartridge.
Separate fuel filter cartridge from top cover.
Check and clean the fuel filter bowl. Remove

dirt and water sediments from filter bowl.
Replace the ‘O’ ring fitted in the top cover

while replacing fuel filter.
CAUTION:
 Always use recommended filters only.

 The fuel filters to be replaced first at 5000
kms and then at every 20000kms.
18
706-MAT-0190:0.10hrs.
CLUTCH FLUID LEVEL & LEAK - INSPECT
Clutch Fluid – SAE J1703 FMVSS No.116 DOT 4 or IS 8654 Type-2
Clutch Master
Cylinder with MAX
Reservoir MIN
Bleed Screw
Slave Cylinder
Assembly
Clutch System - Schematic
CLUTCH FLUID – LEVEL & LEAK - INSPECT

Refer above illustration –
1. Check for Clutch Fluid Level up ‘MAX’ mark on the clutch fluid reservoir [1].
2. Check for Clutch Fluid leakage and correct fitment at all joints –
• Hose connected from reservoir and Clutch master cylinder.
• Clutch Master Cylinder inlet and outlet.
• Clutch Bundy tube to flexible hose joint.
• Clutch slave Cylinder inlet banjo.
• Clutch slave cylinder bleed screw.
 Park the vehicle on level ground/2 post lift /4 post lift.

 Always use recommended fluids only.
 Do not mix different brand fluids.
 Clutch fluid level and leak to be inspected at 5000 kms, 15000 kms & then at
every 10000 kms.
19
706-MAT-0200:0.50hrs.
CLUTCH FLUID LEVEL & LEAK – REPLACE
Clutch Fluid – SAE J1703 FMVSS No.116 DOT 4 or IS 8654 Type-2
CLUTCH SYSTEM - SCHEMATIC
Bleed Screw
CLUTCH FLUID – REPLACE. Refer above illustration –
1. Remove the dust cap of the bleeder screw.

2. If the bleeding operation is done without connecting a tube and in the open air then the
chance of air remaining trapped is high.
3. Connect bleeding tube, to bleeding screw on slave cylinder.
4. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch
fluid.
5. Fill the Reservoir clutch master cylinder up to the top level with recommended clutch
fluid.
6. Operate clutch pedal 3 or 4 times slowly to the full stroke.
7. Holding the clutch in depressed condition loosen the bleeding screw on slave cylinder by
½ to ¾ turn and allow all the air escape in to the container bottle.
8. Repeat the exercise till no air bubbles appears in the bottle.
9. During this operation ensure fluid level in reservoir.
10. Tighten the bleed screw properly.
11. Remove bleeding tube and place the dust cap on bleed screw.
12. Check the fluid level in container and be top up to the ‘MAX’ level. [1]
 Use recommended fluids & don’t mix different brand fluids.

 Clutch fluid to be replaced at 35000 kms, 75000 kms & then at 115000 kms.
before lifting the vehicle & re-connect the LSPV spring & ensure that the setting
20
706-MAT-0210:0.30hrs.
TRANSMISSION OIL – REPLACE &
706-MAT-0209:0.10hrs.
TRANSMISSION OIL – INSPECT
Transmission Oil – MAXIMILE GO 80W90 Synchro

Capacity – 2.0 Lit.
NGT 520 - TRANSMISSION
Transmission Oil – Replace Refer above illustration.
1. Remove the Filler plug.

2. Put the oil collection tray under transmission, Remove the drain plug. Allow the oil to
drain out completely.
3. Clean the metal particles if any deposited on the drain plug. Assemble & torque tight
the drain plug with new washer – 27.5±2.5 Nm.
4. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new
washer and torque to 27.5±2.5 Nm.
5. Check Oil leakage / seepage at –
• Transmission Housing Joints.
• Transmission Oil drain plug.

 Always use recommended oils only.
 Transmission oil to be replaced first at 5000kms, & then at every 90000kms.
 Check TM oil level & leak first at 40000 kms & 65000 kms.
21
706-MAT-0230:0.20hrs.
DIFFERENTIAL OIL (REAR) - REPLACE
Differential Oil – MAXIMILE DO EXL

Capacity – 1.80 Lit.
Rear Axle - Schematic
Differential Oil – Replace Refer illustration shown.
1. Remove the Filler plug [1]

2. Remove the drain plug [2]. Allow the oil to drain out completely.
3. Clean the metal particles if any deposited on the drain plug. Assemble & torque tight
the drain plug with new washer [3] – 47.5± 6.5 Nm.
4. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new
washer [4] and torque to 47.5± 6.5 Nm.
5. Check Oil leakage / seepage at –
• Differential covers joint face
• Differential Oil drain plug.

 Always use recommended oils only.
 Differential oil to be replaced first at 5000, 35000kms and then at every
30000kms.
22
706-MAT-0260:3.00 hrs.
REAR WHEEL BEARING - LUBRICATE
Wheel Bearing Grease – MAXIMILE LCG/ NLGI 2/3
Rear Axle - Schematic
REAR WHEEL BEARING – LUBRICATE. Refer illustration shown.
Dismantling –
• Jack up the vehicle & remove the wheel.
1. Remove the Rear Brake drum.
2. Remove Brake Assembly & Axle shaft retainer by opening 6 retainer bolts on the brake
assembly & axle tube flange.
3. Using the MST 576 & 577, Slide the Axle Shaft Assembly out.
4. Clean & Inspect the Bearing & oil seal.
Assembly –
1. Apply the MAXIMILE LCG3 grease on the bearings.
2. Insert the Axle Shaft Assembly.
3. Put the retainer & Rear Brake Assy and tighten the retainer bolts on the axle tube
flange.
4. Fit the Brake drum and tighten the drum locking screw.
 Rear Wheel bearings to be lubricate at every 45000kms.

23
706-MAT-0270:0.60hrs.
TYRE ROTATION
Tyre Rotation – Refer above illustration.

1. Check & ensure tyre pressure in all five wheels, refer below chart.
2. Rotate (swap the positions) the wheels as shown in the diagram above.
• Driver side rear goes to Driver side front position.
• Driver side front wheel goes to Co-Driver side rear position.
• Co-Driver side rear wheel goes to spare wheel position.
• Spare wheel goes to Co-Driver side front position.
• Co-Driver side front wheel goes to Driver side rear position.
Tyre pressure value: Refer below chart –
COLD TYRE INFLATION PRESSURE

TYRE SIZE P215/75 R15
FRONT REAR
psi 32 32
Kg/cm. sq. 2.2 2.2
 Tyre rotation to be done at 5000 kms & then at every 10000 kms.
24
706-MAT-0221:0.20 hrs.
PROPELLER SHAFT – GREASING
Propeller Shaft Assembly
Propeller Shaft Front end - Yoke Propeller Shaft Rear end - Yoke
Differential Oil – Replace

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

• Always use recommended grease only.
• Propeller shaft sliding joint to be lubricated at every 10000kms.
• Before undercoating a vehicle with any under body protection; the propeller shaft
and the UJs should be covered. This will prevent the undercoating from causing an
unbalanced condition and vibration.
25
706-MAT-0290:0.10 hrs.
BRAKE FLUID – LEVEL & LEAK - INSPECT
Brake Fluid – SAE J1703 FMVSS No.116 DOT 4 or IS 8654 Type-2
1 Brake Fluid Reservoir BRAKE FLUID – LEVEL & LEAK -

CHECK
Refer illustrations –
1. Check for Brake Fluid Level up
MAX
‘Max’ mark on the brake fluid
MIN reservoir [1].
2. Check for Brake Fluid leakage
and correct fitment at all joints
 Hose connected from reservoir
and Clutch master cylinder [2].
 Brake Master Cylinder outlets.
 Brake bundy tube ‘Tee’ joints.
 Brake connections on each
wheel end.
2. Brake Fluid Leak – Check

points
• In case anyone circuit fails, the other circuit will not be affected.
• Always use recommended fluid, do not mix different brand fluids.
• If the activity is done on a 2 post lift, ensure that the LSPV spring is
disconnected before lifting the vehicle & re-connect the LSPV spring & ensure
that the setting height is correct after job complete.
• Brake fluid level & leak to be checked first at 5000 kms & then at every 10000
kms.
26
706-MAT-0300: 1.00hrs.
BRAKE FLUID – REPLACE
Brake Fluid – SAE J1703 FMVSS No.116 DOT 4 or IS 8654 Type-2

Brake Fluid 2
Reservoir 5
4 1
Brake System bleeding layout
The brake fluid should be replaced once in a year or every 40,000 Kms – whichever is earlier. Fluid
reservoir is mounted on the brake master cylinder. Refer above illustration. There are two
compartments in reservoir; fluid is being supplied to front brake circuit and rear brake circuit.
Open the bleed screws on Callipers, Rear brake drums and LSPV and allow the fluid to drain out
completely. To ensure complete draining, brake pedal can be depressed gradually. Do not repeat;
pressing brake pedal without fluid in the system can damage internal seals/ brake parts.
After the fluid is drained, hand tightens bleed screws on Front Callipers, Rear brake drums & LSPV.
Refill recommended fluid in the reservoir till the MAX mark. Ensure that fluid is getting in and air in
the system getting passed through bleed screws; tighten bleed screws as soon as continue flow of
fluid starts.
Refer below mentioned brake bleeding sequence and illustration -
1. Rear left
2. Rear right
3. LSPV
4. Front left
5. Front right
The procedure at each of the bleed point is to pump 2 to 3 times, open the bleed screw by 1/4th
turn, close the bleed screw. Again pump 2/3 times then open the bleed screw keeping the pedal
pressed down. Close the bleed screw and release the pedal. Repeat the operation until no bubbles
are coming. The Bypass valve is inbuilt in the LSPV & it should be bled at the time of bleeding. It is
also advisable to keep the engine running at idling so that the pedal travel is complete.
Refill the fluid in clutch system; ensure that the fluid is getting refilled in system as well as air in
the system is getting pass through the bleed screw on slave cylinder. Tightens bleed screws as
soon as continue flow of fluid starts. Bleed the Clutch System and ensure no air trapped in the
system.
27
While bleeding we suggest that the bleed screw nipple is fitted with a transparent plastic pipe.
This pipe should be submerged in a glass bottle filled with brake fluid. Refer below illustrations.
If any air bubbles are present then it can be easily seen in the container as well as the plastic pipe.
Transparent plastic pipe should be submerged in a glass bottle
The reservoir should be continuously filled with brake oil to avoid air entering thru the empty
reservoir.
Always use brake fluid from a new sealed container to do this activity (an open container may
have got contaminated with moisture.)
 Brake fluid to be replaced first at 35000 kms & then at every 40000 kms; or in a
year, whichever is earlier.
28
706-MAT-0310:0.60hrs.
FRONT BRAKE – CHECK
7 mm
Check Pad Thickness
21 mm
12 mm
Check Disc Thickness
Front Brake – Check

1. Check the disc for abnormal wear/grooves (Minimum usable thickness of the disc is
21mm, check at 12mm inside from outer edge of disc)
2. Loosen & remove the bottom side sliding pin bolt. Swing up the caliper. Remove the
pads & check the pad thickness. The minimum usable pad thickness is 7 mm. (without
backing plate) if observed less; replace the pads. (The groove at the center of the pad
can also be used as a reference. If the pad has worn up to the end of the groove; it
should be replaced)
3. Measure the thickness at the thinnest and worn area of the pad. Replace pad assembly
when pad thickness is less than the limit value.
4. Pad wear indicator is also provided to know pad wear limit.
5. Check for the oil leakage from Calipers/piston seals.
 If the activity is done on a 2 post lift. Then ensure that before the vehicle is lifted
the LSPV spring is disconnected. After lowering connect the LSPV spring and
ensure that the setting height is correct.
 If any pad is worn out (inboard /outboard) then replace both the pads.
 If pads on one wheel only are worn, even then replace the other wheels also.
 Any excessive difference between inboard and outboard wear indicates either
bent or seized sliding pin. Please check the complete hydraulic system besides
the calipers.
 Brake Pads & Disc to be inspected first at 5000 kms & then at every 10000 kms.
Replace before crosses its service limit.
29
706-MAT-0320:0.80hrs.
BRAKE DRUMS/LINERS – CHECK
1 2
1
REFER ILLUSTRATIONS –
1. REAR BRAKE ASSYEMBLY –
BOOT INSPECT.
2. BRAKE LINER - THICKNESS
CHECK.
Brake Drum/ Liners – Check

1. Rear Brake – Open the drum & clean the brakes by blowing compressed air. Check the
wheel cylinder for oil leakage. (It is recommended to check the oil seepage from wheel
cylinder by lifting the dust boots.)
2. Check the brake lining for wear/cracks. The minimum usable thickness of the liner is
3.5 mm (The brake liners must be replaced before the rib starts touching the drum).
3. Measure the wear of the brake lining at the place worn the most.
4. Replace the brake shoe and lining assembly if the lining thickness is less than the limit,
if it is not worn uniformly.
5. After re-assembly, check the wheel freeness in both forward & reverse direction.
 Park the vehicle in inspection pit/ 2 post lift/ 4 post lift

 If the activity is done on a 2 post lift. Then ensure that before the vehicle is lifted
the LSPV spring is disconnected. After lowering connect the LSPV spring and
ensure that the setting height is correct.
 Whenever the shoe, linings are replaced, replace both RH & LH assemblies as a
set to prevent car from pulling to one side when braking.
 If there is significant difference in the thickness of the shoe and the lining
assembly on the left and right sides, check sliding movement of the piston.
 Brake Liners & Drums to be inspected first at 15000 kms & then at every 20000
kms. Replace before crosses its service limit
30
706-MAT-0330:0.30hrs.
PARKING BRAKE - CHECK

1. Check Brake & Clutch Pedals for free play & sponginess. Refer SOP given in Repair
Manual.
2. Check Parking Brake Lever operation & setting.
Park the vehicle on a slope and apply Parking Brake to check the effectiveness.
Release the Parking Brake & check the free rolling.
3. Check the parking cables for correct routing
 Parking brake to be checked first at 5000 kms then at every 10000 kms.
31
706-MAT-0360 & 0370:0.20hrs.

FRONT SUSPENSION BUSH & ARMS - INSPECT
FRONT SUSPENSION – BUSH & ARMS INSPECT
FRONT SUSPENSION BUSH – CHECK. Refer illustrations shown.

1. Check lower control arm bush condition (both LH & RH) for wear & tear, cracks & shift.
Replace if necessary.
2. Check upper control arm 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 & Stabiliser Bar Links + Bushings for wear & tear cracks
& shift. Replace if necessary.
Location Torque Nm
Lower Control Arm Front Mounting 165 ± 15 Nm
Lower control Arm Rear mounting 120 ± 10 Nm
Lower control Arm ball joint mtg. nut 70 ± 10 Nm
Upper Control Arm Side Bushes 120 ± 10 Nm
Upper Control Arm ball joint mtg. nut 26 ± 3 Nm
Upper Arm pin fulcrum mounting nut 130 ± 10 Nm
Shock absorber Top- on Frame 19 ± 03 Nm
Shock absorber Bottom on LCA 19 ± 03 Nm
 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 bushes & arms to be inspected first at 15000 kms & then at every
20000 kms.
32
706-MAT-0380 & 0381:0.20hrs.

REAR SUSPENSION BUSH & LINKS - INSPECT
REAR SUSPENSION – BUSH & LINK INSPECT
Rear Suspension Bush - Check

Refer illustration shown above.
1. Check all the suspension link Rubber Bushes for –
(a) Wear (b) Ageing
(c ) Cracks (d) Metal sleeve separation.
2. Check the Upper & Lower Links & Panhard Rod for damage/ bent etc.
3. Check shock absorber bushes for wear, crack and shift.
 Observe following conditions even after wheel alignment –
(a) Problem in vehicle ride and handling.
(b) Noise from suspension joints even after specified joint torque values.
Location Torque Nm
Upper Link 150 ± 10 Nm
Lower Link 150 ± 10 Nm
Panhard Rod 150 ± 10 Nm
 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 & links to be inspected first at 15000 kms & then at every
20000 kms.
33
706-MAT-0390:0.10hrs.
POWER STEERING FLUID – LEVEL/LEAK - CHECK
Power Steering Oil – SHELL Make "SPIRAX S3 ATF MD3/ CALTEX Make “TEXAMATIC 1888”
Capacity – 0.9 Ltr.
1 Power Steering Fluid –

Level Check
Leak Check Points
POWER STEERING FLUID – LEVEL/ LEAK – CHECK. Refer illustrations.

1. Check the steering oil level in the reservoir [1] – it should be between MAX and MIN
marks. If below MIN, top it up with recommended oil.
2. Check hose joints for oil leakage / seepage at –
 Reservoir
 Power Steering Pump
 Rack & Pinion – Pipe ends & boots.
 Power steering oil level and leak to be inspected at every 10000kms.

 Power Steering fluid level & leak to be checked at 10000 kms, 15000 kms & then
at every 10000 kms.
34
706-MAT-0420:1.00hrs.
WHEEL ALIGNMENT
UPPER
CONTROL ARM
SHIM – CAMBER
ADJUST
SHIM – CASTOR
ADJUST
FULCRUM
PIN
Pre Work for Wheel Alignment Process:

Tyre pressure : Should be 2.2 bar in Front as well as in Rear tyres. Sequence :
For adjusting the Castor -

 The values should be within 2.75 °±1.00 (2 45’ 1.0 )
 The difference between the two wheels should be within ±45'
 The adjusting shims are available in 1.6, 0.4-mm thickness. Addition of shims in front
between the fulcrum lever and the chassis bracket will reduce the castor. Addition of
shims in rear between the fulcrum lever and the chassis bracket will increase the castor
0.4 mm = 9’ (0.15°)
1.6 mm= 37’ (0.62°)
1. Loosen the lower arm mounting bolts, and the upper arm side nuts so that the lower arm
movement is free.
2. Compress the spring by moving the lower arm, using a jack.
3. Loosen the fulcrum mounting bolts.
4. Add or remove shims as required.
5. Tighten the fulcrum mounting bolts to 12.0 to 14.0 Mkg. (87 lb. ft- 101 lb. ft). Also refer to
the Torque chart.
6. After that decompress the spring.
7. Tighten the lower arm mounting bolts. And the upper arm side nuts. As per the Torque
chart.
35
For adjusting the Camber -

The value for any given wheel should be 0°14' ± 0°30' and the maximum difference
between the two wheels should be ± 30'
The shims are available in thickness of 3.2, 1.6, 0.8 mm.
Addition of shim between the fulcrum and the chassis bracket will decrease the
camber.
0.8mm =0.15 ° (9’)
1.6 mm = 0.32 ° (19’)
3.2 mm = 0.62° (37’)
1. To increase the camber – remove the shims
2. Loosen the lower arm mounting bolts, and the upper arm side nuts. So that the lower
arm movement is free.
3. Take out the apron cover behind the wheel by carefully removing the plastic fasteners.
4. Compress the spring by moving the lower arm, using a jack.
5. Loosen the fulcrum mounting bolts, Add or remove shims as required.
6. Tighten the fulcrum mounting bolts to 12.0 to 14.0 Mkg (87 lb. ft- 101 lb. ft). Refer to
the torque chart.
7. After that decompress the spring.
8. Tighten the lower arm mounting bolts. And the upper arm side nuts.
Before tightening shake the vehicle by compressing the front and rear of the vehicle
alternatively by hand.
For adjusting the Toe In - Refer illustrations shown.

Adjust by moving the tie rod.
The tie rods should be adjusted individually.
The tie rods should be adjusted equally on both sides. The variation between left and right
side of the tie rods should be one turn. (If it is more than that, the centralization of the
steering wheel will be affected.)
The total difference should be between 1 to 3 mm. (0.15° to 0.45°).
36
POWER STEERING ASSEMBLY
LH & RH TIE ROD END
Adjusting the Wheel tuning angle-
1. Bring the Wheels in Straight Ahead Position (SAP). At this position confirm that the
turntables Zero are also showing Zero.
2. Turn the steering wheel to Right Hand Side so that the wheel turns through 36±0.5°
(Please refer the specifications)
3. Check the condition of the stopper bolt of LH side; it should touch the bracket on the
lower arm assy.
4. If it is not touching or the wheel is not able to turn through 36±0.5° then loosen the
lock nut adjust the bolt and then lock the bolt with locknut.
5. Turn the steering now towards the Left-hand side and then adjust the stopper on the
right hand side.
Shock Absorber Projection Height – 23 mm.

 Measure the shock absorber stand out from the adjusting nut face to the top.
 While fitting the shock absorber ensure that after torque tightening the standout is 23 mm.
 If the standout is more, then it indicates over tightening or bad rubber washers. Refer to
the torque check list.
37
Wheel Alignment Parameters –
Toe in Partial 0 to 1 mm (0 to 13’)

Toe in Total 0 to 2 mm (0 to 27’)
Camber -23’ to +14’
Difference between LH & RH Camber 30’
Caster 1o 45’ to 3o 75’
Difference between LH & RH Castor 75’
King pin inclination 9 45’ to 11o 75’
o
Wheel turning angle – Inner (Max) 36o

Wheel turning angle – Outer (Max) 36o
 Wheel alignment to be carried if abnormal conditions are noticed or at

40000kms, whichever is earlier.
38
706-MAT-0430:0.10hrs.
BATTERY ELECTROLYTE LEVEL – INSPECT
BATTERY ELECTROLYTE LEVEL - CHECK
Refer above illustration –

 Ensure the electrolyte level between MIN and MAX marks (if the electrolyte level is
less than the MIN mark, then top up the electrolyte to the recommended level with
distilled water.
 Toping 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.
 Tighten the terminals along with cable
fitments properly.
 Battery electrolyte level to be inspected at every service interval.
39
706-MAT-0440:0.10hrs.
BATTERY ELECTROLYTE SPECIFIC GRAVITY - CHECK
BATTERY SP. GRAVITY - CHECK
Refer above illustration.
 Check and ensure the Specific Gravity using Hydrometer.
 The specific gravity of a fully charged battery is as follows -
AMARON – 1.280 to 1.270

EXIDE - 1.240 to 1.230
 Battery electrolyte specific gravity to be inspected at every service interval.
40
706-MAT-0450:0.30hrs.
LIGHTS/HORN/WIPER/WASHER – CHECK
A. Refer below schematic and check for proper functioning of indications and confirm no
‘warning and/ or caution’ indications are shown in the cluster; check and correct if
required.
* indicates that indication lamp is optional in the system & available if applicable.
Scorpio Instrument Cluster - Schematic
Refer below chart for the indication identification given in instrument cluster -
41
B. Check combination switch functions –
Combination Lighting Switches –

• Light Control Lever – Stalk end switch 1 is in neutral position.
• Check the Parking Lights, Headlight Low Beam, Headlight Falsh,
• Front Fog Lights and Rear Fog Lights (If equipped) – Check the functions.
• Light Off – Inner rotary switch 2 is in neutral position.
Turn Indicators –
• Right Direction Indicator: Push the lighting control stalk downwards till you hear an
audible click.
• Left Direction Indicator: Push the lighting control stalk upwards till you hear an audible
click.
NOTE:
• The stalk automatically returns after you make a turn.
• If the turn signal indicator lights in the instrument cluster flashes faster than normal, it
indicates a fused indicator bulb.
42
Wiper and Washer Control Lever –

Front Wipe / Wash
Wiper / washer control lever; Wash/ wipe functions can be activated with the ignition key at
the IGN position.
• Check for Flick-wipe (MIST), Intermittent wiping (INT), Low speed wiping (LO), High
speed wiping (HI), wash/ wipe (PULL) & Adjustable Intermittent wiping (If installed).
NOTE:
• Do not operate the wipers when the windshield is dry. It may scratch the glass.
• To prevent the battery from being discharged, do not leave the lights on for a long time
when the engine is not running.
43
706-MAT-0460:0.30hrs.
HEADLAMP AIMING/ALIGNMENT
Headlamp alignment can be done by two methods.

(1) “USING THE AIMING INSTRUMENT”
(2) “IN THE DARK ROOM”
(1) HEADLAMP ALIGNMENT USING THE AIMING INSTRUMENT:

(Follow instructions of the equipment supplier, if any)
 Ensure that the:

a) Vehicle & headlamp aiming equipment placed on the same Level surface.
b) Check and ensure all four tyre pressures as per specification.
c) The headlamp aiming instrument height should be in the centreline of headlamp.
Refer above illustration -

1. Bring the aiming instrument lens in front of headlamp as shown in above diagram.
2. Then switch ON Headlamp LOW beam (HLLD system actuates in Park ON).
3. Keep the levelling switch in “0” position.
4. Observe the demarcation between light & dark zone. This demarcation line should
coincide with horizontal line at an angle of 15 Deg. Refer illustrations shown below.
5. If the low beam does not coincide with the lines on the screen, adjust the setting Screws
to the set pattern at a required height (i.e. cut-off height marked on aiming instrument),
with the help of star head Screwdriver. Refer illustration below -
44
6. For RHD vehicles the oblique line at 15deg will be oriented towards LH side, and for LHD
vehicles the same will be oriented towards RH side.
7. Check the system function by moving the switch position from 0 to 4, accordingly Cut-off
pattern will move downward & at 0th position the cut-off will come at original – 1.3%
setting.
8. If the beam pattern is moving with the switch operation that means system is OK.
9. After setting both Headlamp cut-off pattern, check the head lamp reflector, There should
not be any fouling between Headlamp Reflector & Housing.
10. The head light centre height is 880mm in Scorpio m2DiCR.
45
(2) HEADLAMP ALIGNMENT IN THE DARK ROOM:
 Ensure that the:

a) Vehicle & black screen/ board both are placed on the same Level surface.
b) Check and ensure all four tyre pressures as per specification.
c) Headlamp levelling switch position is on zero (0).
75cm
Refer above illustration -
1. Keep the vehicle at a distance of 10 meter from the black screen in the dark room.
2. Mark the –1.3% height on the board as shown. i. e. 130mm below the Headlamp centre
height.
3. Headlamp centre height in Scorpio is 880mm.
4. Set both LH & RH headlamp by setting the cut-off pattern at a height marked on the
board/screen.
5. Check the function of system, by operating the switch 0 to 3 and observe the cut-off
pattern movement in down word direction accordingly.
6. At zero position of switch the cut-off should come at –1.3% heights on screen.
Select the switch position as per following table for M-1 category vehicles -
Switch Position Vehicle loading condition

0 Driver / Driver with Front passenger.
1 Driver + Front passenger + Rear seat occupied
2 All seats occupied
3 All seats occupied with luggage
or Driver with luggage at extreme rear side.
NOTE:
1. Head lamp centre height in Scorpio is 880 mm. So here h (cm) is the height 130mm below
the HL-centre height. i.e. –1.3% setting of cut-off pattern.
H (cm) = (880 – 130) = 750mm or 75cm.
2. Distance of vehicle from black board is 10 meters.
46
706-MAT-0470:0.20hrs.
HVAC FILTER - CLEAN
GLOW BOX REMOVAL – from IP assembly
C B
HVAC FILTER ELEMENT REMOVAL
HVAC FILTER - CLEAN

Refer above illustrations A, B, & C -
1. Open and remove the Glove Box [A].

2. Remove the HVAC Filter Cover [B] by opening the snap clips on both sides.
3. Take out HVAC
HVAC particle
Filter filterwith
tray along to be cleaned
Filter at every
Element [B] 5000kms.
4. 
Clean the Filter Element with air blow (If compressed low
HVAC particle filter can be cleaned by air ispressure air. the pressure is
used, ensure
 HVAC particle
low). Clean the tray also. filter can be cleaned by soap solution and clean
Water, if chocked fully.
5. Fit the cleaned HVAC Filter & Cover; lock the snap clips on both sides.
47
706-MAT-0490:0.20hrs.
TYRE PRESSURE – INSPECT AND ADJUST
Tyre pressure value: Refer below chart –
COLD TYRE INFLATION PRESSURE

TYRE SIZE P 215 / 75 R15
FRONT REAR
psi 32 32
Kg/cm. sq. 2.2 2.2
TYRE PRESSURE – CHECK AND ADJUST

Refer above chart –
1. Check and adjust tyre pressure as per the recommended values.

2. Ensure to check and adjust the tyre pressure in the spare tyre.
3. Ensure to replace dust cap on valve seats after checking tyre pressure.
48
706-MAT-0500:0.40hrs.
BODY MOUNTING BOLTS - TIGHTEN
Nut/ Bolt description Spanner Size Quantity Nos. Torque Value – Nm.
Body mtg. bolts 13 mm. 10 nos. 55 ± 05 Nm.
BODY MOUNTS - LOCATIONS
NOTE:
 Body mounts/ triggers on front both are denominated as Mtg. No.1 to 5.
 There are 05 Nos. Body mounts on vehicle left hand side as well as 05 Nos. on vehicle
right side.
 Refer above sketch for body mount locations.
 Park the vehicle in inspection pit /2 post lift/ 4 post lift.

disconnected before lifting the vehicle & re-connect the LSPV spring &
ensure that the setting height is correct after job complete.
49
706-MAT-0510:0.10hrs.
EXHAUST SYSTEM – INSPECT
EXHAUST SYSTEM - LAYOUT
EXHAUST SYSTEM – CHECK. Refer above illustration.
1. Check all the Exhaust mountings for exhaust pipe damage, fouling if any and correct
fittings.
2. Check all the Exhaust joints for leakage and correct fittings.
3. Check rubber hanger for crack and shift, replace and correct if required.
 Park the vehicle in inspection pit/ 2 post lift / 4 post lift.

disconnected before lifting the vehicle & re-connect the LSPV spring & ensure
that the setting height is correct after job complete.
50
SERVICE CHECK LIST
51
MAINTENANCE CHECKLIST 5000 KMS. REMARK

Engine oil R
Engine oil filter R
Accessory Drive belt & Roller - Water pump / Alternator I
Drive Belt - A/C Compressor I
Drive Belt - Power Steering I
Coolant I
Fuel filter element R
Water sediments drain fuel filter (for when indicator glows) I
Clutch fluid - level & leak check B I
Transmission oil R
Differential oil (Rear) R
Tyre rotation I
Propeller Shaft greasing L
Brake fluid - level & leak check B I
Brake pads /Calipers I
Parking brake I
Battery electrolyte level I
Battery electrolyte specific gravity I
All Lights, Horns, Wipers & Washers I
Head light aiming I
Particle filter C
Tyre pressure I
Under chassis nuts and bolts for tightness I
Exhaust pipe mountings & damage / leakage I
Road Test I
Above Services Performed by –

Name of the Technician
Date of Service
Repair order No.
Repair order date
52

Engine oil I
Power steering fluid - level & leak check I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
53

Engine oil R
Engine oil filter R
Tappet Clearance A
Coolant I
Tyre rotation I
Brake Liners/Drums I
Parking brake I
Suspension bushes I
Suspension arms & links I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
54

Engine oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
55

Engine oil R
Engine oil filter R

Coolant I

Tyre rotation I
Parking brake I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
56

Engine oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
57

Engine oil R
Engine oil filter R
Tappet Clearance A
Clutch fluid - level & leak check B R
Tyre rotation I
B
Brake fluid - level & leak check R
Parking brake I
Suspension bushes I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
58

Engine oil I
Transmission oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
59

Engine oil R
Engine oil filter R
Drive Belt - A/C Compressor R
Drive Belt - Power Steering R
Coolant R
Air filter element** R
Rear wheel bearings L
Tyre rotation I
B
Brake fluid - level & leak check I
Parking brake I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
60

Engine oil I

Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
61

Engine oil R
Engine oil filter R
Tappet Clearance A
Coolant I
Tyre rotation I
Parking brake I
Suspension bushes I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
62

Engine oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
63

Engine oil R
Engine oil filter R
Coolant I
Transmission oil I
Tyre rotation I
B
Parking brake I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
64

Engine oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
65

Engine oil R
Engine oil filter R
Tappet Clearance A
Accessory Drive belt & Roller - Water pump / Alternator R
Coolant I
Tyre rotation I
B
Brake fluid - level & leak check R
Parking brake I
Suspension bushes I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
66

Engine oil I

Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
67

Engine oil R
Engine oil filter R
Coolant I
Air filter element** R
Tyre rotation I
B
Parking brake I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
68

Engine oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
69

Engine oil R
Engine oil filter R
Tappet Clearance A
Coolant I
Transmission oil R
Rear wheel bearings L
Tyre rotation I
Parking brake I
Suspension bushes I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
70

Engine oil I

Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
71

Engine oil R
Engine oil filter R

Coolant R
Tyre rotation I
Parking brake I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
72

Engine oil I

Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
73

Engine oil R
Engine oil filter R
Tappet Clearance A
Coolant I
Tyre rotation I
Brake fluid - level & leak check B R
Parking brake I
Suspension bushes I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
74

Engine oil I
Particle filter C
Tyre pressure I
Road Test I

Date of Service
Repair order No.
Repair order date
75

MAN-00131 - SCORPIO m2DiCR - Maintenence Manual

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MAINTENANCE MANUAL

TECHNICAL PUBLICATION CELL

Job Description Repair Time {Manhours}

Repair Code Torque Specified

Lubricant Quantity Tool Specified

This chart is only a sample.

Always wear clean uniform

Parts and tools

Oil Drain & Refill –

 Park the vehicle on level ground/2 post lift* /4 post lift

Oil Level Check –

m2DiCR – Engine Oil Filter – Dismantled

Oil filter Removal –

 Never use a wrench/spanner to tighten the oil filter.

m2DiCR – Engine Tappet Clearance Adjust

TAPPET CLEARANCE – INSPECT & ADJUST.

Refer illustration shown.

ACCESSORY DRIVE BELT TO BE

Refer illustrations below.

ACCESSORY DRIVE BELT - LAYOUT

Refer illustrations shown.

4. Uneven Rib Wear – 5. Misalignment –

Refer illustrations shown.

 Water Pump–Alternator drive belt is 4PK type and it is recommended to be

Water Pump-Alternator Drive Belt

Alternator stay rod & nuts for

WATER PUMP-ALTERNATOR DRIVE BELT – REPLACE

 Water Pump–Alternator drive belt is 4PK type and it is recommended to be

Steering Pump Drive Belt

AC COMPRESSOR DRIVE BELT TO BE INSPECTED FOR – Refer illustration.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at

AC Compressor Drive Belt

AC COMPRESSOR DRIVE BELT – REPLACE

Refer illustration shown.

Steering Pump Drive Belt

POWER STEERING DRIVE BELT TO BE INSPECTED FOR – Refer illustration.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at

Steering Pump stay bracket with

POWER STEERING DRIVE BELT – REPLACE

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at

Coolant – MAXIMILE Coolant. Capacity – 7.5 Liters.

Coolant Level & Leak - Inspect 1

COOLANT LEVEL - INSPECT

1. Check the coolant level when the engine is cold.

 Never remove the radiator cap when the engine is hot.

Coolant – MAXIMILE Coolant. Capacity – 7.5 Liters.

 Never remove the radiator cap when the engine is hot.

Nut/ Bolt description Quantity Spanner Torque Value – Nm.

Air Intake Assembly – Dismantled

AIR FILTER ELEMENT – REPLACE. Refer illustration shown above –

 Do not clean the air filter element.

Put the tray below before attending removal of

Remove the fuel inlet and outlet hoses from

2. Ensure correct fitment of fuel inlet & outlet

Remove the filter top cover with help of ‘Torx’

Remove the fuel filter upper cover.

Use flat screw driver to remove the top cover.

Remove top cover along with fuel filter

Separate fuel filter cartridge from top cover.