2006 - Maintenance Manual (R0 0806 CRDe) (All New)

SCORPIO CRDe (All New)
MAINTENANCE MANUAL
940MATR000806EN
CONFIDENTIAL RELEASED BY :
• ONLY FOR INTERNAL CIRCULATION WITHIN
M&M AUTHORISED DEALERS & SERVICE CENTRES TECHNICAL PUBLICATION CELL
• PASSING ON TO THRID PARTY IS NOT PERMITTED MAHINDRA & MAHINDRA LTD – NASHIK
• ALWAYS CHECK FOR THE LATEST VERSION
REVISION 0 – AUGUST 2006
TABLE OF CONTENTS
HOW TO USE THIS MANUAL
Section 1. Maintenance Schedule
Section 2. Maintenance Service Checklist
Section 3. SOPs
940 113 Cooling System

Check Radiator coolant level and coolant hose & heater hose
940 113 010
connections for leaks.
940 113/126 020 Check Cooling – heating hoses for leakage
940 113 030 Change Engine coolant.
940 113 040 Check Fluid Reservoirs levels
940 110 Engine

Check Drive belt tension & Check the drive belts for cracks,
940 110 020/070
fraying, wear.
940 110 050 Check Engine oil level and leakage.
940 110 060 Adjust intake and Exhaust valve clearance.
940 110 080/090 Check/Replace belt tensioner / idler pulley
940 110 100 Change Engine oil & Oil filter
940 110 110 Check oil lines
940 110 130 Replace Accessory Belt
940 112/114 Air, Fuel & Exhaust

940 114 010 Replacement of air cleaner
940 112 020 Rectify fuel leakage if any / Check fuel lines
940 112 030 Remove drain plug fuel tank and drain off sediments.
940 112 040 Check & drain water from Fuel filter
940 112 050 Replace fuel filter element
940 114 060 Exhaust pipes and mountings, Check
940 112 060 Fuel Tank & Strainer Cleaning
940 112 070 Fuel Tank Strainer Replacement
940 126 HVAC

940 126 030 Replcace A/C Particle filter
940 126 031 Clean A/C Particle filter
940 126 040 Clean the evaporator
940 126 050 AC Performance Test
940MATR000806E
940 115 Manual Transmission & Clutch
940 115 010 Clutch fluid. Check & Top up.
940 115 020 Check Transmission Gear oil
940 115 021 ReplaceTransmission Gear oil
940 115 030 Clean & refit breather
940 120 Steering

Check All stg rods & Arms ( Loose , damage , wear ) + tighten
940 120 010
intermediate shaft bolts
940 120 020 Check stg Ball joint and dust covers
Check Power steering reservoir fluid level and hose connections
940 120 040
for leaks.
940 116 Front Axle

940 116 010 Change grease in front wheel hub and adjust bearing play .
940 117 Rear Axle

940 117 010 Check & change Rear Axle wheel bearing grease.
940 117 020 Rear Axle Differential gear oil Check.
940 117 030 Rear Axle Differential gear oil Change.
940 119 Brake

Check brake pads, disc & other brake components for wear,
940 119 010
deterioration & leaks.
Check brake lining, drums & other brake components for wear,
940 119 020
deterioration & leaks.
940 119 030/050 Check Brake pedal and parking brake operation
940 119 040 Check or Change Brake fluid.
940 114/119 020/070 Vacuum Connections – Check
940 119 080 LSPV Setting
940 119/115 Pedals & Controls

Check foot brake, parking brake & clutch for free play stroke &
940 119/115 010
operation.
940 116/117 Suspension & Drive Shaft

Check shock absorber & its bushes (for oil leakages / damages),
940 116/117 020
Replace if necessary.
Check condition of bushes, rubber links in anti-roll bar.
940 116/117 030
Check condition of rubber bushes in lower link of front
940 116 040
suspension.
940 116 050 Check condition of pivot bushes in top wishbone.
940 117 021 Check & Grease Propeller shaft & sliding yoke.
940MATR000806E
124 /
940
125 129
Electrical
Check the Operation of all instruments, gauges, lights and
940 125 010
accessories.
940 129 030 Check Operation of Horn (s) wiper and washer.
Check Operation of headlights ( High & Low beam ) & leveling
940 128 040
mechanism
940 125 050 Check Operation of warning lights.
Check Battery fluid level, specific gravity and conditions of
940 124 020
battery terminals
940 129 060 Check Grease the Wiper motor linkages
940 125 080 Shock Sensor Activation
940 125 090 Instrument Cluster Clock Setting
940 132 Interiors & Mechanisms

940 132 010 Check Front and rear seats, and seat belts for operation.
940 132 030 Check seat belts, buckles, retractors & adjuster.
940 136 020 Check All moldings, trims and fittings for fit and alignment.
940 134 040 Check All windows for operation & alignment.
940 135 050 Check Hood, NVH covers, door panels for fit and alignment.
940 133 070 A Check & apply grease Bonnet opening lever & lock plate.
940 133 080 Fuel Lid Opener - Check Operation
940 135 Exterior Trims

940 135 010 Foot Step Filtment
940 135 020 Exterior Trims - Check for Fit & Alignment
940 118 Wheels & Tyres

940 118 010 Tyres rotation & Inflation pressure (Including Spare tyre )
940MATR000806E
HOW TO USE THIS MANUAL
PURPOSE – The purpose of the Maintenance Manual to guide the technician

in doing the Settings & Adjustments required for trouble-free operation of the
Scorpio CRDe (All New) vehicle. These operations need to be done at the
service intervals, as recommended by the manufacturer.
The maintenance manual is divided in to 3 sections –
Section 1 gives the overall maintenance schedule of the Scorpio CRDe (All
New) vehicle. The various settings/adjustments/checks and replacements are
shown against the service intervals.
Section 2 provides quick reference checklist for each of the services. The
individual operations to be carried out at each of the service intervals are shown
in the checklist.
Section 3 deals with the standard operating procedures to be followed while

undertaking any of the repairs or adjustments.
RECOMMENDED PRACTICE AT THE DEALERSHIP WORKSHOP
• Customer visits the Dealership for a scheduled service

• The Service Advisor makes job card and prints the relevant service
check list and attaches it to the job card
• The technician refers to the checklist and ensures that all operations as
mentioned in the checklist are carried out
• The floor supervisor ensures that all the operations are carried out as
per the checklist
• In case of any doubt in the procedure of carrying out the operations, the
technician refers to the SOPs.
• The quality inspector checks and certifies that none of the operations
are left out
940MATR000806E
SECTION 1
MAINTENANCE SCHEDULE
940MATR000806E
MAINTENANCE SCHEDULE - SCORPIO CRDe (All New)
12months
15months
18months
21months
24months
27months
30months
33months
36months
39months
42months
45months
48months
51months
54months
57months
60months
100000 /
9 Months
3months
6months
10000 /
20000 /
25000 /
30000 /
35000 /
40000 /
45000 /
50000 /
55000 /
60000 /
65000 /
70000 /
75000 /
80000 /
85000 /
90000 /
95000 /
15000 /
SOP No.
5000 /
SYSTEM
MODEL
NATURE OF WORK TO BE DONE
Daily
PDI
by SERVICE CENTRE

Check Radiator coolant level and coolant hose & heater
940 113 010 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √
hose connections for leaks.
940 113 030 Change Engine coolant. R R
940 113 040 Check Fluid Reservoirs levels √ √ √ √ √ √ √ √ √ √ √
940 110 Engine
940 110 020 Check Drive belt tension √ √ √ √ √ √ √
940 110 050 Check Engine oil level and leakage. √ √
940 110 060 Adjust intake and Exhaust valve clearance. √ √ √ √ √
Check the drive belts for cracks, fraying. Wear &
940 110 070 √ √ √ √ √ √ √ √ √ √ √ √
tension.
940 110 080 Check/Replace belt tensioner pulley √ √ √ √ √ R √ √ √ √ √ √ √ √ √ R
940 110 090 Check/Replace belt idler pulley √ √ √ √ √ R √ √ √ √ √ √ √ √ √ R
940 110 100 Change Engine oil & Oil filter R R R R R R R
940 110 110 Check oil lines √ √ √ √ √ √ √
940 110 120 Check Diesel smoke [or] as per local regulation √ √
940 110 130 Replace Accessory Belt R
Replacement of air cleaner foam element [or when service
940 114 010 R R
indicator shows red band, whichever is earlier]
Rectify fuel leakage if any / Check fuel lines [Every
940 112 020 √ √ √ √ √ √
20,000 till 80,000 and then every 10,000 Kms]
940 112 030 Remove drain plug fuel tank and drain off sediments. √
Check & drain water from Fuel filter [or when indicator in
940 112 040 √ √ √ √ √ √ √ √ √ √
the cluster glows]
940 112 050 Replace fuel filter element R R R R R
Exhaust pipes and mountings, Check and if necessary
940 114 060 √ √ √ √ √ √
replace.
940 126 HVAC
940 126 010 Check Air conditioning / cooler Refrigerant. √ √ √ √ √ √ √ √ √ √ √
940 126 020 Tighten the bolts on brackets and compressor. √ √ √ √ √ √ √ √
940 126 030 Replcace A/C Particle filter R R R R R R
Clean the evaporator [Every 40,000 Kms. Or every 9 months
940 126 040 √ √
in normal condition & 4 months in dusty condition]
940 126 050 AC Performance Test A&W
940 115 010 Clutch fluid. Check & Top up. √ √ √ √ R √ √ √ R √ √
940 115 020 Check Transmission Gear oil √ √ √ √ √ √ √ √ √ √ √ √ √ √ √
940 021 ReplaceTransmission Gear oil R R R R R R
940 115 030 Clean & refit breather √ √
940 120 Steering
Check All stg rods & Arms ( Loose , damage , wear ) +
940 120 010 √ √ √ √ √ √ √ √ √ √ √
tighten intermediate shaft bolts
940MATR000806E
940 120 020 Check stg Ball joint and dust covers √ √ √ √ √ √ √ √ √ √
12months
15months
18months
21months
24months
27months
30months
33months
36months
39months
42months
45months
48months
51months
54months
57months
60months
100000 /
9 Months
3months
6months
10000 /
20000 /
25000 /
30000 /
35000 /
40000 /
45000 /
50000 /
55000 /
60000 /
65000 /
70000 /
75000 /
80000 /
85000 /
90000 /
95000 /
15000 /
SOP No.
5000 /
SYSTEM
MODEL
Daily
PDI
by SERVICE CENTRE
940 120 030 Check Steering wheel linkage & gear box oil. √ √ √ √ √ √
Check Power steering reservoir fluid level and hose
940 120 040 √ √ √ √ √ √ √ √ √ √ √
940 116 Front Axle
Change grease in front wheel hub and adjust bearing
940 116 010 √ R √ R
play .
940 116 020 Check Front Axle Drive shafts ( Bent or boot damage ) √ √ √ √ √
940 117 Rear Axle
Check & change Rear Axle wheel bearing grease./ Smooth
940 117 010 R R
rotation
940 117 020 Rear Axle Differential gear oil Check - Top up. √ √ √ √ √ √ √ √ √ √ √
940 117 030 Rear Axle Differential gear oil Change. R R R R R R
940 119 Brake
Check brake pads, disc & other brake components for
940 119 010 √ √ √ √ √ √ √ √ √ √
wear, deterioration & leaks.
Check brake lining, drums & other brake components for
940 119 020 √ √ √ √ √ √ √ √ √ √
940 119 030 Check Brake pedal and parking brake operation √ √ √ √ √ √ √ √ √ √ √ √
@@
940 119 040 Check or Change Brake fluid. √ √ √ √ √ R √ √ √ R √ √
940 119 050 Check and adjust parking brakes. √ √ √ √ √ √ √ √ √ √ √ √
940 114/119 020/070 Vacuum Connections - Check √ √ √ √ √ √ √ √ √ √ √ √
940 119 / 115 Pedals & Controls
Check foot brake, parking brake & clutch for free play
940 119/115 010 √ √ √ √ √ √
stroke & operation.
940 116/117 Suspension
940 116 010 Check Wheel alignment & rotate the wheels as per manual. √ √ √ √ √ √ √ √ √ √
Check shock absorber & its bushes (for oil leakages /

940 116/117 020 √ √ √ √ √
damages), Replace if necessary.
Check condition of bushes, rubber links in anti-roll bar.
940 116/117 030 @@ √ √ √
Check condition of rubber bushes in lower link of front
940 116 040 @@ √ √ √
suspension. Replace if necessary.
Check condition of pivot bushes in top wishbone.
940 116 050 @@ √ √ √
Replace if necessary
Check and tight the suspension arm mounting bolts and ball
940 116/117 060 √ √ √ √ √ √ √ √ √ √
joint mounting bolts to the specified torque
940 117 021 Check & Grease Propeller shaft & sliding yoke. √ √ √ √ √ √ √ √ √ √ √
940 4 / 125 129 Electrical
940 125 010 √ √ √ √ √ √ √ √ √ √ √
accessories.
940MATR000806E
12months
15months
18months
21months
24months
27months
30months
33months
36months
39months
42months
45months
48months
51months
54months
57months
60months
100000 /
9 Months
3months
6months
10000 /
20000 /
25000 /
30000 /
35000 /
40000 /
45000 /
50000 /
55000 /
60000 /
65000 /
70000 /
75000 /
80000 /
85000 /
90000 /
95000 /
15000 /
SOP No.
5000 /
SYSTEM
MODEL
Daily
PDI
by SERVICE CENTRE
Check Battery fluid level, specific gravity and conditions

940 124 020 √ √ √ √ √ √
of battery terminals [or Once in six months ]
940 129 030 Check Operation of Horn (s) wiper and washer. √ √ √ √ √ √ √ √ √ √ √
Check Operation of headlights ( High & Low beam ) &
940 128 040 √ √ √ √ √ √ √ √ √ √ √
leveling mechanism
940 125 050 Check Operation of warning lights. √ √ √ √ √ √ √ √ √ √ √
Check Grease the Wiper motor linkages [or Once in a
940 129 060 √ √
year before monsoon]
940 125 080 Shock Sensor Activation √
940 125 090 Instrument Cluster Clock Setting √
940 Interiors & Mechanisms
Check Front and rear seats, and seat belts for
940 132 010 √
operation.
Check All moldings, trims and fittings for fit and
940 136 020 √
alignment.
940 132 030 Check seat belts, buckles, retractors & adjuster. √ √ √ √ √ √
940 134 040 Check All windows for operation & alignment. √
Check Hood, NVH covers, door panels for fit and
940 135 050 √
alignment.
940 133 060 Check & lubricate Latches, Keys and locks for operation √ √ √ √ √ √ √ √ √ √ √ √
Check & apply grease Door lock striker, Check arm, Bonnet
940 133 070 √ √ √ √ √ √ √ √ √ √ √
opening lever & lock plate.
940 133 080 Fuel Lid Opener - Check Operation √
940 135 010 Foot Step Filtment √
940 135 020 Exterior Trims - Check for Fit & Alignment √
940 118 010 Tires rotation & Inflation pressure (Including Spare tyre ) √ √ √ √ √ √ √ √ √ √
940 GENERAL
940 100 Under Body Inspection
Check oil level & leak on Transmission , Transfer and
differential
940 100 010 √ √ √ √ √ √ √ √ √ √ √
propeller shafts, drive shafts, engine & body mounting
bolts.
Lubricate locks, hinges & latch
940 100 020 Tighten bolt and nuts of steering linkage, gear box, √ √ √ √ √ √ √ √ √ √
suspension,
940 Road Test
Check clutch operation, parking brake operation, steering

control & returnability, Engine performance, Squeaks &
940 100 30 rattles, Body & Chassis noise, operation of service / parking
√ √ √ √ √ √ √ √ √ √ √ √
brakes, gear shifting, instrument cluster, operation of HVAC
940MATR000806E
12months
15months
18months
21months
24months
27months
30months
33months
36months
39months
42months
45months
48months
51months
54months
57months
60months
100000 /
9 Months
3months
6months
10000 /
20000 /
25000 /
30000 /
35000 /
40000 /
45000 /
50000 /
55000 /
60000 /
65000 /
70000 /
75000 /
80000 /
85000 /
90000 /
95000 /
15000 /
SOP No.
5000 /
SYSTEM
MODEL
Daily
PDI
by SERVICE CENTRE
940 FINAL INSPECTION.

Check & ensure normal working of engine using diagnostic
940 100 040 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √
equipment
940 General Inspection
Check Sound System & Controls , Retractable Aerial, Child

lock, Power Window Controls, Power Lock system &
940 100 050 control, Cigarette Lighter and Remote Control Mirrors. √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √
Check proper operation of Security system and voice
messaging system (if fitted),
√ - Inspect these items and their related parts. If necessary, correct, clean, replenish, adjust or replace
R - Indicates Replace or change
@@ - Or once in a year, whichever is earlier
940MATR000806E
SECTION 2
SERVICE CHECKLIST
940MATR000806E
PDI CHECK LIST - SCORPIO CRDe (All New)
MODEL SYSTEM SOP No. NATURE OF WORK TO BE DONE TICK
940 113 010
940 110 Engine
940 110 020 Check Drive belt tension
940 110 050 Check Engine oil level and leakage.
940 110 070 Check the drive belts for cracks, fraying. Wear & tension.
Rectify fuel leakage if any / Check fuel lines [Every 20,000 till
940 112 020
80,000 and then every 10,000 Kms]
940 114 060 Exhaust pipes and mountings, Check and if necessary replace.
940 126 HVAC
940 126 010 Check Air conditioning / cooler Refrigerant.
940 120 Steering
940 120 010
940 120 030 Check Steering wheel linkage & gear box oil.
Check Power steering reservoir fluid level and hose connections
940 120 040
for leaks.
940 117 Rear Axle
940 117 010 Check & change Rear Axle wheel bearing grease./ Smooth rotation
940 117 020 Rear Axle Differential gear oil Check - Top up.
940 119 Brakes
940 119 030 Check Brake pedal and parking brake operation
940 119 040 @@
Check or Change Brake fluid.
940 119 050 Check and adjust parking brakes.
940 114/119 020/070 Vacuum Connections - Check
Check foot brake, parking brake & clutch for free play stroke &
940 119/115 010
operation.
940 24 / 125 129 Electrical
940 125 010
accessories.
940 124 020
battery terminals [or Once in six months ]
940 128 040
mechanism
940MATR000806E
Page5 of 30
PDI CHECK LIST - SCORPIO CRDe (All New)
940 125 080 Shock Sensor Activation
940 125 090 Instrument Cluster Clock Setting
940 132 010 Check Front and rear seats, and seat belts for operation.
940 136 020 Check All moldings, trims and fittings for fit and alignment.
940 134 040 Check All windows for operation & alignment.
940 135 050 Check Hood, NVH covers, door panels for fit and alignment.
940 133 060 Check & lubricate Latches, Keys and locks for operation
Check & apply grease Door lock striker, Check arm, Bonnet opening
940 133 070
lever & lock plate.
940 133 080 Fuel Lid Opener - Check Operation
940 135 010 Foot Step Filtment
940 135 020 Exterior Trims - Check for Fit & Alignment
940 118 010 Tires rotation & Inflation pressure (Including Spare tyre )
GENERAL
Check oil level & leak on Transmission , Transfer and differential
940 100 010
propeller shafts, drive shafts, engine & body mounting bolts.
940 Road Test
Check clutch operation, parking brake operation, steering control &
returnability, Engine performance, Squeaks & rattles, Body & Chassis
940 100 30
noise, operation of service / parking brakes, gear shifting, instrument
cluster, operation of HVAC
940 100 040 Check & ensure normal working of engine using diagnostic equipment

Check Sound System & Controls , Retractable Aerial, Child lock,
Power Window Controls, Power Lock system & control, Cigarette
940 100 050 Lighter and Remote Control Mirrors.
Check proper operation of Security system and voice messaging
system (if fitted),
940MATR000806E
Page6 of 30
5000 KMS CHECK LIST - SCORPIO CRDe (All New)
940 113 010
940 110 Engine
940 021 ReplaceTransmission Gear oil
940 117 Rear Axle
940 119 Brake
940 119 040 @@
940 GENERAL
940 Road Test
Check clutch operation, parking brake operation, steering control
& returnability, Engine performance, Squeaks & rattles, Body &
940 100 30
Chassis noise, operation of service / parking brakes, gear
shifting, instrument cluster, operation of HVAC
940 100 040
equipment
lock, Power Window Controls, Power Lock system & control,
940 100 050 Cigarette Lighter and Remote Control Mirrors.
system (if fitted),
940MATR000806E
940 113 010
940 110 Engine

940 112 040
the cluster glows]
940 126 HVAC
940 126 050 AC Performance Test
940 120 Steering
940 120 010
940 120 040
940 117 Rear Axle
940 119 Brake
940 119 010
940 119 020
940 119 040 @@
940 116/117 Suspension / Driveline
940 116 010 Check Wheel alignment as per manual.
940 116/117 060
940 24 / 125 129 Electrical
940 125 010
accessories.
940MATR000806E
940 128 040
mechanism
940 133 070
940 GENERAL
940 100 010 differential

940 100 020 Tighten bolt and nuts of steering linkage, gear box,
suspension,
940 Road Test

940 100 30
rattles, Body & Chassis noise, operation of service / parking

940 100 040
equipment

940 100 050 control, Cigarette Lighter and Remote Control Mirrors.
940MATR000806E
Check Radiator coolant level and coolant hose &
940 113 010
heater hose connections for leaks.
940 126 HVAC
Check & ensure normal working of engine using
940 100 040
diagnostic equipment
Check Sound System & Controls , Retractable Aerial,
Child lock, Power Window Controls, Power Lock
system & control, Cigarette Lighter and Remote
940 100 050
Control Mirrors.
940MATR000806E
940 113 010
940 110 Engine

Rectify fuel leakage if any / Check fuel lines [Every 20,000
940 112 020
till 80,000 and then every 10,000 Kms]
Check & drain water from Fuel filter [or when indicator in the
940 112 040
cluster glows]
940 114 060
replace.
940 126 HVAC
940 120 Steering
940 120 010
940 120 040
940 116 Front Axle
940 116 020 Check Front Axle Drive shafts ( Bent or boot damage )
940 117 Rear Axle
940 119 Brake
940 119 010
940 119 020
940 119 040 @@
940 119/115 010
stroke & operation.
940 116/117 Suspension & Driveline
940MATR000806E
940 116 010 Check Wheel alignment & as per manual.
940 116/117 020
940 116/117 060
940 24 / 125 129 Electrical
940 125 010
accessories.
940 124 020
battery terminals [or Once in six months ]
940 128 040
mechanism
940 133 070
940 GENERAL
940 100 010 differential
suspension,
940 Road Test
control & returnability, Engine performance, Squeaks & rattles,
940 100 30 Body & Chassis noise, operation of service / parking brakes,
gear shifting, instrument cluster, operation of HVAC
940 100 040
equipment
lock, Power Window Controls, Power Lock system & control,
940 100 050 Cigarette Lighter and Remote Control Mirrors.
system (if fitted),
940MATR000806E
940 113 010
940 110 Engine
940 110 080 Check/Replace belt tensioner pulley
940 110 090 Check/Replace belt idler pulley
940 116 Front Axle
940 116 010
play .
940 100 040
equipment

940MATR000806E
940 113 010
940 110 Engine
940 110 070
tension.
Check & drain water from Fuel filter [or when indicator
940 112 040
in the cluster glows]
940 126 HVAC
940 120 Steering
940 120 010
940 117 Rear Axle
940 119 Brake
940 119 010
Check brake lining, drums & other brake components
940 119 020
for wear, deterioration & leaks.
940 119 040 @@
Check Wheel alignment & rotate the wheels as per
940 116 010
manual.
Check condition of bushes, rubber links in anti-roll
940 116/117 030 @@
bar. Replace if necessary.
Check condition of rubber bushes in lower link of
940 116 040 @@
front suspension. Replace if necessary.
940 116 050 @@
940MATR000806E Replace if necessary
940 116/117 060
940 24 / 125 129 Electrical
Check the Operation of all instruments, gauges, lights
940 125 010
and accessories.
940 128 040
leveling mechanism
Check & apply grease Door lock striker, Check arm,

940 133 070
Bonnet opening lever & lock plate.
940 118 010 Tires rotation & Inflation pressure (Including Spare tyre)
940 GENERAL
differential
940 100 010
bolts.
suspension,
940 Road Test
940 100 30 rattles, Body & Chassis noise, operation of service / parking
brakes, gear shifting, instrument cluster, operation of
HVAC
940 100 040
equipment
Child lock, Power Window Controls, Power Lock system
& control, Cigarette Lighter and Remote Control
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 GENERAL
940 100 040
equipment
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 110 070
tension.
940 110 120 Check Diesel smoke [or] as per local regulation
Replacement of air cleaner foam element [or when
940 114 010
service indicator shows red band, whichever is earlier]
940 112 020
Check & drain water from Fuel filter [or when indicator
940 112 040
in the cluster glows]
940 114 060
replace.
940 126 HVAC
Clean the evaporator [Every 40,000 Kms. Or every 9

940 126 040
months in normal condition & 4 months in dusty condition]

940 120 Steering
940 120 010
940 120 040
940 116 Front Axle
940 116 020 Check Front Axle Drive shafts ( Bent or boot damage)
940 117 Rear Axle
940 119 Brake
940 119 010
940 119 020
940 119 040 @@
940 119/115 010
stroke & operation.
940MATR000806E
940 116 010
manual.
Check and tight the suspension arm mounting bolts and
940 116/117 060
ball joint mounting bolts to the specified torque
940 24 / 125 129 Electrical
940 125 010
and accessories.
Check Battery fluid level, specific gravity and

940 124 020
conditions of battery terminals [or Once in six months]
940 128 040
leveling mechanism
940 129 060

940 133 070
940 GENERAL
differential
940 100 010
bolts.
suspension,
940 Road Test
940 100 30 rattles, Body & Chassis noise, operation of service /
parking brakes, gear shifting, instrument cluster, operation
of HVAC
940 100 040
equipment
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 126 HVAC
940 GENERAL
940 100 040
equipment
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 110 070
tension.
Check & drain water from Fuel filter [or when
940 112 040
indicator in the cluster glows]
940 126 HVAC
940 120 Steering
940 120 010
940 120 040
940 116 Front Axle
Change grease in front wheel hub and adjust
940 116 010
bearing play .
940 117 Rear Axle
Check & change Rear Axle wheel bearing grease./
940 117 010
Smooth rotation
940 119 Brake
Check brake pads, disc & other brake components
940 119 010
940 119 020
940 119 040 @@
940MATR000806E
940 116/117 060
940 24 / 125 129 Electrical
940 125 010
and accessories.
940 128 040
leveling mechanism
Check & lubricate Latches, Keys and locks for
940 133 060
operation
940 133 070
Tires rotation & Inflation pressure (Including Spare tyre
940 118 010
)
940 GENERAL
differential
940 100 010
bolts.
suspension,
940 Road Test
940 100 30 rattles, Body & Chassis noise, operation of service /
parking brakes, gear shifting, instrument cluster,
operation of HVAC
940 100 040
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 GENERAL
940 100 040
940 100 050
Control Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 110 070
tension.
940 112 020

940 112 040
Exhaust pipes and mountings, Check and if
940 114 060
necessary replace.
940 126 HVAC
940 120 Steering
940 120 010
940 120 040
940 117 Rear Axle
940 119 Brake
940 119 010
Check brake lining, drums & other brake
940 119 020
components for wear, deterioration & leaks.
940 119 040 @@
Check foot brake, parking brake & clutch for free
940 119/115 010
play stroke & operation.
940 116/117 Suspension & Driveline
940 116 010
manual.
940 116/117 020
Check condition of bushes, rubber links in anti-roll
940 116/117 030 @@
bar. Replace if necessary.
940MATR000806E
Check condition of rubber bushes in lower link of

940 116 040 @@
front suspension. Replace if necessary.

940 116 050 @@
Replace if necessary
940 116/117 060
940 24 / 125 129 Electrical
940 125 010
and accessories.
940 124 020 conditions of battery terminals [or Once in six months
]
940 128 040
leveling mechanism
Check Grease the Wiper motor linkages [or Once in
940 129 060
a year before monsoon]
940 133 060
operation
940 133 070
Tires rotation & Inflation pressure (Including Spare
940 118 010
tyre )
940 GENERAL
differential
940 100 010
bolts.
suspension,
940 Road Test
Check clutch operation, parking brake operation,
steering control & returnability, Engine performance,
940 100 30 Squeaks & rattles, Body & Chassis noise, operation of
service / parking brakes, gear shifting, instrument
940 100 040
940 100 050
Control Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 GENERAL
940 100 040
equipment
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 110 070
tension.
940 112 040
the cluster glows]
940 126 HVAC
940 115 020 Check Transmission Gear oil level
940 120 Steering
940 120 010
940 120 040
940 117 Rear Axle
940 119 Brake
940 119 010
940 119 020
940 119 040 @@
940 116/117 060
940 24 / 125 129 Electrical
940 125 010
and accessories.
940MATR000806E
940 128 040
leveling mechanism
940 133 070
940 GENERAL
differential
940 100 010
bolts.
suspension,
940 Road Test

940 100 30
rattles, Body & Chassis noise, operation of service / parking

940 100 040
equipment
940 100 050
Mirrors.
940MATR000806E
940 113 010
940 110 Engine
940 126 HVAC
940 116 Front Axle
940 116 010
play .
940 GENERAL
940 100 040
equipment
940MATR000806E
940 113 010
940 110 Engine
940 110 070
tension.
940 110 120 Check Diesel smoke [or] as per local regulation
940 110 130 Replace Accessory Belt
Replacement of air cleaner foam element [or when
940 114 010
service indicator shows red band, whichever is earlier]
940 112 020
Remove drain plug fuel tank and drain off
940 112 030
sediments.
940 112 040
112 060 Clean Fuel Tank & Strainer
112 070 Replace Fuel Tank Strainer
940 114 060
replace.
940 126 HVAC
Clean the evaporator [Every 40,000 Kms. Or every 9
940 126 040 months in normal condition & 4 months in dusty
condition]
940 120 Steering
940 120 010
940 120 040
940 116 Front Axle
940 116 020 Check Front Axle Drive shafts ( Bent or boot damage )
940 117 Rear Axle

940 119 Brake
940 119 010
940 119 020
940 119 040 @@
940MATR000806E
Check foot brake, parking brake & clutch for free
940 119/115 010
play stroke & operation.
940 116/117 020
940 116/117 060
940 24 / 125 129 Electrical
940 125 010
and accessories.
940 124 020 conditions of battery terminals [or Once in six months
]
940 128 040
leveling mechanism
940 129 060
940 133 060
operation
940 133 070
Tires rotation & Inflation pressure (Including Spare tyre
940 118 010
)
940 GENERAL
differential
940 100 010
bolts.
suspension,
940 Road Test
Check clutch operation, parking brake operation,
steering control & returnability, Engine performance,
940 100 30 Squeaks & rattles, Body & Chassis noise, operation of
service / parking brakes, gear shifting, instrument
940 100 040
940 100 050
Control Mirrors.
940MATR000806E
SECTION 3
STANDARD OPERATING
PROCEDURES
940MATR000806E
Ref : 940-113-010
940-113-040
Coolant Level Check System : Cooling
1
2
2
1. - Check the coolant level in recovery tank with respect to Maximum

(MAX) level mark & top up if found less.
- Check the coolant level in the radiator & top up if found less.
2. Check all the Hoses & Clips for leakage and correct fitting.
APPLICABILITY
COOLANT SPEC. REFER MAINTENANCE CHART

QUANTITY AS REQUIRED
FREQUENCY REFER MAINTENANCE SCHEDULE
Scorpio CRDe ( All New) Maintenance Manual- Ver 0 Jul 06
The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a
result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction,
translation, transmission, in part or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2006 Mahindra &
940MATR000806E
Mahindra Ltd
Ref : 940-113-030
Coolant Replacement System : Cooling
1. Drain the coolant from the cooling system by opeinging the drain plug of
Radiator or engine block.
2. Assemble back the drain point & fill new coolant with respect to
Maximum (MAX) level mark.
3. Check all the Hoses & Clips for leakage and correct fitting.
APPLICABILITY

QUANTITY REFER MAINTENANCE CHART

940MATR000806E
Mahindra Ltd
Ref :940-113/126-020
Cooling heating Hose & Connections
System : Cooling-Heating
Check
1. Check all the Hoses / Joints & Clips for leakage and correct fitting.
APPLICABILITY


940MATR000806E
Mahindra Ltd
ENGINE
Scorpio CRDe (All New) Maintenance Manual- Ver 0 Jul 06

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of
changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation,
940MATR000806E
transmission, in part or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2006 Mahindra & Mahindra Ltd
Ref : 940-110-020
Accessory Belt Tension - Check 940-110-070
System : Engine
1. Check the Belt Tension…

- Turn on the Belt Tension Gauge, select reading mode in Hertz (Hz) & hold
the probe approximately 5mm distance in Front of the belt ( CAUTION: Do
not touch the probe to the belt, this can damage the probe!) as shown in
the illustration above by X.
- Tap on the belt near the probe.
- Note the reading. If the reading is within 125 TO 145, this should be OK.
- If the reading is less than 125 Hz then it needs adjustment .
2. Adjust the belt tension ….

2.A - Loosen the Tensioner Pulley Shaft Nut.
2.B – Tighten the Belt Tensioning Bolt.
2.C - Tighten the Tensioner Pulley Shaft Nut

940MATR000806E
3. Repeat the procedure as per the Step-1
- If the belt tension value should be 140+5 Hz.
- If the value is less than 140+5 Hz, Repeat the Steps 2 & 3.
APPLICABILITY
BELT SPEC. 7 PK – 1790 - GATES

940MATR000806E
Ref : 940-110-050
Engine Oil Level & Leak - Check System : Engine
2
1
1. Pull out the dip stick & check for the oil level ( Vehicle should be parked
on leveled ground & engine should be cold ) & top up if required.
2. Check hose joints for Oil leakage / seepage at –

• Oil pan & crankcase joint.
• Oil pan Drain plug. APPLICABILITY
• Oil filter joint.
Oil REFER MAINTENANCE CHART

940MATR000806E
Mahindra Ltd
Ref : 940-110-060
Tappet Adjustment System : Engine
1. Remove NVH Cover & 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 valve at dancing / rocking

position.
• Adjust the tappet clearance of 1st cylinder both Inlet & Exhaust valves as
per specifications*.

940MATR000806E
Mahindra Ltd
• Turn the engine 1800 further in the direction of engine rotation. Adjust
tappet of 3rd cylinder valves as per specifications*.
tappet of 4th cylinder valves as per specifications*.
tappet of 2nd cylinder valves as per specifications*.
APPLICABILITY
* TAPPET CLEARANCE SPECIFICATIONS ( COLD )

INLET VALVE 0.45 mm ( 18 thou)
EXHAUST VALVE 0.45 mm ( 18 thou)

940MATR000806E
Mahindra Ltd
Ref : 940-110-080
Belt Tensioner & Idler Pulley Bearing - 940-110-090
Change System : Engine
1. Loosen the Tensioner bolt to relieve the tension.
2. Loosen the Tensioner Pulley Nut. Take out the pulley assembly with Dust
Shield, washer & take the belt out.
Loosen the Idler Pulley Bolt. Take out the pulley assembly with Dust
Shield & washer.
3. Remove the Circlip from the Tensioner Pulley Assembly & take the
bearing out. Install the new bearing in the pulley on a hand press & fit
the circlip. Repeat the procedure for Idler Pulley Bearing too.

940MATR000806E
4. Put back the Idler Pulley Assembly along with dust shield & washer on the
bracket, hand tighten the Bolt.
Put the belt in place & fit the Tensioner Pulley Assembly along with dust
shield & washer on the bracket, hand tighten the nut.
Tighten the Tensioner Pulley Nut as well as Idler Pulley Bolt with torque
of 32.5 ±2.5 Nm.
5. Tighten the Tensioner Bolt so as to get the specified belt tension; follow
Maintenance Procedure : 940-110-020/070 for checking / adjusting the
belt tension.
APPLICABILITY


940MATR000806E
Ref : 940-110-100
Engine Oil & Oil Filter - Change System : Engine
Park the vehicle on leveled ground

1. Open the oil filler cap
2. Put the oil collecting tray below the sump, loosen & remove the Drain
Plug. Allow the oil to be drained for 15 min.

940MATR000806E
Mahindra Ltd
3. Remove the oil filter using oil filter wrench.
4. After the oil is completely drained, fit the new Oil Filter (Lubricate the
filter O ring with fresh engine oil). Hand tight the oil filter.
5. Fit the Drain Plug with a new washer. Torque tight the Drain plug -
27.5±2.5 Nm.
6. Fill the fresh oil as per capacity
7. Pull out the dipstick & check oil level.

• Oil pan & crankcase joint.
• Oil pan Drain plug.
• Oil filter joint.
APPLICABILITY


940MATR000806E
Mahindra Ltd
Ref : 940-110-110
Oil Lines - Check System : Engine
1. Check for Oil leakage / seepage and correct fitment at –

• Alternator oil inlet & return lines.
• Turbocharger oil inlet & return lines.
• Oil Separator Balancer hose
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-110-130
Accessory Belt - Change System : Engine
1. Loosen the Tensioner bolt to relieve the tension.
2. Loosen the Tensioner Pulley Nut. Take out the pulley assembly with Dust
Shield, washer & take the belt out.
3. Take the belt out.
4. Put the new belt in place & fit the Tensioner Pulley Assembly along with
dust shield & washer on the bracket, hand tighten the nut.
Tighten the Tensioner Pulley Nut with torque of 32.5 ±2.5 Nm.

940MATR000806E
5. Tighten the Tensioner Bolt so as to get the specified belt tension; follow
Maintenance Procedure : 940-110-020/070 for checking / adjusting the
belt tension to the installation tension --170 ±2 Hz.
6. Run the engine for 5 minutes & confirm the stabilized tension is at 140 to
145 Hz.
APPLICABILITY

940MATR000806E
AIR, FUEL & EXHAUST

940MATR000806E
Mahindra Ltd
Ref : 940-114-010
Air Filter Element - Change System : Air Intake
1. Open the clean Hose clip & separate the hose.
2. Open the Air Cleaner Top Cover Bolts.
3. Remove the Air Filter Element along with grates & clean the bottom bowl.
4. Separate the Top as well as bottom Grates & replace the Air Filter
Element; assemble the grates & put the assembly back in place. Position
The new element properly, taking care of lug projections.
940MATR000806E
Mahindra Ltd
5. Assemble the top cover & tighten the top cover bolts in diagonally opposite
order – Torque 4.5 Nm.
6. Assemble the Clean Hose on the Air Cleaner Outlet-Air Mass Sensor Neck &
tighten the Hose Clip.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-112-020
Fuel Lines - Check System : Fuel
1. Check for Fuel leakage and correctness at all joints at –

• Fuel tank.
• Fuel Filter.
• High pressure pump.
• Common Rail and Injectors.

940MATR000806E
Mahindra Ltd
Ref : 940-112-030
Drain Sediments From Fuel Tank System : Fuel
1. Place a clean tray below the fuel tank. Loosen & remove the fuel tank
drain bolt & drain the sediments.
2. Fit the fuel tank drain bolt & torque tighten to 27± 2.5 Nm with new
washer.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-112-040
Fuel Filter – Drain the water System : Fuel
1. Loosen Water in Fuel Sensor at the bottom of the Fuel Filter.
2. Allow the Water accumulated in the filter to drain out.
3. Tighten the Water in Fuel Sensor properly.
APPLICABILITY
REFER MAINTENANCE SCHEDULE

FREQUENCY OR WHEN THE WATER IN FUEL
INDICATOR IN CLUSTOR GLOWS

940MATR000806E
Mahindra Ltd
Ref : 940-112-050
Fuel Filter – Change System : Fuel
1. Loosen the Fuel Filter Element.
2. Loosen Water in Fuel Sensor at the bottom of the Fuel Filter element.
3. Fit the Water in Fuel Sensor taken out from old Fuel Filter Element on the
New Fuel Filter Element.
4. Fit the New Element fitted with sensor on the filter body, tighten properly.
APPLICABILITY
REFER MAINTENANCE SCHEDULE

FREQUENCY
OR IN CASE OF CHOAKING

940MATR000806E
Mahindra Ltd
Ref : 940-114-060
Exhaust System Check System : Exhaust
1
1
2 2
1
2
1. Check all the Exhaust Joints & Clips for leakage and correct fitting.
2. Check all the Exhaust Mountings for Exhaust Pipe Fouling and correct
fitting.
APPLICABILITY


940MATR000806E
Mahindra Ltd
Ref : 940-112-060
Fuel Tank & Strainer - Cleaning System : Fuel
Remove the Fuel Tank from the vehicle.
1. Take out the ‘Fuel Strainer with main line assembly’ by removing the
fastening bolts.
2. Blow the compressed air gradually with low pressure as per the
direction indicated by the arrow in the illustration above.
Clean the fuel tank. Complete the Fuel Tank Assembly & refit it on the
vehicle
APPLICABILITY
FREQUENCY Every 40,000 Kms.

result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The
reproduction, translation, transmission, in part or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2006
940MATR000806E
Mahindra & Mahindra Ltd
Ref : 940-112-070
Fuel Strainer - Replace System : Fuel
Remove the Fuel Tank from the vehicle.
1. Take out the ‘Fuel Strainer with main line assembly’ by removing the
fastening bolts. Replace the ‘Fuel Strainer with main line assembly’.
Clean the fuel tank. Complete the Fuel Tank Assembly & refit it on the
vehicle.
APPLICABILITY
FREQUENCY Every 80,000 Kms.

940MATR000806E
HVAC

940MATR000806E
Ref : 940-126-030
HVAC Filter - Replacement System : HVAC
Remove the Glove Box.

1. Remove the HVAC Filter Cover by opening the snap clips on both sides.
2. Take out HVAC Filter Element.
3. Put the new Filter Element.
4. Fit the HVAC Filter Cover & lock the snap clips on both sides.
APPLICABILITY
Frequency Refer Maintenance Schedule

940MATR000806E
Ref : 940-126-031
HVAC Filter - Cleaning System : HVAC
Remove the Glove Box.

1. Remove the HVAC Filter Cover by opening the snap clips on both sides.
2. Take out HVAC Filter Element.
3. Clean the Filter Element with air blow ( !! – If compressed air is used,
please ensure the pressure should be low ).
4. Fit the cleaned HVAC Filter & Cover; lock the snap clips on both sides.
APPLICABILITY
Frequency Refer Maintenance Schedule

940MATR000806E
Ref : 940-126-040
HVAC Filter - Cleaning System : HVAC
Remove the Glove Box, remove Blower connection & remove Blower
Assembly.
1. Insert “ Coil Rinse Nozzle ” inside the Climate Box Assembly at the
blower neck.
• Spray “ Coil Rinse ” at least 2 times .
• After Spraying , the Liquid becomes Foam & enters in the Evaporator
coil.
• Assemble the removed Blower Assembly again.
• Wait for 10 minutes.
940MATR000806E
2. Close all the Vents / louvers .
3. Start AC with Blower on 1st speed ,Run the Engine at 1500 RPM for 5
minutes.
• Put AC Off & put Blower on 4th Speed for 5 minutes , Close all the
Vents.
• All the Evaporator Containments & Water ( Liquid ) will drain out
through the Drain Hose & Evaporator becomes clean.
APPLICABILITY

940MATR000806E
Ref : 940-126-050
HVAC – Performance Test System : HVAC
1. These tests have to be performed at ambient temperature ranging from

300 – 400 C.
2. Vehicle must be in shed with bonnet closed and engine speed should be
set at 1500 RPM with AC on.
3. Blower to be set in 3rd speed, ventilation to be set recirculation mode
and temperature control to be set to the maximum cool.
4. In 10 minutes close door test the average grill temperature should be
less than 120 C. (Open Door Test - in 10 minutes open door test the
drop in average grill temperature with respect to ambient
temperature should be 150 C).

940MATR000806E
Mahindra Ltd
MANUAL TRANSMISSION & CLUTCH

940MATR000806E
Ref : 940-115-010
Clutch Fluid Level & Leakage- Check System : Clutch
1. Check for Clutch Fluid Level up ‘Max’ mark on the reservoir

2. Check for Clutch Fluid leakage and correct fitment at all joints –
• Clutch Master Cylinder outlet.
• Clutch Bundy tube to flexible hose joint.
• Flexible hose to Coiled Bundy tube joint.
• Clutch slave Cylinder inlet.
• Clutch slave Cylinder bleed screw.
3. Change Fluid @ 40000kms or 1 Yr. APPLICABILITY
FLUID SPEC. REFER MAINTENANCE CHART
REFER MAINTENANCE
FREQUENCY
SCHEDULE

940MATR000806E
Ref : 940-115-020
Transmission Oil Level & Leak - Check System : Transmission
1. Remove the Filler plug* & check the oil level

(* - vehicle should be parked on leveled surface)
2. Check for Oil leakage / seepage at –

• Transmission Housing Joints.
• Transmission Oil drain plug.
APPLICABILITY
Oil REFER MAINTENANCE Chart

940MATR000806E
Mahindra Ltd
Ref : 940-115-021
Transmission Oil - Change System : Transmission
1. Remove the Filler plug*

2. Put oil collection tray under transmission, Loosen & remove the drain plug.
Allow the oil to drain out completely.
3. 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 with 27.5±2.5 Nm torque.
• Transmission Housing Joints.
• Transmission Oil drain plug. APPLICABILITY
OIL REFER MAINTENANCE CHART


940MATR000806E
Mahindra Ltd
Ref : 940-115-030
Transmission Breather - Clean System : Transmission
• Remove the breather using screw driver from the transmission.
• Clean it externally & blow compressed air from bottom.
• Fit back the clean breather.
APPLICABILITY

940MATR000806E
Mahindra Ltd
STEERING

940MATR000806E
Mahindra Ltd
Ref : 940-120-030
Steering Linkages - Check 940-120-010
System : Steering
1. Check Both joints / bolts on Steering Intermediate Shaft for Tightness* and
correct fitting.
2. Push the Steering Column Release lever down & Check the Steering Tilt
Mechanism for smooth Operation.
APPLICABILITY
* I-SHAFT BOLT TORQUE 25 Nm

940MATR000806E
Mahindra Ltd
Ref : 940-120-020
Steering Ball Joints & Dust Covers - Check
System : Suspension
1. Check Dust boots ( both LH & RH ) for cracks/ leakage/damages. Replace

in case of any damage observed.
2. Check Ball Joints ( both LH & RH )for axial play/boot cut. Replace if
observed.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-120-040
Power Steering Oil Level & Leak - Check System : Steering
1. Take out the Reservoir cap, check the dip stick for oil level.
• Reservoir.
• Power Steering Pump.
• Rack & Pinion – Pipe Ends & Boots.
APPLICABILITY
Oil Texamatic

940MATR000806E
Mahindra Ltd
FRONT AXLE

940MATR000806E
Mahindra Ltd
Ref : 940-116-010
Front Hub Greasing System : Front Axle
Dismantling –
• Jack up the vehicle & remove the wheel.
• Remove the caliper assembly without disconnecting the brake hose.
Caution: Ensure that the brake hoses are not stretched/ damaged. Put
the caliper without straining the brake hose.
1. Remove the hub cover using a screwdriver.

2. Using the MST 571, remove the outer locknut.
3. Take out the lock washer and the inner nut.
4. Pull out the hub along with the bearings.
5. Remove the Oil Seal.

940MATR000806E
Mahindra Ltd
Inspection –
• Inspect the rollers and the inner races of the bearings for Scoring,
pitting/ brinelling or spalling.
• If any damage is noticed – inspect the outer races also.
• To remove & refit the outer races, use MST.
• If the outer race / cup is found to be loose in the housing then it is
advisable to replace the hub. Trying to recondition the hub bore is
not recommended.
• If the bearing seating area or the oil seal seating area in the
spindle is worn then replace the spindle.
Assembly –
• Apply the MAXIMILE LCG3 grease on the bearings.
1. Locate the inner bearing cone in the hub.
2. Press the new oil seal using the MST 574.
Note: The lip of the oil seal should be coated with grease. Also fill
grease in the cavity where the oil seal spring is present.
3. Press the hub assembly on the spindle & fill the grease.
4. Locate the inner cone of the outer bearing.
5. Tighten the inner nut. and back off by 90 degrees .The hub play should
be within 0.010 to 0.030 mm.
Ensure that the hub assembly is being rotated while the inner nut is
being tightened. This is essential to ensure that the roller centralize
themselves and also so that they abut properly.
6. Put the locking washer & tighten the outer nut.
7. Applying Anabond RTV 673 sealant & Press the hub cover using the MST
575.
APPLICABILITY

940MATR000806E
Mahindra Ltd
REAR AXLE

940MATR000806E
Mahindra Ltd
Ref : 940-117-010
Rear Axle Hub Greasing System : Rear Axle
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.

940MATR000806E
Mahindra Ltd
Assembly –
1. Apply the MAXIMILE LCG3 grease on the bearings.
2. Insert the Axle Shaft Assembly.
3. Put the retainer & Rear Brake Assembly and tighten the retainer bolts
on the axle tube flange.
4. Fit the Brake drum and tighten the drum locking screw.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-117-020
Differential Oil Level & Leak - Check System : Rear Axle
1. Remove the Filler plug* & check the oil level (top up if required)

• Differential Housing - Cover Joint.
• Differential Oil drain plug.
APPLICABILITY

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result
of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction,
translation, transmission, in part or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2006 Mahindra & Mahindra
Ltd 940MATR000806E
Ref : 940-117-030
Differential Oil - Change System : Rear Axle
1. Remove the Filler plug* (* - vehicle should be parked on leveled surface).
2. Put oil collection tray under transmission, Loosen & remove the drain plug.
Allow the oil to drain out completely.
3. Assemble & torque tight the drain plug with 47.5 ±6.5 Nm.
4. Fill fresh differential oil as per specified capacity & assemble the filler
plug with 47.5 ±6.5 Nm torque.

• Differential Housing - Cover Joint.
• Differential Oil drain plug. APPLICABILITY
Oil REFER MAINTENANCE Chart
QUANTITY REFER MAINTENANCE Chart

940MATR000806E
Mahindra Ltd
BRAKES

940MATR000806E
Mahindra Ltd
Ref : 940-119-010
Brakes - Check 940-119-020
System : Brakes
Park the vehicle on leveled ground. Jack the vehicle up & remove the wheel
1. Check the disc for wear ( Minimum usable thickness of the disc is 21mm).
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 6.3 mm. 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 upto
the end of the groove ; it should be replaced)
Check for the oil leakage from Calipers.

940MATR000806E
Mahindra Ltd
3. 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.)
4. Check the brake lining for wear/cracks. The minimum usable thickness of
the liner is 3.5 mm.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-119-040
Brake Fluid Level & Leakage- Check System : Brake
1
2
2
2
1. Check for Brake Fluid Level up to ‘Max’ mark on the reservoir

2. Check for Brake Fluid leakage and correct fitment at all joints –
• Brake Master Cylinder outlet.
• Brake Bundy tube to flexible hose joint.
• Flexible hose joints at Front Calipers & LSPV.
• LSPV inlet & outlet.
• Wheel Cylinder inlets & bleed screws.
3. Change Fluid @ 40000kms or 1 yr.
APPLICABILITY
FLUID SPEC. REFER MAINTENANCE 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 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. © 2006 Mahindra & Mahindra
Ltd 940MATR000806E
Ref : 940-114-020
Vacuum Lines - Check 940-114-070
System : Emission / Brakes
1. Check for vacuum leakage and correct fitment of all joints –

• Alternator vacuum pump outlet.
• 3 way tee connector joints.
• Vacuum reservoir taps.
• Brake Booster NRV.
• Vacuum Modulator taps.
• EGR Valve Nipple.
• Air cleaner Clean Hose nipple ( Check for the blockage of the nipple in
case of Black smoke)
AScorpio CRDe ( All New) Maintenance Manual- Ver 0 Jul 06

940MATR000806E
Mahindra Ltd
Ref : 940-119-0
LSPV Setting System : Brakes
Park the vehicle on leveled ground. The vehicle should be in unladen

condition.
1. Remove the ‘e’ clip .
2. Remove the washer.
3. Remove the LSPV spring from the bolt & allow it to hang freely. Insert the
pin on the ‘LSPV setting tool’ into the spring eye.

940MATR000806E
Mahindra Ltd
4. Loosen the nut & slide the bolt into the slot on the bracket to allign it
with the slot on the ‘LSPV setting tool’. Tighten the nut & fix the position
of the bolt once it is alligned in the slot on the ‘LSPV setting Tool’.
Fit back the LSPV spring by stretching it & fit the washer & the ‘e’ clip.
APPLICABILITY

940MATR000806E
Mahindra Ltd
PEDALS & CONTROLS

940MATR000806E
Mahindra Ltd
Ref : 940-119-050
940-119-030
Pedals and Parking Brake - Check 940-115-010
System : Brake
1. Check Brake & Clutch Pedals for free play# & sponginess.
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.
• Check the parking cables ( especially rear ) for correct routing / fouling
APPLICABILITY
# Clutch Pedal Free Play 5-6 mm

# Brake Pedal Free Play 3 mm
* Park Lever Setting 5-6 Notches
940MATR000806E
Mahindra Ltd
SUSPENSION & DRIVE SHAFT

940MATR000806E
Mahindra Ltd
Ref : 940-116-020
Shock Absorber - Check 940-117-020
System : Suspension
1. Check Front Shock Absorbers ( both LH & RH )for leakage, Correct Fitment,
Bush Condition & damages.
2. Check Rear Shock Absorbers ( both LH & RH )for leakage, Correct Fitment ,
Bush Condition & damages.

940MATR000806E
Mahindra Ltd
Ref : 940-116-030
Stabiliser Bar & Link Bush - Check 940-117-030
System : Suspension
Front Stabiliser Bar –
1. Check Front Stabiliser Bar Link Bushes ( both LH & RH ) for wear or
damage. Replace if necessary.
2. Check Front Stabiliser Link Ball Joints ( both LH & RH )for axial play/boot
cut. Replace if observed.

940MATR000806E
Mahindra Ltd
3. Check Front Stabiliser Bar Bushes for wear or damage. Replace if
necessary.
Check & ensure the following Torque -

• Stabiliser Bar Link Mounting nut on LCA : 19±3 Nm
• Stabiliser Bar Link nut on Stabiliser Bar : 70±10 Nm.
Rear Stabiliser Bar –
2. Check Rear Stabiliser Link Ball Joints ( both LH & RH )for axial play/boot
cut. Replace if observed.
3. Check Rear Stabiliser Bar Bushes for wear or damage. Replace if

necessary.

• Stabiliser Bar Link Mounting nut on Chassis : 40±10 Nm.
• Stabiliser Bar Link nut on Stabiliser Bar : 40±10 Nm.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-116-040
Suspension Bushes - Check 940-116-050/060
System : Suspension
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.
• Upper arm side bushes : 120 ± 10 Nm

• Upper arm Ball joint mounting nut : 26 ± 3 Nm

940MATR000806E
Mahindra Ltd
• Lower control arm front mounting : 165 ± 15 Nm
• Lower control arm rear mounting : 120 ± 10 Nm
• Lower control arm ball joint mounting nut : 70 ± 10 Nm
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref : 940-117-021
Propeller Shaft – Check & Grease System : Drive Shaft
1. Inspect the Sliding yoke for Grease & play, fill the grease through the
grease nipple with pressurized gun.
2. Inspect the Universal Joint for Grease & play, fill the grease through the
grease nipple with pressurized gun.
3. Check & torque tight the Companion Flange Nuts at both Transmission as
well as Axle end with – 60.5 ±5.5 Nm.
APPLICABILITY
GREASE REFER MAINTENANCE Chart

940MATR000806E
Mahindra Ltd
ELECTRICALS

940MATR000806E
Mahindra Ltd
Ref : 940-125-010
940-125-050
Instruments, Lights & Accessories - Check 940-128-040
940-129-030
System : Electricals
1. Check all instruments & gauges in instrument cluster for proper operation.
2. Check combination switch for all the functions & operation of respective
applications.
• Head lights & aiming as well as flashing.
• Turn signal & Hazard.
• Wipe & Wash – All Modes.
• Horn operation.

940MATR000806E
Mahindra Ltd
Ref : 940-124-020
Battery - Check System : Electricals
1. Check Battery condition for –

• Check Battery electrolyte level visually with respect to ‘Max’ level
indication; and top up if found less (do not exceed ‘Max’!).
• Check and ensure the Specific Gravity# using Hydrometer.
2. Check the connections at –
• Battery Terminals for correctness & Tightness
• Battery Earth for correctness & Tightness
APPLICABILITY
# Specific Gravity
Amaron 1280
Exide 1240

940MATR000806E
Ref : 940-129-060
Wiper Linkages - Grease System : Wiper
• Remove the Plenum Applique .
• Grease the wiper motor linkages.
APPLICABILITY

940MATR000806E
Mahindra Ltd
Ref :940-125-080
Shock Sensor Activation System : Security Syst.
The default setting is ‘OFF’ from Factory. Position of Shock Sensor

Sensitivity setting screw is kept at minimum.
If desired by the customer, the Shock Sensor can be activated & sensitivity of
the same can be set by adjusting the screw as per the following
procedure………
1. Open the door
2. With the vehicle key in the key cylinder, turn the ignition ‘ON’ and then
‘OFF’.

940MATR000806E
Mahindra Ltd
3. Press and release the valet switch six times.
4. Press & hold the valet switch.
5. Six-siren chirp sound verifies the shock sensor mode ‘ON’ / ‘OFF’ feature.
6. While holding the valet switch, press the remote lock / unlock button; a
single chirp sound verifies the shock sensor mode ‘ON’.
7. Two-siren chirp sound verifies the shock sensor mode ‘OFF’.
8. Release the valet switch
9. Turn the ignition ‘ON’.
10. Remove the floor Console & locate the Shock Sensor Sensitivity Setting
Screw on the Security System Control Unit on left side ( towards the co-
driver seat).
11. Set the sensitivity as per customer requirement / validation. Rotating

the screw in clockwise direction in creased the sensitivity and rotating
in anti-clockwise direction decreases the sensitivity.

940MATR000806E
Mahindra Ltd
Ref : 940-125-090
Instrument Cluster Clock - Setting System :Instruments
1. Initial display of LCD
2. Press the SET knob for 3 secs. The hours digit starts flashing
3. Press the MODE knob to increment the display numbers
4. Press and release the SET knob to toggle between the hour and the
minutes.
940MATR000806E
Mahindra Ltd
5. While the numbers are flashing , Press the MODE knob to increment the
display numbers .
6. If no knob is pressed for 5secs, the current set value is stored and the
display stops flashing.

940MATR000806E
Mahindra Ltd
INTERIORS & MECHANISMS

940MATR000806E
Mahindra Ltd
Ref : 940-132-010
Seats / Seat Belt - Check 940-132-030
System : Seats
1. Check Seat Belts for proper operation ( Lock / unlock & smooth
retraction).
2. Check Seats for Recliner operation & upholstery damage.
3. Check Seats for Slider operation.

940MATR000806E
Mahindra Ltd
Ref : 940-136-020/50
Body Trims - Check 940-135-020
System : Trims
1. Check all Trims for Fit-Finish, Damage / Mismatch –

• All Interior trims
• All Exterior trims.

940MATR000806E
Mahindra Ltd
Ref : 940-134-040
Power Window Mechanism - Check System : Mechanisms
1. Press the Power window switch ( Master switch on the floor console first &
then the individual switch on the door trim for rear doors ) & check
opening of Power Window Mechanism.
2. Lift up the Power window switch ( Master switch on the floor console first
& then the individual switch on the door trim for rear doors ) & check
closing of Power Window Mechanism.

940MATR000806E
Mahindra Ltd
Ref : 940-133-070-A
Bonnet & Release Mechanism - Check System : Mechanisms
1. Pull the Bonnet Release Lever & check Operation of Bonnet Latch &
Mechanism.
2. Adjust the Dampener height to achieve the Bonnet setting.

940MATR000806E
Mahindra Ltd
Ref : 940-133-080
Fuel Lid Mechanism - Check System : Mechanisms
1. Press the Fuel Lid opening switch & check Operation of Fuel lid Mechanism
(unlocking & Opening of fuel lid).
2. Lock the fuel lid & check for proper locking.

940MATR000806E
Mahindra Ltd
EXTERIOR TRIMS

940MATR000806E
Mahindra Ltd
Ref : 940-135-010
Foot Step Fitment System : Accessories
1. Mount the foot-step (not to tighten fully) to the vehicle using 6 nos. M8
mounting set screws.
2-A. Put 2 screw grommets on body panel first & fit both snaps to
mount on front fender trim.
2-B. Mount the end cap with fastners in the 2 holes ( same old mudflap
mounting ).
2-C. Fit one M5 Truss head screw (SF0207014). Fit two M5 CSK screws
from top and nuts from bottom of foot step.
3-A. Mount the Push pin ( to splash shield ).

3-B. Mount two M5 CSK screws from top and nuts from bottom of foot
step
3-C. Mount two Truss head screws and nuts from back (SF 0207014).

940MATR000806E
Mahindra Ltd
Ref : 940-118-010
Tyre Rotation System : Wheels
1. Check & ensure tyre pressure at 2.2 bar / 32psi in all five wheels.
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.
APPLICABILITY

940MATR000806E
Mahindra Ltd

2006 - Maintenance Manual (R0 0806 CRDe) (All New)

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SCORPIO CRDe (All New)

940 113 Cooling System

940 110 Engine

940 112/114 Air, Fuel & Exhaust

940 126 HVAC

940 120 Steering

940 116 Front Axle

940 117 Rear Axle

940 119 Brake

940 119/115 Pedals & Controls

940 116/117 Suspension & Drive Shaft

940 132 Interiors & Mechanisms

940 135 Exterior Trims

940 118 Wheels & Tyres

PURPOSE – The purpose of the Maintenance Manual to guide the technician

The maintenance manual is divided in to 3 sections –

Section 3 deals with the standard operating procedures to be followed while

RECOMMENDED PRACTICE AT THE DEALERSHIP WORKSHOP

• Customer visits the Dealership for a scheduled service

NATURE OF WORK TO BE DONE

940 113 Cooling System

NATURE OF WORK TO BE DONE

Check shock absorber & its bushes (for oil leakages /

NATURE OF WORK TO BE DONE

Check Battery fluid level, specific gravity and conditions

Check clutch operation, parking brake operation, steering

NATURE OF WORK TO BE DONE

940 FINAL INSPECTION.

Check Sound System & Controls , Retractable Aerial, Child

940 General Inspection

940 112/114 Air, Fuel & Exhaust

Lubricate locks, hinges & latch

Check clutch operation, parking brake operation, steering

940 FINAL INSPECTION.

Check Sound System & Controls , Retractable Aerial, Child

940 110 100 Change Engine oil & Oil filter

Check Sound System & Controls , Retractable Aerial, Child

Check & apply grease Door lock striker, Check arm,

Clean the evaporator [Every 40,000 Kms. Or every 9

940 115 Manual Transmission & Clutch

Check Battery fluid level, specific gravity and

Check & apply grease Door lock striker, Check arm,

Check & drain water from Fuel filter [or when

Check condition of rubber bushes in lower link of

Check condition of pivot bushes in top wishbone.

Check clutch operation, parking brake operation, steering

940 FINAL INSPECTION.

940 117 Rear Axle

1. - Check the coolant level in recovery tank with respect to Maximum

COOLANT SPEC. REFER MAINTENANCE CHART

COOLANT SPEC. REFER MAINTENANCE CHART

Scorpio CRDe ( All New) Maintenance Manual- Ver 0 Jul 06

COOLANT SPEC. REFER MAINTENANCE CHART

Scorpio CRDe ( All New) Maintenance Manual- Ver 0 Jul 06

Scorpio CRDe (All New) Maintenance Manual- Ver 0 Jul 06

1. Check the Belt Tension…

2. Adjust the belt tension ….

Scorpio CRDe (All New) Maintenance Manual- Ver 0 Jul 06

BELT SPEC. 7 PK – 1790 - GATES

FREQUENCY REFER MAINTENANCE SCHEDULE

Scorpio CRDe (All New) Maintenance Manual- Ver 0 Jul 06

2. Check hose joints for Oil leakage / seepage at –

Scorpio CRDe ( All New) Maintenance Manual- Ver 0 Jul 06