🏷️ Basic Information

Make:

Mahindra

Model:

XUV500

Product Name:

Manual DE TALLER DE MAHINDRA XUV 500

Internal Code:

MAH-XUV500-TSM-ENG-2011-2016

👋 Introduction

Vehicle Segment:

Compact SUV / Crossover

Competitive Landscape:

Competed against models like the Hyundai Creta, Nissan Terrano, Renault Duster, and sometimes higher variants of compact sedans. Positioned as a feature-rich, value-oriented SUV.

Design Philosophy:

Known for its 'mHawk' engine and sculpted 'Dynamic Quadra-volution' design language. Offered a spacious cabin and a high seating position.

Value Proposition:

Provided a blend of SUV styling, comfort, and features at a competitive price point, making it a popular choice in its segment.

📋 Manual Details

Primary Coverage:

Mechanical, Electrical, Electronics, Bodywork

Total Pages:

2000

Type:

Workshop Manual / Service Manual

Language:

English

Format:

Likely Digital (PDF, as is common for large technical manuals), potentially printable

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, cylinder head, valve train, piston assembly, crankshaft, camshafts, timing system, cooling system, lubrication system, fuel injection system (mechanical aspects), turbocharger system (mechanical aspects).

Engine Electrical And Electronics:

Engine control module (ECM) diagnostics, sensors (crankshaft position, camshaft position, MAF, MAP, O2, throttle position), actuators (injectors, ignition coils, throttle body), ignition system, starting system, charging system, emission control systems (EGR, catalytic converter), diagnostic trouble codes (DTCs).

Transmission Mechanical:

Manual transmission (if applicable), Automatic transmission (if applicable) - internal components, clutch system, drive shafts, differentials, gearbox overhaul, fluid specifications, torque converter (automatic).

Transmission Electronics:

Automatic transmission control unit (TCU) diagnostics, shift solenoids, transmission fluid temperature sensors, gear position sensors, electronic shift control systems.

Chassis And Suspension:

Front suspension (MacPherson strut, control arms, anti-roll bar), rear suspension (Multi-link independent suspension), steering system (hydraulic power steering, electric power steering if applicable), wheel bearings, hub assemblies, alignment specifications.

Brakes And Wheels:

Brake system components (discs, pads, calipers, master cylinder, brake booster), ABS (Anti-lock Braking System) diagnostics, EBD (Electronic Brakeforce Distribution), brake fluid specifications, parking brake system, wheel specifications, tire pressure monitoring system (TPMS).

Bodywork And Chassis:

Body structure, exterior panels (doors, hood, tailgate, fenders), interior trim, glass and seals, corrosion protection, structural repair procedures, welding specifications, body panel replacement, chassis alignment.

Electrical System General:

Wiring diagrams, fuse box locations, relay functions, battery system, lighting system (headlights, taillights, interior lights), horn, power windows, central locking system, mirrors, wipers, washers, interior electronics.

Comfort And Convenience:

Air conditioning (HVAC) system components and service, climate control module, heater core, blower motor, seat adjustment mechanisms, power seats, sunroof operation, keyless entry system, immobilizer system.

Airbags And Restraints:

Airbag control module (ACM), airbag sensors, airbags (front, side, curtain), seatbelt pre-tensioners, SRS (Supplemental Restraint System) diagnostics and service procedures.

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), fluid level checks and top-ups, tire rotations, brake inspections, battery checks, spark plug replacement (if applicable), belt inspections and replacement.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides for various systems (engine, transmission, brakes, electrical), fault code interpretation and resolution.

Repair And Overhaul:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems, including engine rebuild, transmission overhaul, suspension component replacement, brake caliper overhauls, body panel repair and replacement.

Diagnostics:

Wiring diagrams for electrical and electronic systems, connector pinouts, signal tracing, use of diagnostic scan tools, interpretation of sensor data, electronic module testing.

Bodywork Repair:

Procedures for dent removal, panel straightening, welding, seam sealing, rust repair, body component alignment, glass replacement, interior trim installation.

Depth Of Information:

Comprehensive, covering all aspects from routine maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures for electronic systems and structural repair guidelines for bodywork.

Target Audience:

Professional automotive technicians, advanced DIY enthusiasts.

📊 Manual Specifications

Digital Format:

PDF (assumed based on page count and common practice for large manuals), likely with searchable text and hyperlinked sections.

Print Suitability:

High resolution suitable for printing individual sections or the entire manual.

Binding:

N/A (for digital format). If printed, likely coil-bound or perfect-bound for ease of use.

Paper Quality:

N/A (for digital format). If printed, would typically be on durable, good-quality paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Code:

mHawk

Engine Type:

Turbocharged Direct Injection Diesel

Displacement:

2179 cc (2.2 Liters)

Configuration:

Inline 4-cylinder

Horsepower:

140 PS (approx. 138 bhp) at 4000 rpm (for early models, may vary slightly)

Torque:

320 Nm (approx. 236 lb-ft) at 1600-2800 rpm (for early models, may vary slightly)

Fuel Delivery:

Common Rail Direct Injection (CRDi)

Emission Standard:

BS4 (Bharat Stage IV) compliant for most models in India, potentially Euro 4/5 in export markets.

Coolant Type:

Ethylene Glycol based coolant, typically a 50/50 mix with deionized water. Refer to manual for specific M&M approved coolant.

Engine Oil Grade:

API CI-4 Plus or ACEA E7 specification, viscosity grade SAE 15W-40 is common. Consult manual for precise recommendation.

Oil Capacity:

Approximately 5.5 - 6.0 Liters (including oil filter). Refer to manual for exact capacity.

Turbocharger Type:

Variable Geometry Turbocharger (VGT)

🔧 Transmission

Transmission Type:

6-speed Manual Transmission (6MT)

Transmission Type:

6-speed Automatic Transmission (6AT) with torque converter (introduced in later phases).

All Wheel Drive:

Available on select variants (often designated 'W8' or higher), typically with an electronically controlled All-Wheel Drive (AWD) system. Also available in 2WD.

Manual Transmission Fluid:

API GL-4 or GL-5 gear oil, viscosity SAE 75W-90 is common. Refer to manual for specific M&M recommendation.

Automatic Transmission Fluid:

Mercon V or equivalent Automatic Transmission Fluid (ATF). Refer to manual for specific M&M approved fluid.

📐 Dimensions

Length:

Approx. 4585 mm

Width:

Approx. 1890 mm

Height:

Approx. 1785 mm

Wheelbase:

Approx. 2660 mm

Seating Capacity:

7 Seater (2+3+2 configuration)

Boot Space:

Varies with third-row seat usage. Can be around 90-100 liters with third row up, significantly more when folded down. Refer to manual for exact figures.

Gross Vehicle Weight:

Varies by variant, typically around 2350 kg - 2450 kg. Consult manual for specific GVW.

Kerb Weight:

Varies by variant, typically around 1800 kg - 1900 kg. Consult manual for specific kerb weight.

Towing Capacity:

Not typically specified or advertised heavily by Mahindra for this model; refer to manual if available.

🛡️ Safety Features

Global Ncap Rating:

4-star rating for adult occupant protection in Global NCAP crash tests for models equipped with side airbags. Earlier models without side airbags had lower ratings.

ABS:

Standard on most variants, Anti-lock Braking System

Ebd:

Standard on most variants, Electronic Brakeforce Distribution

Esp:

Available on higher variants, Electronic Stability Program (also known as ESP, ESC, or VSC)

Hill Hold Control:

Available on some higher variants

Hill Descent Control:

Available on AWD variants

Airbags:

Up to 6 airbags (driver, co-driver, side airbags, curtain airbags) on higher variants. Base variants may have fewer or no airbags.

Seatbelts:

3-point ELR seatbelts with pre-tensioners and load limiters for front seats, 3-point seatbelts for second row, 2-point seatbelt for middle seat in third row.

Child Seat Anchors:

ISOFIX child seat anchors on second-row outer seats.

💡 Technology Features

Touchscreen System:

Higher variants featured a touchscreen infotainment system with features like Bluetooth connectivity, USB, AUX-in, and navigation. Specific system varies by trim level.

Audio System:

Upgraded audio systems with multiple speakers were available on top-end trims.

Cruise Control:

Available on select higher variants.

Reverse Parking Camera:

Available on higher variants, often paired with parking sensors.

Bluetooth:

Standard on many variants for hands-free calling and audio streaming.

Voice Commands:

Some advanced systems included voice command functionality for infotainment and phone operations.

🔧 Maintenance

Oil And Filter Change:

Typically every 10,000 km or 12 months, whichever comes first. Consult manual for specific interval.

Air Filter Replacement:

Every 20,000 km or as per manual recommendation, depending on operating conditions.

Fuel Filter Replacement:

Every 40,000 km or as per manual recommendation, especially critical for diesel engines.

Coolant Replacement:

Typically every 40,000 km or 2 years. Consult manual for specific coolant type and interval.

Transmission Fluid Change:

Manual: Every 60,000 km or 4 years. Automatic: Every 40,000 km or 3 years, or as indicated by transmission fluid condition. Always refer to the workshop manual.

Brake Fluid Type:

DOT 3 or DOT 4, depending on the system's requirements. Consult manual for precise specification.

Power Steering Fluid:

Hydraulic Mineral Oil or specified ATF for hydraulic systems. For electric power steering, no fluid is typically required for the steering rack itself. Consult manual.

Engine Performance:

Some users reported occasional turbo lag, especially in early models. Check for proper wastegate operation and sensor readings.

Transmission Reliability:

Early automatic transmission variants sometimes experienced issues with smooth shifting or reliability. Check for ATF level and condition, and diagnostic codes related to the TCU.

Suspension And Steering:

Wear on suspension components (bushings, ball joints) and steering rack issues have been reported by some owners due to road conditions. Regular inspections are advised.

Electrical Gremlins:

Minor electrical issues, such as sensor malfunctions or issues with power accessories, can occur. Comprehensive wiring diagrams in the manual are crucial for diagnosis.

Clutch Wear:

In manual transmission models, clutch wear can be dependent on driving style and conditions. Over time, the clutch may require replacement.

Dpf Issues:

If equipped with a Diesel Particulate Filter (DPF) in specific markets, regeneration issues or clogging could occur with frequent short trips. Refer to manual for DPF maintenance procedures.

📚 Vehicle History

Manufacturer Origin:

Mahindra & Mahindra Ltd. is an Indian multinational automotive manufacturing corporation headquartered in Mumbai, India. Known for its utility vehicles and tractors.

First Generation Launch:

The Mahindra XUV500 was first launched in India in September 2011. It was a significant departure for Mahindra, marking its entry into the monocoque SUV segment with a more modern and premium offering.

Facelifts And Updates:

Received several updates and facelifts during its production run. Notable updates include powertrain refinements, interior and exterior styling changes, and the introduction of new features like automatic transmission and updated infotainment systems.

Platform:

Built on a monocoque chassis, a first for Mahindra SUVs, offering better handling and ride comfort compared to body-on-frame SUVs.

Manufacturing Locations:

Primarily manufactured at Mahindra's Nashik facility in India. Exported to various international markets.

Production Period:

The first generation (codename W201) covered the years 2011-2016, after which a significantly updated second generation was launched.

🏆 Awards & Recognition

Automotive Awards:

Received numerous awards upon launch, including 'SUV of the Year' and 'Viewers' Choice SUV of the Year' from various Indian automotive publications and forums.

Safety Award:

Achieved a 4-star safety rating from Global NCAP for adult occupant protection in specific configurations, highlighting its safety advancements.