REPAIR MANUAL

MAN-00145

RELEASED BY –

TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.

Rev1 – SEPTEMBER 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. Page 1
Page 1
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

About the Repair Manual

This Repair Manual is published for the information and guidance of the service technician
of authorized MAHINDRA & MAHINDRA dealers to help them provide efficient and
correct service and maintenance on Mahindra vehicle. It contain information on the
operation and maintenance of the MAHINDRA New BOLERO Zlx/ Slx/ Sle 2WD BS-IV (8
Seater) as well as descriptions of the major units and their functions in relation to the
other components of the System.

To ensure customer satisfaction with Mahindra products, proper service and maintenance by
Mahindra Dealer Technicians is essential. Technician should know and understand the
content of this manual before starting actual work on the vehicle. The copy of this manual
should be kept in a handy place on the shopfloor for quick and easy reference.

This manual includes special notes, important points, service data, precautions that are
needed for the maintenance, adjustments, service, removal and installation of Engine and
other aggregate components.

All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. Dealers will be provided
Technical Service Bulletins or Supplementary Notes in case modifications done in future.

All rights are reserved to make changes at any time without prior notice.

Pictures, photographs used in this manual are illustrations only and may pertain to some
variation than actual in the vehicle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 2
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Index…

• How to use this manual……………………………………………………………………..

• Safety Instructions………………………………………………………………………………
• Vehicle Specification…………………………………………………………….……………
• Vehicle Maintenance……………………….…………………………………….……………
• Engine……………………………………………………………....................……………
• Air Intake System……………………………………………………………………..………………..
• Cooling System………………………………………………………………………….………………..
• Fuel System…….………………………………………………………………………..………………..
• Emission Control System………………………………………………………….…………………
• Clutch……………………………………………….……………...................……………
• Transmission…………………………………………………………………………………………
• Propeller Shaft...………………………………………………………………….. ………….
• Rear Axle……………..………………………………………………………………………………
• Steering System…………………………………………………………………….…………….
• Front Suspension……………………………………………………………………………..…
• Rear Suspension…………………………………………………………………..…………….
• Brakes……………………………………………………………………………………..……………
• Wheels and Tyres…………………………………………………………………..……………
• Chassis…………………………………………………………………………………….……………
• Electricals…………………………………………………………………………………………….
• Air Conditions……………………………………………………………………………………..
• Appendices…………………………………………………………………………………………..

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 3
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

How to use this manual

There is table of contents for the whole manual on the second page of this manual, where
the required section can be easily found. Also, there is content on the first page of each
section, where the main objects in that section are listed. Each section is further divided in to
sub-sections –

• Description section gives an overview of the functioning of the system.

• Specification section provides information on the dimensions and type of system.
• Construction, Operation and Identification section gives details of construction of
System, its operation and serial number identification.
• Care of the system details the maintenance and adjustments, if any, to be carried out on
the system to keep it functioning at its best performance level.
• Trouble shooting section details a generic trouble shooting for major problems.
• In-car repair outlines the procedure to carryout minor repairs/adjustments without
removing the aggregate from the vehicle.
• Dismantling/overhauling section covers the detailed process and procedures to be
followed, while repairing the system. This is generally carried out after removing the
aggregate/system from the vehicle.
• Assembly section covers the detailed process and procedures to be followed, while
repairing the system.
• Tightening torques is the specified torque values for all crucial fasteners in the
Component/ vehicle system.
• Repair & maintenance data provides information on the dimensions of a new part as
well as how much wear can be tolerated on a specific part, respectively.
• Mahindra Special Tools (MST) lists out the special tools should be used for the service
and repair work described in that section.
• Appendices are provided in the last section of this manual. It includes of Abbreviations,
measuring units, Lubrication chart, Greasing points, Do’s & Don’ts, Vehicle preservation
notes and List of MST’s applicable to this model.

The proper performance of service is essential for both the safety of the technician and the
efficient functioning of the system. The service methods in this repair manual are described
in such a manner that the service may be performed safely and accurately. Service varies
with the procedures used, the skills of the technician and the tools & Parts available.
Accordingly, anyone using service procedures, tools or parts which are not specifically
recommended by MAHINDRA & MAHINDRA must first completely satisfies himself that
neither his safety nor the vehicle’s safety will be jeopardized by the service method selected.

In spite of our best efforts to make the manual error-free, a few errors could have inadvertently
crept in. If you identify errors, functional or typographical, please inform your TEKline or
pillay.ajay@mahindra.com. Suggestions to improve the manual and make it more user-friendly are
also welcome.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 4
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Safety Instructions

1. General Precautions –

• Make sure that vehicle is in neutral, parking brakes is ‘ON’ and wheels are blocked before
doing any work or diagnostic procedure on the engine or vehicle.

• When it is necessary to do service work with the engine running, make sure that the parking
brake is set fully and the transmission is in Neutral. Keep hands, hair, clothing, tools, etc. away
from the fan and belts when the engine is running.

• Make sure the work area is ventilated and well lit. When it is necessary to run the engine
indoors, make sure that the exhaust gas is forced to stream outdoors.

• Do not perform service work in areas where combustible materials can come in contact with a
hot exhaust system. When working with toxic or flammable materials, make sure that the
area you work in is well-ventilated.

• Make sure that the Transmission, Transfer Case, Oil/ Exhaust system has cooled down
sufficiently before attempting to remove any components, for your safety.

• Use correct lifting devices. Whenever raising a vehicle for service, be sure to follow the
instructions.

• Keep work area clean, dry and well organized.

• Keep tools and parts off the floor or in a trolley.

• Use safety blocks and stands.

• Wear proper safety equipment as recommended and authorized for the job. Wear proper
hearing protection.

• Wear protective safety glasses/ goggles or face shields. Wear safety shoes.

• Wear correct work clothing, do not wear wrist watches, jewelry, rings, loose or hanging
apparel, such as ties, torn clothing, unzipped jackets that can catch on moving parts.

• New and used engine oil, Brake or Clutch oil, Radiator Coolant, Transmission and Differential
oils can be hazardous. Continuous contact with used engine oil has been found to cause [skin]
diseases. Brief contact with used oil may irritate skin. To minimize your exposure to used
engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves)
when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and
water.

• Recycle or properly dispose the used Coolant, oil and filters.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 5
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Make sure that charged fire extinguishers are available in the workshop.

• Make sure a first Aid Kit is available in workshop.

2. Vehicle Safety –

• Before starting any service work, cover fenders, seats and any other parts that are likely to get
scratched or stained during servicing. Also, be aware that what you wear (e.g. but-tons,
buckles) may cause damage to the vehicle’s finish.

• When servicing an electrical part that does not require use of battery power, disconnect the
negative cable of the battery.

• When removing the battery, be sure to disconnect the negative cable first and then the
positive cable. When reconnecting the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.

• Whenever you use oil seals, gaskets, packing, O-rings, locking washers, split pins, self-locking
nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new
gaskets, packing, etc., be sure to remove any residual material from the mating surfaces.

• Make sure that all components are cleaned properly before reassembling. When use of a
certain type of lubricant, bond or sealant is specified, be sure to use the specified and
recommended type only.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 6
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Safety Symbols
Carefully read, understand and follow the safety symbols/ instructions given in this manual.

• Legend of the Safety Symbols

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

Term/ Symbol Denotation

DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, may result in
property damage.
Indicates important information relevant to
the vehicle, the vehicle's use or to sections
of this manual to which particular attention
must be paid for optimum use of the vehicle.

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

not,” “do not do this,” or “never”.

• Legend of the symbols

Symbol Denotation

set/ place

Locate/ show

Move/ Fit

Turn Clockwise

Turn anti-clockwise

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 7
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Vehicle Specification

Refer following chart for New BOLERO Zlx/ Slx/ Sle vehicle specifications data –

Vehicle data
Basic model MAHINDRA BOLERO DX 2WD 8 SEATER
Type (Brief description) Passenger Vehicle
Category of the vehicle M1
Engine
Model m2DiCR GP
Type Direct Injection.
Bore x stroke, mm 88.9 x 101.6
No. of cylinders 4
Displacement 2523
Compression ratio 18:1
Max. Engine output, kW @ rpm 46.3 kW @ 3200 rpm
Max. Torque, Nm @ rpm 195 Nm @ 1500 - 1800 rpm
Air cleaner type Dry type
Clutch
Type Single Plate Dry Clutch
Gear box
Make & model NGT 520 Opt. NGT 530 Opt. BA10/5
Type / model All Synchromeshed
No. Of gears 5 Forward, 1 Reverse
Gear ratio
1st 3.78 : 1
2nd 2.09 : 1
3rd 1.38 : 1
4th 1.00 : 1
5th 0.79 : 1
6th N.A.
Rev. 3.52 : 1
Drive Axle (Front / Rear / All) For 2WD- Rear, for 4WD- Front & rear
Front axle ratio 3.73 : 1
Rear axle ratio 3.73 : 1
Steering
Type and brief description Manual Steering. - Recirculating ball type with UJ.
Power Steering: Worm and roller type with UJ. Opt.
Rack & Pinion
Steering wheel diameter, mm 406 opt. 380
Ratio For Rigid Axle :-
Manual -20:1 to 23:1;Power Steering - 18.2:1;
For IFS :-
Manual -24:1; Power Steering -18.2:1;
Opt : Rack & Pinion Power Steering -40.1mm/rev
Frame

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 8
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Long member size, mm Rectangular Tubular, 115 X 60 X 4 Opt. 115 X 60 X 3.6

Opt. 115 X 60 X 3.0 Opt. 115 X 60 X 3.2
L - 3880 Opt. 3994, W - 758 Frt & 941 Rr for Bolero,
Bolero DX /DI.
L - 4262.4, W - 758 Frt & 941 Rr for Bolero XL/XLS
Number of cross members For 2680mm WB
For Rigid Axle :- 5 Intermidiate Cross Members
For IFS :- 6 Intermidiate Cross Members & Rear bumper
Opt. 5 Intermidiate Cross Members & Rear bumper bar
For 2794mm WB
7 Intermediate Cross Member & Rear bumper Bar
Suspension
Type and brief description Front: Rigid Opt. IFS
Rear: Rigid
Spring Leaf Spring for Rigid; Front Coil Spring for IFS
Anti-roll bar Front: Torsion type
Rear: Torsion type (only for Bolero XL/XLS)
Shock absorbers Hydraulic Double acting, Telescopic
Brake
Service brake (Brief description) Tandem Master Cylinder With Vacuum Assisted Servo
Auto Slack Adjuster Fitted (Yes / No) Yes
Front (Disc / Drum) Disc
Rear (Disc / Drum) Drum
Total braking area, cm2 199.2/574
Parking brake On the rear wheels.
Secondary brake Unfailed part of service brakes
Wheels and tyres
Wheel rim size 6.0J X 15 opt. 5.5J X 16
Size: 215/75R15; Optional. 185/85 R16
Tyre size designation including ply SIZE 215/75 R15 185/85 R16
rating / load index / speed rating Ply Rating 5 8
Load Index 100 105
Speed Rating S Q
Tyre Type (Radial / Cross / Tube / Type :- Radial, With tube
Tubeless) Optional:- Radial Tubeless
FOR 215/75R15 FOR 185/85R16
Laden Tyre pressure (front & rear),
Front 2.1 2.6
kg/cm2
Rear 2.4 3.5
Electrical system
System voltage, V 12V
Battery rating, Ah 12V, 75 Ah Opt,72Ah Opt. 65 Ah
Wiper motor Link Type
Wiping system (Brief description) Two Wiper arms & blades, 2 Speed & Intermittent Wash
& Wipe Type
Fuel tank
Material CRCA Steel As Per IS 513
Capacity, l 60 liters.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 9
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Dimensions
Wheel base, mm For BOLERO DX / DI, BOLERO :- 2680 Opt. 2794 ;
For BOLERO XL/XLS :- 2794
Overall width, mm 1745
Overall length, mm For BOLERO, BOLERO DX / DI :- 4080 opt 4107 & 4194
opt.4221
For BOLERO XL/XLS :- 4467 opt 4494
Overall height, mm For BOLERO, BOLERO DX / DI :- 1880 Opt. 1910
For BOLERO XL/XLS :- 1977
Front track, mm 1443
Rear track, mm 1346
Min. ground clearance, mm For BOLERO, BOLERO DX / DI: -
180 for IFS & 183 for Rigid.
For BOLERO XL/XLS :- 195

Weights BOLERO , BOLERO DX /DI BOLERO XL/XLS

2WD 4WD
Maximum GVW, kg (for rigid vehicles) 2330 2330 2580
Maximum GCW, kg (for articulated / N.A. N.A. N.A.
combination vehicles)
Maximum FAW, kg 910 910 980
Maximum RAW, kg 1420 1420 1600
Kerb weight with 90% fuel (with spare 1670 1710 1830
wheel , tools, etc.), kg
Maximum gradeability in 1st gear 10.2 deg for 2WD
15 deg for 4WD

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 10
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Vehicle Identification Number (VIN) -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 11
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Vehicle Maintenance

1. Refer following chart for New BOLERO Zlx/ Slx/ Sle vehicle maintenance schedule-

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 12
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

2. Refer following chart for New BOLERO Zlx/ Slx/ Sle vehicle Lubricants recommendations –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the
Page 13
vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than 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.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

ENGINE - m2DiCR (BS-III & BS-IV)

Contents…

• Description……………………………………………………………………………………
• Engine Overall Specification..…………………………………………………….
• Identification………………………………………………………………………………..
• Care of the System……………………………………………………….……………..
• Trouble Shooting……………………………………………….....................
• In Car Repairs…………………………………………………………………….………..
• Dismantling…………………………………………………………………………........
• Inspection…………………………………………………………………………….......
• Assembly………………………………………………………………………………………
• Technical Specification & Wear Data………………………………………..
• Lubricants & Sealants………………………………………………………………….
• Tightening Torques……………………………………………………………………..

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 14
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description -

The 4 Cylinder, 2.5 Litres, 4 Stroke, Turbocharged direct injected diesel engine with a bore and stroke
of 88.9 X 101.6 mm develops maximum Engine output of 55.3 kW @ 3200 RPM and Maximum
Torque of 200 Nm @ 1400 to 2000 RPM.

A turbocharger controls the boost. The compressed air is cooled by the charge intercooler which is
mounted upstream of the turbocharger. The cooled air enters the inlet manifold’s plenum and it
enters the Cast iron cylinder head through the inlet valves having a 45-degree angle.

The piston features re-entrant type combustion chamber and having ferrous ring insert in the Top
ring groove. A 3-ring pack is used. The top ring is asymmetrical barrel face and with CKS coating and
keystone shape. The 2nd ring is tapper faced. The 3rd is Conformable Oil Ring. The piston is having an
offset of 0.8 mm

The forged connecting rod is connected to induction-hardened crankshaft. The small end of the
connecting rod is trapezoidal shaped to reduce the mass as well as to ensure higher loading. The
crankshaft is induction hardened with the filets hardened & ground. The flywheel has a shrunk fit
ring gear and also a ball bearing to act as pilot for the gearbox input shaft. The front end is having a
rubber moulded dampener pulley.

The helical timing gears drive the FIP and the camshaft. The valves are overhead valves.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 15
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specification (Engine) –

Description of Engine:
Type (Compression Ignition / Positive Ignition) Compression Ignition
Working principle: (Four / two stroke),(DI / IDI )
(NA/TC/TCIC/ Any other ) 4 stroke, Turbocharged, DI engine.

Model name and identification m2DiCR 4Cyl 2.5L GN

Type of fuel used Diesel
No.& Layout of cylinders & firing order 4 cylinder, Inline
Swept volume cc 2523 cc
Bore (mm) 88.9
Stroke (mm) 101.6
Compression ratio (specify tolerance) 18.6 : 1 ± 1.0
Max. Net power of engine on bench (kW @ rpm) 55.3 KW ±2% @ 3200 rpm
Maximum net torque on bench (Nm @ rpm) 200 Nm ±2% @ 1400 - 2200 rpm
Combustion System:
Combustion chamber type (Hemispherical/ squish/others) Re-entrant type
Minimum cross section area of ports:
Inlet (cm2) 850
Outlet (cm2) 649
Max. lift of valves
Inlet mm 10.1 mm
Exhaust mm 10.2 mm
Angle of valves / port (w.r.t. top dead centre) 90 deg w.r.t. TDC
Inlet
Opening 9º BTDC
Closing 35º ABDC
Exhaust
Opening 42º BBDC
Closing 10º ATDC
Reference or setting ranges Cold Condition
Valve gap (Hot or Cold as applicable)
Inlet 0.4 mm in cold condition
Exhaust 0.5 mm in cold condition
Engine Speeds:
Idling speed (rpm) (specify the tolerance) 825 ± 75 rpm
Maximum rated speed (Specify the tolerance) 3200 + 100/ - 0 rpm
Minimum rated speed (Specify the tolerance) 1440 ± 50 rpm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 16
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Identification -

The engine serial number is punched on cylinder block on front pad. Refer illustration shown.
Sample of Engine No. : - GJ91A xxxxx (xxxxx Sr. No)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 17
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System -

Following maintenance jobs are defined in this section –

1. Engine Oil Change

2. Engine Oil Level & Leak Check

3. Engine Oil Filter Replacement

4. Tappet Clearance – Inspect and Adjust

5. Accessory Drive Belt Tension Check and Adjust

6. Accessory Drive Belt Replace

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 18
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 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
ENGINE OIL – REFILL SCHEMATIC

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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 19
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• ENGINE OIL – LEVEL & LEAK - INSPECT

Engine Oil – Level & leak Check

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.
• 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.
• Ensure that the engine is not running.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 20
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 21
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• TAPPET CLEARANCE – INSPECT & ADJUST

*Tappet Clearance (In cold Condition) -

 Inlet Valve – 0.40 mm (16 thou)
 Exhaust Valve – 0.50 mm (20 thou)

Steps to adjust Valve Tappet Clearance -

Remove the oil filler cap and hose.

Remove the EGR pipe and the Intake pipe connected

between TC and intake manifold.

Remove the tappet cover mounting nuts along with

the rubber washer.

Ensure that the HVAC heating hoses are kept aside

and avoid from damage.

Remove the tappet cover.

NOTE: Check for oil leak/ seepage traces from the

gasket if any. Ensure to remove oil gasket safely.

Adjust the valve tappet clearance as per the

procedure given below; follow the firing order.

The tappet clearance should be adjusted in cold

condition and values are Inlet – 0.4 mm & Exhaust
0.5 mm.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 22
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Pointer on Cam cover - to

align Damper Pulley
marking/ Crank Position

Adjust the tappet clearance as per the following procedure …

1.Bring no.1 piston at TDC. Ensure no 4 cylinder Rockers at dancing /rocking position.
2.Ensure and match the pointer to Damper pulley marking. Refer illustration.
3.Adjust the tappet clearance of 1st/ 2nd/ 4th /6th valves; serial nos starting from front side of
engine.
4. Turn the engine 360o further in the direction of engine rotation (Bring no.4 piston at TDC.
Ensure 1st cylinder Rockers at dancing / rocking position).
5. Ensure and match the pointer to Damper pulley marking.
6. Adjust the tappet clearance of 3rd /5th / 7th / 8th valves; serial nos starting from front side of
engine.
Refer below schematic for Engine Valve and its serial numbers layout -
Note: The valves layout is (from the front) -
In - Ex -Ex – In - In - Ex – Ex - In

01 – 02–03 –04– 05 – 06– 07– 08

• To rotate the engine it is suggested that the Gear be engaged and one rear wheel lifted and the
wheel turned.
• The other alternative is that the engine be turned only in the direction of rotation by using the
main driving pulley nut.

• If the main drive pulley nut is used to turn the engine then re-torque the main drive pulley
nut. Failure to do so may cause the pulley to come out due to loosening.
• Always do valve tappet clearance setting when engine is cold.
• Ensure the tightening Rocker Screw Nut to 20 ± 2 Nm.
• Ensure metallic sleeve in gasket & gasket position in groove while assembling Rocker
Cover.
• The tappet clearance to be check & adjust at every 20000kms.
• *Tappet Clearance – In cold Condition -
Inlet Valve – 0.40 mm (16 thou)
Exhaust Valve – 0.50 mm (20 thou)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 23
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 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. A
cord or rough edged ribs. A thumping noise may result. In severe cases, the belt can
noise may also be heard when jump off the pulley.
running.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 24
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Refer illustrations shown.

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.

•
•

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 25
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 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

Refer illustration shown.
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)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 26
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 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.
2. 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.

 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)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 27
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• ACCESSORY DRIVE BELT – REPLACE

(AC Compressor Drive Belt- Gates/ Rolunds AVX 13V)

AC Compressor Drive Belt

AC Compressor stay bracket
& nut to adjust belt tension

AC COMPRESSOR DRIVE BELT – REPLACE

Refer illustration shown.

1. Remove Fan, shroud and NVH cover.
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.
 Assembly procedure is reverse to the removal of drive belt.
 Check and adjust Water Pump-Alternator drive belt tension.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at 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)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 28
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• ACCESSORY DRIVE BELT – INSPECT

(Power Steering Drive Belt- Rolunds AVX 10V)

Water Pump -
Alternator Drive Belt

Steering Pump Drive Belt

AC Compressor 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.
2. 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.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at every 10000kms.
 Replace belt first at 45000 kms & then at every 30000 kms.
 Recommended value for Power Steering drive belt is – 210 + 5/175 + 5 Hz (New/Used)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 29
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 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

Refer illustration shown.
1. Remove Fan, shroud and NVH cover.
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.
 Assembly procedure is reverse to the removal of 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.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at every 10000kms.
 Replace belt first at 45000 kms & then at every 30000 kms.
 Recommended value for Power Stg. drive belt is – 210+5/175+5Hz (New/Used)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 30
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting -

Refer to the Service diagnosis chart. Additional tests & diagnostic procedures may be necessary for
specific engine complaints that cannot be isolated using only the diagnostic chart.

Information concerning the additional checks is provided within the following diagnostic.

Cylinder compression pressure Test

The results of the cylinder compression test can be utilized to diagnose several engine malfunctions.

Before carrying out the compression test, ensure that the battery is in good working condition.
Otherwise the indicated pressures may not be valid for diagnostic purpose.

 Remove all the injectors.

 Fit the dummy injector and connect it with the compression gauge.
 Disconnect the FIP’s solenoid.
 Crank the engine.
 Note that the compression value should be 30 bars.
 Repeat the procedure for the other cylinder.
 Refer to the Specification for the value.

Engine cylinder Head Gasket Failure Diagnosis

A leaking engine cylinder head gasket usually results in loss of power, loss of coolant and engine
misfiring, overheating and poor fuel economy.

An engine cylinder head gasket leak can be:

A. Between adjacent cylinders

- Or -
B. Between a cylinder and adjacent water jacket.

Cylinder head gasket failure between cylinders is indicated by

Loss of power and /or engine misfiring.

Cylinder head gasket leaking between a cylinder and coolant passage results in coolant foaming or
overheating and loss of coolant indicate an engine water jackets.

Cylinder to Cylinder Leakage Test:

Check the cylinder compression pressure as already explained. Leakage between cylinders will be
result in drop of compression pressure by nearly 50 to 70% in the affected cylinders.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 31
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Cylinder to Water jacket Leakage Test

• Remove the radiator cap.

• Warm up the engine and allow it to warm up until the engine thermostat opens.
• If large combustion /combustion pressure leak exist, bubbles will be visible in coolant.
• If bubbles are not visible, install a radiator pressure tester and pressurize the cooling circuit. If a
cylinder is leaking combustion pressure into the water jackets then the tester’s needle will
pulsate with every combustion stroke of the cylinder.

Symptom Causes Remedial action

Engine will not start & emit 1. Air intake obstructed  Clean the element or replace the
black smoke element.
 Check for free operation of
Turbocharger.
2. Defective injectors  Calibrate injectors.
3. Lack of compression.  Check compression pressure.- if
low check for valve seat ,rings &
liner wear
4. Cylinder head gasket  Replace the cyl. head gasket.
failure
5. Engine timing- Valve and  Check engine timing.
FIP injection timing.

Noisy engine & black 1. Improper injection  Check & correct the Timing.
smoke. timing.
2. Faulty injectors.  Clean or replace injectors.
3. Loose main bearings  Tighten the main bearings.
4. Broken parts  Inspect and replace the broken
5. Rockers loose or out of parts.
adjustment.  Adjust tappet.

Engine speed falls off. 1. Defective FIP.  Rectify the FIP.

2. FIP solenoid connection  Check & connect properly the 12
improper. V supply to solenoid.
3. Throttle lever or  Check the accelerator cable &
accelerator cable throttle lever.

Engine does not give full 1. Air intake restricted.  Clean filter, replace if required.
power. 2. Clogged fuel filter.  Replace filters.
3. Incorrect tappet  Adjust tappets in cold condition.
clearance.  Check & correct timing.
4. Injection pump timing.  Calibrate injectors
5. Defective injectors.  Plug the leaks, replace hose or clip
6. Air leaks in pressure line if required.
after turbocharger(
Turbo to intercooler,
intercooler & intercooler
to intake manifold)  Replace the hose or tighten
7. Air leak in pipe –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 32
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

manifold to FIP  Locate the kink/block in return

8. Fuel return pipe to tank pipe and rectify.
blocked.  Check the pipe, washer & rectify.
9. Boost pressure
pipe/hose assembly  Check the compression, replace if
damaged. required.
10. Valve leak  Get the Turbocharger repaired at
authorized TEL dealer.
11. Turbocharger damaged.
 Replace gaskets.

12. Gas leaks between

exhaust manifold &  Remove the restriction in exhaust
cylinder head. system.
13. Restricted exhaust  Tighten the TC mounting bolts.
system. Replace gasket if required.
14. Exhaust gas leak
between turbo &  Change the gasket or the hose.
manifold.  Remove the restriction.
15. Fuels supply line kink
creating restriction.  Fit the correct banjos

16. FIP inlet & outlet banjos  Repair or replace the FIP.
interchanged.  Check compression.
17. Defective FIP  Replace piston rings.
18. Compression leak.
19. Jammed piston rings
Irregular idling 1. Leaking HP unions.  Tighten the unions or replace the
High-pressure pipes.
2. Accelerator cable sticky  Replace the accelerator cable.
3. Air entering into fuel  Replace all the banjo washers and
system. check for the cracks in fuel line
particularly from Tank to FIP
 Check all the pipes, for cracks,
4. Idling stop out of aging leaks- replace
adjustment  Adjust the idling stop.
 Repair or replace FIP.
5. Defective FIP

Noisy engine & high smoke 1. Cylinder head gasket  Replace the cylinder head gasket.
( White/ Grey) defective.  Lap the valve seats or regrind.
2. Worn out or damaged
valve seats.  Check the FIP timing.
3. FIP timing  Tighten the injector holder.
4. Leaking injector holder

Black smoke. 1. Air intake restricted.  Check for hoses, clean or replace
element.
2. Incorrect tappet setting.  Adjust tappets.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 33
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

3. Defective injectors  Check injectors.

4. Improper FIP timing  Correct the timing
5. Air leaks.  Check for leaks between
Turbocharger to intercooler,
intercooler & intercooler to inlet
manifold.
6. Defective FIP.  Rectify or replace FIP.
7. Restricted exhaust  Remove restriction or replace
system. parts.
8. Gas leak between  Replace manifold gasket or parts.
exhaust manifold &
cylinder head.  Overhaul engine.
9. Worn out rings, liners &
valves.

Excessive oil consumption 1. Clogged air filter  Clean or replace elements.

element.
2. Restriction in air intake  Locate & remove restriction.
to compressor duct.
3. Restrictions in  Remove the restriction in the
turbocharger oil drain drainpipe.
line.
4. Damaged oil separator  Replace the oil separator.
5. Turbocharger damaged.  Change oil, filter, service the
Turbocharger & use
recommended oils & drain
intervals. Follow the
recommended procedure while
shutting down.
 Repair Turbocharger.
6. Worn out rings, liners,  Overhaul engine.
and valves.
7. External oil leaks  Stop the external oil leakages.
8. Leakages through inlet  Change the manifold gasket or
manifold mounting face replace the manifold.
allowing dust entry.
9. Bend/kink in any of the  Remove the bend or kinks.
oil return pipe’s/vacuum
hoses.
10. Defective vacuum pump.  Replace the vacuum pump.

Blue smoke. 1. Clogged air filter  Clean or replace elements.

element.
2. Restriction in air intake  Locate & remove restriction.
to compressor duct.
3. Air leak between the  Locate the leaks, change hose or
Turbocharger to intake clamp if required.
manifold.
4. Excess oil.  Correct the oil level.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 34
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

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

replace if required.
6. Wear in piston rings &  Check the compression pressure,
liner. replace rings & liners
7. TC oil seal leaks  Check the Turbocharger if
defective get it attended.
White smoke. 1. Improper FIP timing.  Check & correct timing.
2. Defective cylinder head  Replace the cylinder head gasket.
gasket.  Use the correct banjo with new
3. Inlet or outlet banjo not banjo washers.
proper.  Remove the restrictions.
4. Restriction in fuel supply
Starter will not work or only 1. Electrical complaints.  See the electrical section.
cranks slightly 2. Check water level.  If water level reduced drastically
then check for hydrostatic lock.
 Remove the water in the cylinder
3. Hydrostatic lock and find the cause for water
entry.
Starter will not crank the 1. Weak battery.  Check the battery specific gravity.
engine.  Clean & tighten battery
2. Corroded or loose connections.
battery connection  Repair starter.
3. Faulty starter.  Rectify earthing.
4. Improper earthing.  Check connection or replace
5. Defective FIP’s solenoid. solenoid.
6. Faulty FIP timing.  Check the FIP timing.
 Replace FIP
7. Faulty FIP.
Noisy valves 1. Tappets loose.  Set the tappet clearances.
2. Rocker arms touching  Install the correct rocker cover
the rocker cover. gasket. If after that also the
problem persist change the rocker
cover.
3. Thin or diluted oil.  Change oil.
4. Low oil pressure.  Check the oil level.
5. Bent push rods.  Install new push rods.
6. Worn rocker arms.  Replace the rocker arms.
7. Worn valve guides.  Replace the valve guides.
8. Excessive runout of  Grind valve seats and valves.
valves seats
9. Oil thickening  Replace oil & find the reasons of
thickening, rectify.
Oil pressure drop 1. Low oil level.  Check engine oil level.
2. Defective oil pressures  Install new sensor.
sensor.
3. Clogged oil filter.  Replace filter.
4. Clogged oil strainer.  Clean the strainer.
5. Pressure relief valve in  Clean the valve & bore and
oil filter bracket stuck. assemble.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 35
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

6. Oil leaks- internal.  Check the gasket between the

block & front cover or any of the
MOG plugs
7. Worn parts in oil pump.  Replace the worn parts or pump.
 Check oil clearances.
8. Excessive oil clearances  Change oil to correct viscosity.
9. Thin or diluted oil.  Remove the valve, inspect, clean
10. Excessive bearing & refit.
clearance.  Remove sump, inspect the parts &
11. Oil pump relief valve replace.
stuck.  Install new pump.
12. Oil pump suction tube
loose, bent or cracked.  Install new pump
13. Oil pump cover warped
or cracked
Oil leaks 1. Worn oil seals  Replace seals.
2. Misaligned or  Replace gasket.
deteriorated gaskets.
3. Loose fastener, broken  Tighten fastener
or porous metal parts  Repair or replace.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 36
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the system –

The performance of the engine is dependent on ensuring that the following maintenance is carried
out as per the schedule without fail.

Fan belt tension: All drive belts to be checked and adjusted first at 5000, 15000 and then every
10000 kms. AC Compressor and Power steering belt to be replaced at 40,000 kms; and engine main
accessory drive belt to be replaced at 75,000 kms.

Air cleaner: The air cleaner element to be cleaned at every 5,000 Kms. If the red band shows earlier
then the element has to be cleaned. The element should be replaced at every 40,000 Kms or when
the element paper is torn when inspected by a light bulb. For the detailed procedure, refer to the Air
Intake System.

Engine Oil: The oil filter and the oil should be changed first at 5000, 15,000 and then at every 10,000
Kms. The oil should conform to CG4 grade and with a viscosity Index of 15W40. It should be kept in
mind that in the turbocharger engine the oil has to have do an additional load of lubricating and
cooling the Turbocharger shaft If any oil of lower specification is used it can break down under the
high thermal load at the turbine end of the shaft especially during the hot shutdown.

This oil grade also ensures that the oil consumption is within the desire limits. Use Maximile
Premium Grade of oils. (If oil conforming to CF4 grade is used then oil change interval has to be made
5000 Kms. Oil below CG 4 are not acceptable i.e. MIL 2104 C oils are not acceptable)

Cooling system: Ensure that no leakages are present. For details of the coolant and ratio refer the
Cooling System.

Turbocharger: The engine is having an exhaust gas driven turbocharger. The turbocharger shaft
speed varies from about 40,000 when engine is idling to about 1, 70,000 when the engine is having
the full rated RPM.

Thus it is very critical that while shutting down, the engine is allowed to run at idle for at least one
minute. Similarly the engine should be run at idle for 1 minute at starting before accelerating. Refer
Turbocharger in the Intake system for further details.

Tappet setting has to be carried out first at 15000 kms and then at every 20,000 Kms.

 The jobs listed and described in this section can be performed without removing the main
aggregate from the vehicle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 37
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs -

The in car repairs which can be carried out without removing the Engine are:-

• High pressure Pump Removal & Refitment

• Unit Pump Assembly Removal

• Injector Removal

• Turbocharger Removal

• Intake Manifold Removal & Refitment

• Exhaust Manifold Removal & Refitment

• Alternator and Vacuum Pump Removal

• Oil Sump Removal & Refitment

• Rocker Arm/ Shaft Removal & Refitment

• Valve and Cylinder Head Removal & Refitment

• Piston/ Rings and Connecting Rod Removal & Refitment.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 38
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• High Pressure Pump Removal -

Pre removal activities -

• Remove breather cap and hose from Rocker Arm Cover.
• Remove Rocker Arm Cover and gasket. Refer below illustrations for BS-III & BS-IV variant.

• Bring the 1st cylinder in compression.

(To confirm the first cylinder TDC position remove

the 1st cylinder injector, insert the dummy injector
and the dial gauge. Check by the dial if the piston is
in TDC)

Refer sample sketch.

This is a Sample sketch…

Ensure to –

• Remove the HP fuel line connected between

HP Pump and Common Rail assembly.

• Remove the fuel line connected between fuel

filter and HP Pump.

• Remove the wiring socket fitted on HP Pump.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 39
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the Lubrication oil inlet pipe connected

from cylinder block to HP Pump cam box.

Remove the front inspection cover from the timing

cover.

NOTE:
Ensure that ‘O’ ring of the inspection cover is not
damaged, so that it can be reused. Replace it if
found damaged.

Remove the HP Pump shaft lock nut & washer.

Remove the washer with the help of flat screw

driver.

NOTE:
Ensure that the flywheel is locked before attending
HP Pump shaft lock nut removal.

Loosen and remove the three mounting nuts on

HP Pump flange assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 40
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Use MST 091904H9 - Pusher tool;

Fix the tool on the front cover, use inspection

cover mounting holes as reference mounting
points for this tool. Refer illustration shown.

Align the center bolt with Pump shaft. Tight center

bolt of pusher tool to push the HP Pump back.

• While mounting special tool on front cover, ensure that both the mounting bolts are
tightened simultaneously; it will avoid damage to the front cover.
• While removing HP Pump ensure that shaft key is taken away along with pump.
• Avoid damage as well as woodruff key fall-off inside the front cover while removing pump
assembly.
• Replace woodruff key in case found damaged.

High Pressure Fuel Pump (m2DICR) - Schematic

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 41
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Unit Pump Assembly with Cam box Removal –

Pre removal activities –

• Ensure that engine is in ‘OFF’ condition.

• Make sure that Engine components are

cool down before starting work on engine,
to avoid personal injury.

• Disconnect the wiring harness connector

from unit pump.

• Remove Fuel inlet line connected on UPCR

unit pump.

• Remove high pressure fuel line connected

from UPCR to Common Rail assembly.

Remove 02 nos. mounting bolts form unit pump.

• Ensure that both mounting bolts are

removed simultaneously while
dismantling the unit pump assembly.

• After removing 02 nos. mounting bolts,

unit pump assembly can be removed out
from cam box.

Remove the tappet using Pick up tool.

Tappet Pick up tool No. 0305CAB0002ST

• While reassembling of Unit Pump on Cam box –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 42
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Ensure all parts are clean.

• Check unit pump mounting threads before assembly.
• Tightening torque – 20 + 3 Nm & Bolt spec – M8 x 35

Tappet insertion –

• Fit tappet guide pin with washer (1mm thickness)

• Lubricate and put tappet with slot matching to guide pin.
• Check free up & down movement of tappet.

• It is not recommended to dismantle or do any kind of service with Unit Pump Assembly.
• The part will not have any warranty in case found dismantled and / or opened.
Insert the tappet using Pick up tool -

Refer illustration –
Showing the sketch of tool and the edge of tappet where tool can be fixed while picking up it from
bore.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 43
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Ensure camshaft lobe is at lowest lift during unit pump mounting. It will avoid pressure on
unit pump plunger. Refer below illustration.

• Ensure that both mounting bolts are assembled and tighten simultaneously while assembling
the unit pump assembly on cam box. Refer below illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 44
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• High Pressure Pump Cam Box Overhaul –

Pre removal activities –

• Remove HP fuel pump from engine. Refer earlier section SOP of HP Pump removal.
• Remove the Unit Pump assembly from HP fuel pump. Refer earlier section SOP of Unit Pump
Removal.
• Remove Tappet from cam box assembly. Refer special tool usages and illustrations shown in
earlier section.

Refer exploded view of the Cam box disassembly –

• Remove tappet locking pin and washer.
• Remove Cam box housing cover plate and ‘O’ ring.
• Remove Camshaft assembly.

NOTE: Points to be check and confirm before installation/ assembly –

• Ensure all parts are cleaned.
• Replace Cam box gasket installed between HP Pump and the flange assembly.
• Check and ensure no damage to the ‘O’ rings of Unit pump and Cam box cover plate.
• Check and ensure proper fitment of Cam shaft key and key way.

Never open the Unit Pump; It is not recommended to do any service on Unit Pump assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 45
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Injector Removal –

Pre removal activities -

• Remove the wiring harness socket connected to the injector.
• Remove the breather hose and cap; avoid dust entry from oil filler area.
• Remove the HP fuel line between the injector and CR assy.
• Remove the fuel return line connected on the injector.

Remove the injector locking clamp. Use allen key to

remove the locking bolt.

Use MST 0305CAB0001ST

Injector removal Delphi tool.

Put the special tool barrel along with stud and lock
nut over the injector.

Use slot portion over the injector leak-off pipe and

ensure that the injector leak-off pipe should not get
damaged while removing.

Fix the stud with lock nut over the injector.

Rotate the lock nut in clockwise direction so that

and pull out the injector.

Align and fix stud lower portion inner threads to the

to the injector head outer threads.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 46
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Turbocharger Removal -

Refer below schematic Exploded view of Turbocharger assembly Removal -

Removal of the Turbocharger Assembly -

Pre-removal activities –

• Allow engine, TC to cool before starting

the job.
• Apply WD 40 rust free solution on rusty,
jam mounting nuts of the Turbocharger
and exhaust pipe fittings.
• Replace fasteners while assembly.

Remove the air intake hose, intake pipe, EGR

valve and EGR pipe connected to exhaust,
turbocharger and Intake system.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 47
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the TC oil feed pipe banjo connected on

TC housing.

Remove the oil return pipe mounting bolts from

TC housing.

Remove the TC to exhaust pipe mounting nuts.

• It is recommended to apply rust cleaning spray (WD 40) on the TC and Exhaust manifold
mounting nuts before attempting to removal job; or else the nut or/ and stud can break,
damage/ will come off.
• Do not use sealant while assembling TC oil outlet pipe.
• Remove the old gasket part, crumb and clean the mating faces of TC and Oil return Pipe.
• Use new fasteners and gasket whenever oil outlet pipe is being replaced.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 48
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Intake Manifold Assembly Removal –

NOTE:
• Following are the steps to remove Intake Manifold alone from the vehicle.
• If the Cylinder head is getting removed, in that case we recommend to remove cylinder head
along with intake manifold, exhaust manifold and then disassemble the components.
Remove the Intake pipe fitted over the rocker cover
assembly.

Remove breather hose.

Remove the High pressure fuel pipe from HP Pump to

Common Rail and Common Rail to Injectors; to avoid
damages.

Remove wiring harness socket from CR assy; then

remove Common Rail assembly by removing its 02
nos. mounting bolts.

Remove intake manifold mounting bolts.

Remove the intake manifold assembly.

Ensure that before assembly, the remaining part of

manifold gasket is removed and cleaned from the
mating faces on Manifold and cylinder head.

• Always replace with new gasket.

• Check for air leakages if any after completion of
the assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 49
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Exhaust Manifold Assembly Removal –

• If the Cylinder head is also getting removed, in that case we recommend removing cylinder
head along with intake manifold & exhaust manifold and then disassemble it.
Refer below schematic for Exhaust Manifold disassembly -

Remove the Intake pipe assembly.

Remove EGR valve assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 50
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove EGR pipe fitted on the exhaust manifold

assembly.

NOTE: In case it is BS-IV engine –

• Drain the coolant from the engine.

• Remove the coolant hoses on EGR cooler.
• Remove the EGR cooler assembly.

Remove TC assembly before attempting to remove

Exhaust manifold.

Refer TC assembly removal section.

Remove the dip stick and dipstick guide tube

mounting bracket fitted on cylinder head.

Remove exhaust manifold mounting nuts.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 51
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Use flat screw driver in case exhaust manifold found

sticky to cylinder head.

Remove the gaskets.

• Always replace with new gaskets.

• Torque tightens all the mounting bolts/ nuts as per recommended sequence and torque values.
• Check for exhaust gas leakages if any after completion of the assembly.
• In case mounting nuts found jam, rusty apply ‘WD 40’ rust cleaner on the nuts, bolts before
attempt to remove.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 52
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Alternator and Vacuum Pump Assembly Removal –

NOTE:
• Remove the battery terminals before attempt to removal of any Electrical equipment.
• Alternator & Vacuum pumps to be removed together during removal of any one
component.
Refer schematic for Alternator & Vacuum Pump assembly –
Alternator Brace Spacer

Engine Fan can be removed before attempting to

remove alternator assembly to get better access.

Loosen the fan mounting bolts and remove Fan.

NOTE:
Ensure not to damage to the fan blades.

Remove Oil supply and drain hoses on the vacuum

pump assembly fitted behind alternator.

Remove vacuum hose from vacuum pump.

Remove wiring socket connected on alternator

assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 53
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Loosen alternator brace lock nut to loosen the drive

belt.

Remove the accessory drive belt.

Loosen alternator bottom mounting bolt.

Loosen alternator up side mounting bolt.

Hold and support alternator assembly by hand.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 54
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the Alternator and vacuum pump assembly.

• Ensure proper fitment of Vacuum & Oil inlet, outlet hoses on Alternator & Vacuum Pump.
• Ensure for tightens of all hose clamps and no leakages after assembled.

Refer schematic for lubricating Oil hoses fitment on Alternator & Vacuum Pump -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 55
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Oil Sump Removal and Refitting –

Pre removal activities –

• Lift the vehicle on certified post.
• Remove the oil filler cap before removing drain plug, to ensure free oil flow.
• Remove the oil sump drain plug and drain the complete engine oil.
• Engine should be hot while draining the oil.

Remove the oil sump mounting bolts.

NOTE:
Follow the bolts removal-sequence; it is reverse
to the mounting bolt tightening order.

Inspection – Refer illustration below.

• Check oil sump for cracks, if any.
• Check oil sump mating face for damage and deformation, if any.

Pre installation –
• Remove/ scrub the gasket part from oil sump and cylinder block mating surfaces.
• Degrease the gasket coated surface and the cylinder block mating surface.
• Tighten the oil sump mounting bolts in sequence.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 56
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Apply the ‘SILASTIC 1080 RTV’ Silicone Sealant at four

joints/ locations on cylinder block –

Refer illustrations for joints on cylinder block.

1. Cylinder block and Front cover mating

surface joint and

2. Cylinder block and Rear oil seal retainer

mating surface joint.

Follow the torque tighten sequence while fitting oil

sump mounting bolts.

• Put new washer and tighten the drain plug to 25 +/- 3 Nm torque.
• Refill the recommended brand and specification of engine oil.
• Check and insist for correct oil level after refilling.
• Wait for 15 min after fitting oil sump.
• Start the engine and check for oil leakage, if any.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 57
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Rocker Arm Shaft and Rocker Arm Removal –

Remove the Intake pipe fitted over the rocker

cover assembly.

Remove breather hose.

Remove the tappet cover mounting nuts along

with the rubber washer.

Remove the tappet cover.

NOTE:
Check for any oil leak/ seepage traces from the
gasket if any. Ensure to remove oil gasket safely.

Loosen all the valve-tappet adjusting screws and

turn adjusting screw back all the way to allow all
rocker arms to move freely.

• Loosen the rocker arm shaft bracket bolts in

numerical order a little at a time.
• Failure to do so will adversely affect the rocker
arm shaft.
• Ensure to do this before removing rocker arm
shaft bracket bolts.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 58
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Sample illustration of Rocker Arm Shaft Assembly..

• Loosen and remove the nuts on the valve lever shaft brackets.
• Loosen and remove the locating screw and washer from the oiler bracket.

Remove rocker arm shaft with rocker arm and

rocker arm spring.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 59
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Inspection:
Insert a round wire brush through the bore of the rocker arm shaft and clean out the drilled oil holes.
Clean the oil holes in the rocker arm shaft brackets and the oil holes and grooves in the bores of the
rocker arm.

Examine the rocker arm bearing areas around the diameter of the shaft and if scores and abrasion
marks are found along the length of the shaft, replace the shaft. Use a micrometer to measure the
rocker arm fitting portion outside diameter. If the measured value is less than the specified limit, the
rocker arm shaft must be replaced.

Rocker Arm Shaft and Rocker Arm Clearance

1. Use either a vernier calliper or a dial indicator to measure the rocker arm inside diameter.
2. Measure the rocker arm shaft outside diameter. If the measured value exceeds the specified
limit, replace either the rocker arm or the rocker arm shaft.
3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to
clean the rocker arm oil port.

Rocker Arm Check

• Inspect the rocker arm valve stem contact surfaces for step wear and scoring.
• If the contact surfaces have light step wear or scoring, they may be honed with an oil stone.
• If the step wear or scoring is severe, the rocker arm must be replaced.
Bracket
• Inspect the threads in the tapped hole in the top of the rocker arm shaft brackets and if
necessary clean with a proper size tap. Replace the bracket if either side is worn or scored.
• If the tip of adjusting screw is badly worn, replace it.

Check the shaft for alignment –

1. Using “V” blocks and dial gauge check runout. If runout exceeds its limit, replace rocker arm
shaft.
2. Roll it across a smooth level surface, if the shaft will not roll freely, or if it rolls with a bumping
motion, the shaft is out of alignment and must be replaced.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 60
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Cylinder Head and Valves Removal –

Pre-removal Activities –

• Park the vehicle on certified post.

• Use fender covers to avoid paint damage.
• Drain the engine coolant from Radiator as well as engine block.
• Remove wiring harness sockets as well as coolant hoses from the engine.

Remove the intake pipe mountings fitted over the

rocker cover.

Remove the intake pipe hoses at TC end and intake

manifold end.

Remove the breather hose, cap and rocker cover.

Ensure that the rocker cover gasket is removed

safely.

Remove the EGR valve assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 61
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the EGR pipe assembly.

Remove the coolant temperature sensor wiring

socket.
Remove the Fan assembly.
Remove the coolant hoses connected on
Thermostat and water pump.

Ensure that coolant is drained from radiator as

well as through engine block drain plug.

Remove the oil intake pipe banjo from TC housing.

Remove the two mounting bolts on oil outlet pipe

fitted below the TC housing.

Endure that gasket is removed completely. Do not

reuse the gasket. Do not apply sealant while
assembly, it may block the oil supply can cause TC
failure.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 62
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the exhaust front pipe from the TC end.

Remove the TC assembly from engine.

Remove high-pressure pipes connected between

injectors and Common Rail.

Remove Common Rail assembly by removing its 02

nos. mounting bolts.

Remove all the injector assemblies.

Refer Injector removal process given in earlier

section.

NOTE:
Use Injector Removal tool –
MST 0305CAB0001ST
(Injector removal Delphi tool)

Ensure to put a plastic cap/ plugs over the injector threads and tip to avoid dirt entry and damages.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 63
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the coolant hose connected from water

pump to thermostat housing.

Use plier to remove the hose clips.

Remove the Thermostat assembly.

Remove the coolant pressure switch from cylinder

head.

Remove the rocker arm shaft and rocker arms

assembly.

Refer rocker arm shaft assembly removal

procedure in this section.

Remove all the push rods from cylinder head

assembly.

The components attached to the cylinder head like

Intake manifold, Exhaust manifold can be
separated before or after cylinder head removed
from engine/ vehicle compartment.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 64
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the cylinder head mounting bolts.

• Ensure that while removing the bolts loosening

are the reverse of the tightening sequence.
• Use MST 127 spanner for removal & refitting
of Cyl bolts No. 2, 7 & 9 reference to above
layout.

Carefully remove the cylinder head off the block.

Remove & discard the cylinder head gasket.

Refer above schematic for cylinder bolts tightening sequence.

Remove the exhaust manifold assembly from cylinder

head.

Remove the intake manifold assembly from cylinder

head.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 65
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

With the valve spring compressor, compress the valve

springs on those valves which are in the closed
position.

Remove the exhaust valve spring retainer,

Remove the exhaust valve spring. Lift out all exhaust

valves and tag or place them in a rack to indicate the
location from where each was removed from the
cylinder block.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 66
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

If the valve sticks in the guide and cannot be easily

lifted out, pull the valve upward as far as possible and
remove the spring.

Lower the valve and remove any carbon deposits

from the valve stem. This will allow removing the
valve.

Refer below schematic for cylinder head and its components disassembly -

Cylinder Head and Valve sub-components Inspection & Repair –

Make the necessary repairs, part replacements if excessive wear or damage is found during
inspection.

CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of
the cylinder head lower face.
2. The cylinder head lower surface warpage is more than the limit, it should be replaced.

Manifold Fitting Face Warpage

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 67
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the measured values are greater than the
specified limit but less than the maximum grinding allowance.
If the measured values exceed the maximum grinding allowance, the cylinder head must be
replaced.

Exhaust Manifold Warpage

Use a straight edge and a feeler gauge to measure the manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the manifold must be replaced.

Valve Stem and Valve Guide Clearance

1. With the valve stem inserted in the valve guide, set the dial indicator needle to "0".
2. Move the valve head from side to side.
3. Read the dial indicator. Note the highest dial indication.
4. If the measured values exceed the specified limit, the valve and the valve guide must be
replaced as a set.

Valve Guide Replacement

Valve Guide Removal

Use a hammer and the valve guide replacer to drive out the valve guide from the cylinder head
lower face.

Valve Guide Installation

1. Apply engine oil to the valve guide outer circumference.
2. Attach the valve guide installer to the valve guide.
3. Use a hammer to drive the valve guide into position from the cylinder head upper face.
4. Measure the height of the valve guide upper end from the upper face of the cylinder head.

If the valve guide has been removed, both the valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter
• Measure the valve stem diameter at three points.
• If the measured value is less than the specified limit, the valve and the valve guide must be
replaced as a set.

Valve Thickness
• Measure the valve thickness.
• If the measured value is less than the specified limit, the valve and the valve guide must be
replaced as a set.

Valve Depression
1. Install the valve to the cylinder head.
2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from
the cylinder head lower surface.
If the measured value exceeds the specified limit, the valve seat insert must be replaced.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 68
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Valve Contact Width

1. Check the valve contact faces for roughness and unevenness. Make smooth the valve
contact surfaces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit, the valve seat insert must be replaced.

Valve Seat Insert Replacement

Valve Seat Insert Removal

1. Allow the valve seat insert to cool for a few minutes. This will invite contraction and make
removal of the valve seat insert easier.
2. Use a screwdriver to pry the valve seat insert free. Take care not to damage the cylinder
head.
3. Carefully remove carbon and other foreign material from the cylinder head insert bore.

Valve Seat Insert Installation

1. Carefully place the attachment (having a smaller outside diameter than the valve seat insert)
on the valve seat insert.
NOTE:
The smooth side of the attachment must contact the valve seat insert.
2. Use a bench press to gradually apply pressure to the attachment and press the valve seat
insert into place.
NOTE:
Do not apply an excessive amount of pressure with the bench press. Damage to the valve seat
insert will result.

Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15°, 45°, and 75° blades) to minimize scratches and other rough areas.
This will bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut
away unblemished areas of the valve seat surface.
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the valve guide.
3. Apply abrasive compound to the valve seat insert surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact with the entire circumference of the
valve.

Valve Spring Free Height

Use a vernier caliper to measure the valve spring free height.
If the measured value is less than the specified limit, the valve spring must be replaced.
Valve Spring Squareness
Use a surface plate and a square to measure the valve spring squareness.
If the measured value exceeds the specified limit, the valve spring must be replaced.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 69
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Valve Spring Tension

Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve spring must be replaced.

The cylinder head gasket is of the Multi Layer Steel Type gasket. Though it can be assembled either
way it is recommended that for optimum performance the Top, which is identified by the lettering,
is facing upward. (The cylinder Head gasket cannot be reused – even if it appears to be good.)

Do not use any sealant/lubricant like shellac or oil on either block or head or gasket face.

The cylinder head bolts are to be tightened with slight trace of clean engine oil. (2-3 drops only). Do
not put excess quantity of oil.

10 3 6 8

12 1 13

15
16
7 2 9

14 5 4 11

The cylinder head mounting bolts tightening sequence is as shown in above layout.
Use MST 127 spanner for removal & refitting of Cyl bolts No. 2, 7 & 9 reference to above layout.

The tightening torque’s is 90 Nm then followed by 60-degree angular torque. Again torque by 60
degree. The angular torque in 2 stages ensures that the tightening/clamping loads of all the bolts are
very close to each other.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 70
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
 Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Working principle, of the subsystems of the Engine -

Oil circulation: An external gear type pump sucks the oil through the strainer. The oil pump is driven
by the gear, which is mounted, on the crankshaft. The oil pump delivers pressurized oil to the supply
bore in the block.
Rocker shaft

Idler gear
To alternator
1
vacuum pump

Main bearing

2
Oil jet
Cam bearing

3
Main Oil gallery

Main PRV
4
UPCR - HP
Fuel Pump
Oil filter
bypass Oil
filter
5

Safety
Valve

Oil filter Supply to

Pump
bracket Turbocharger

Strainer

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 71
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

The filtered oil goes through the centre of the oil filter and is connected to the main oil gallery.

The main oil gallery runs to the front of the block where it is delivered to the timing cover. From
therein it takes a small loop in the timing cover and again comes to the front of the block, goes to
another oil gallery.

Oil from the main oil gallery goes to the crankshaft main journal and camshaft, while from the rear
end it is supplied to the alternator’s vacuum pump. The oil supply for the turbocharger is from the oil
filter bracket.

The oil routed from the main oil gallery lubricates the timing gears and the idler gear bush. Part of
this oil gets sprayed from idler shaft hole. The camshaft gear and the thrust plate are lubricated by
engine oil routed from the first camshaft bushing through the camshaft hole.

The oil from the First camshaft bush goes to the top of the cylinder and enters an oil gallery, which
extend up to 110 mm from the front. Oil from this gallery comes to the base of the first rocker shaft-
mounting bracket. The oil then enters the rocker shaft. Oil enters the rocker bushing at through two
holes facing the bottom half. At the same time it sprays from the oil hole at the side of the rocker to
lubricate the valve stem and the surfaces over which the valve cap slides. The oil then returns to the
sump through the push rod holes in the cylinder head.

There are two pressure relief valves provided, the primary one is provided in the pump. The second
one is at the oil filter bracket. It senses the oil pressure going to the filter and at the other end it
senses the oil pressure after the filter. The advantage of this valve is that if there is a drop in oil
pressure downstream of the filter then it compensates by allowing more oil to go into the oil cooler
and filter assembly. This compensation ensures that even if the internal leaks are present they are
counterbalanced.

The UPCR HP fuel pump is also provided with lubrication through engine oil. A separate pipe is
connected from the oil gallery/ cylinder block to the HP Fuel pump cam box assembly by means of
banjo bolts.

Refer below chart for lubrication system specification -

Lubrication system
1. Description of system Force Feed lubrication
2. Lubrication oil capacity lit 7 litres
3. Position of lubricant reservoir Below crankcase
4. Lubricating oil grade Maximile 10K:API CF4/CG4 / SAE 15 W 40
5. Feed system (pump, injection in to intake mixing
with fuel etc.,) Through oil pump

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 72
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Dismantling & overhauling of the Engine.

Comprise of 5 steps:

• Removal of the engine

• Engine Dismantling.

• Engine Inspection

• Engine Assembly

• Engine Testing

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 73
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Engine Removal from vehicle –

Engine Assembly Removal from Vehicle

 Make sure that jacks and safety stands are placed properly; hoist brackets are attached to
the correct position on the engine.
 Make sure that vehicle will not roll off stands and fall while working under it.
 Make sure that engine is cold before starting removal to avoid burning injury.

 Use fender covers to avoid paint surface damage.

 Hold & unplug wiring connectors carefully to avoid damage.
 Mark all wiring and hoses to avoid misconnections.
 Cover all unplugged connectors and hose to avoid interfere with other parts.
 Drain all fluids/ oil before starting engine removal activity.
 Drained fluids are to be stored safely/ discarded properly in case not reused.

ENGINE REMOVAL STEPS –

To prepare for engine overhaul, it is necessary to remove the engine from the vehicle. The
procedure for the removal of the engine is as follows -
1. Park the vehicle properly on lift arm.
2. Open and remove the bonnet/ hood assembly.
3. Disconnect the battery terminals & remove the battery.
4. Remove engine cooling fan by loosening rear lock nut and remove shroud assembly.
5. Put the tray below radiator and drain the coolant from radiator by opening drain cock, as
well as drain plug on block. Recover the coolant - if it is clean, it may reused for top up.
6. Remove the WH connectors on: Oil pressure switch, Water temp. Sensor, Starter motor.
7. Remove air filter hose connections and remove the filter assembly.
8. Remove hose from Turbocharger and intake manifold.
9. Remove the exhaust pipe from the Turbocharger outlet elbow.
10. Remove the oil filter using the MST 163 or use filter removal wrench available in market.
11. Drain the oil from the engine oil sump.
12. Remove the starter motor connections and remove the assembly.
13. Remove the fuel lines from filter; High Pressure fuel Pump and injectors return line.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 74
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

14. Remove hoses connected on the water pump as well as from radiator.
15. Remove both side hood stay rods.
16. Remove Air intake pipe and hoses to avoid damages while removing the engine.
17. Remove Radiator assembly.
18. Remove all the vacuum hose connections; to avoid damage while engine removal.
19. Remove steering intermediate shaft assembly.
20. Remove the propeller shaft assembly.
21. Remove bell housing mounting bolts on engine rear side.
22. Put firm support below the TM assembly and remove the cross member below TM assembly,
detach TM assembly from engine and take it out safely.
23. Attach the engine lifting bracket (front and rear lifting hooks) to a chain hoist/ or wire ropes.
24. Remove the engine front LH & RH side insulators mounting bolts; slowly lift the engine
upward and remove both insulators.
25. Check all around the engine and compartment for any other parts required to be removed/
disconnected and remove or disconnect necessary parts, connections.
26. Support the engine with lifting device. Pull the engine forward or roll the vehicle backward,
until the clutch clears the flywheel housing. Lift and pull out the engine from compartment.

 Make sure that engine parts or/ and body parts are not getting damaged while taking engine
out from vehicle.

ENGINE INSTALLATION –

Engine installation is in the reverse order of removal. Refit the mounts to the assembled engine
before locating it in engine compartment. Perform following checks and adjustments-

 Refill the engine oil, check and correct/ top up oil level if required.
 Refill the coolant in radiator & reservoir, check & correct fluid level as per procedure.
 Refill the TM with oil, check & correct the level.
 Refill the clutch fluid, Bleed the clutch system.
 Clean the battery posts and terminals, apply jelly/ corrosion prevent before assemble it.
 Inspect for fuel leakage after installation of fuel lines. Turn ignition switch on (do not crank
engine) so that the fuel pump will operate for 2-3 seconds and the fuel line can be pressurizes;
repeat this for two to three times and check and arrest fuel leakages.
 Attach the diagnostic tool to coupler and check for any fault code; attend the fault, correct the
connections and erase the code. If still fault code persists, follow diagnostic manual procedures
to clear the code.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 75
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Engine Disassembly -

Engine dismantling is carried out in a sequence which is outlined in the following manner. In the
sequence it is assumed that the engine is out of the vehicle. Some of the operations of the
procedures are also applicable separately with the engine in the vehicle, provided that whenever
necessary the part of the engine to be dismantled is first made accessible by removal of engine
accessories or other parts.

During the disassembly operations the engine should be mounted in a suitable engine repair stand. If
an engine repair stand is not available, disassembly operations should be performed in a careful
manner to prevent accident and damage to engine parts.

• Dismantling -

Use of Engine holding bracket and stand for safety -

Remove the engine from vehicle, keep it safely in

hanged situation and fix the bracket to fit it on engine
stand.

Refer sample sketch…

After fixing the engine with bracket mount it on the

engine stand.

Refer sample sketch…

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 76
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the alternator assembly

Remove the rocker cover.

Remove the leak off pipe from all the injectors

Remove the High-pressure pipes connected between

the injectors and CR assy. And CR assy to HP fuel
pump.

Remove the CR assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 77
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Loosen the alternator brace nuts.

Remove the accessory drive belt.

While assembly takes care that main drive pulley is assembled correctly. It should be noticed that
the main drive pulley can be assembled in either direction; however the front end is identified by
holes drilled for balancing (these are not thorough holes). If assembled wrongly it will cause
misalignment by 5 to 6 mm.

Remove the hose connected from Water pump to

thermostat.

Remove the thermostat assembly

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 78
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Refer schematic below for the thermostat disassembly -

Remove the water pump assembly

Remove injectors.

Use MST 0305CAB0001ST

Injector removal Delphi tool.

Refer SOP prescribed in earlier section.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 79
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the inspection cover on the front cover.

Ensure that the “O” rings on the front cover is kept securely so that it can be reused if not damaged
while reassembly.

Remove the HP Pump shaft locking bolt and washer.

Using the pusher tool remove the HP fuel pump.

Refer SOP prescribed earlier in this section.

Remove the Common rail assembly.

Remove inlet manifold assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 80
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the rocker shaft assembly

Remove the push road from cylinder head assembly.

Loosen and remove the cylinder head mounting

bolts.

NOTE:
Follow bolt removal sequence while loosening the
cylinder head mounting bolts.

Remove the cylinder head along with the exhaust

manifold.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 81
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the damper pulley by removing pulley

mounting bolt.

Use the flywheel lock tool while removing damper

pulley bolt.

Remove the flywheel assembly.

Use the flywheel lock tool.

Refer below schematic for Flywheel disassembly -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 82
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Rotate the engine with the help of rotating handle

given on stand.

Remove oil sump by removing mounting bolts.

Follow the bolt removing sequence.

Remove oil pump mounting bolt.

Remove oil pump and strainer assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 83
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the ladder mounting bolts and ladders from

the crank case.

Loosen and remove Rear Oil Seal retainer plate

mounting bolts.

Follow the bolt removal sequence.

Remove the rear oil retainer plate and seal.

Rotate the engine with the help of rotating handle

given on stand.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 84
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the circlip on idler shaft pulley.

Remove idler gear.

Use flat screw driver, push gear from back side and
remove the gear easily.

Remove the crank shaft gear.

Use flat screw driver, push gear from back side and
remove the gear easily.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 85
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Loosen the camshaft thrust plate mounting bolts.

Remove the camshaft gear by removing thrust plate

mounting bolts.

Ensure that the tappets are hold by magnetic stick

inserted from cylinder head side.

Rotate the engine with the help of rotating handle

given on stand.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 86
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Check proper marking/ numbering of crank shaft

main bearing caps.

Check proper marking/ numbering of crank shaft

main bearing caps.

If the markings are not readable, new markings/

numbers can be punched; first should be started
from engine front.

Remove connecting rod big end cap mounting bolts.

Check and ensure big end cap position while

removing it.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 87
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Use mallet/ wooden pallet to hit on con rod end to

remove piston out.

Remove the piston assembly from down word,

cylinder head side. Hold and avoid piston dropping
while removal.

Rotate the crankshaft and remove all the connecting

rod big end cap mounting bolts and remove piston
assemblies one by one.

NOTE: Follow the procedure suggested for first

piston removal mentioned above.

Remove crank shaft main bearing cap mounting

bolts.

Remove the crank shaft main bearing no. 1;

No. 1 counts from the engine front side.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 88
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the main bearing caps along with bearing

shell halves.

Remove the lower thrust washers on both the sides.

Remove the lower thrust washers on both the sides.

Removal of the lower outer side thrust washer.

The grooved sides face outward.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 89
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the lower inner side thrust washer.

• The grooved sides face outward.

• Thrust washer thickness is fixed and must not be
changed by grinding or shimming.

Remove the upper outer side thrust washer.

Use flat screw driver to push the bottom side thrust

washer from one end and remove it from other end.

Lift the crank shaft carefully and remove from the

engine.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 90
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the crankshaft upper bearing shells.

Remove the cylinder liners using the MST 145.

Remove the Idler gear shaft by removing its three

nos. mounting bolts.

 Rotate the engine. Remove the tappets while reversing the engine.

Piston assembly dismantling –

Remove the circlip to remove gudgeon pin.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 91
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Use nose pliers to remove circlips from both side of

the gudgeon pin.

After removing the circlips use mallet to punch and

push the gudgeon pin to remove from the piston.

Check Piston and assembly components for service

limit and damages if any.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 92
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Inspection:

 All the components should be inspected for wear. Any components, which are beyond the
wear limits, have to be replaced.
 Over & above the wear limits: The following points also need to be ensured.

Piston:
Check for scuffing/scoring on the skirt. A hard thick layer of carbon lacquer on top land is acceptable.
(If the thick layer is present on the piston check that the liner does not have scuffing)
However scuffing of the top land and skirt giving indication of overheating which is not acceptable.

Liner:
Any scoring on the liner is not acceptable.

Crankshaft:
Check for scoring on the main as well as connecting rod journal. If scoring is nominal and will not the
increase the oil clearance then the crankshaft can be used in, as it is condition. However if it is
unacceptable then the journal has to be ground up to service limits only. Any deep groove in the rear
end oil seal seating area is unacceptable. It will result in oil leaks.

Valve:
If valve tip is worn out/ ridged then not acceptable

Main bearing and connecting rod bearing. –

If the scoring is nominal and oil clearance is not affected, then it can be reused. However if flaking
/peeling of the bimetal in any particular zone only is present then use new shell. Look for foreign
particle embedded, deep scratches.

Dampener pulley rubber bonding-

Inspect for any gap between the rubber ring and the outer/inner ring. Cracks on ring. Any deep
groove in the front oil seal seating area is unacceptable. It will lead to leakages.

If any deterioration of rubber or gap noticed between the ring and the rubber replace the dampener
pulley.

It is suggested that the dampener pulley be replaced at every 3,00,000 Kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 93
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Engine Assembly

The assembly sequence is the reverse of the dismantling procedure.

To obtain a good life of the rebuilt unit absolute cleanliness of the parts is taken as a prerequisite and
also the fact that all the parts have been inspected.

The additional points which are mentioned are necessary to give you the engine life same as the
original engine.

Bolts:
The following bolts are recommend to be replace every time they are opened-if the Maximum length
exceeds the specification. However the connecting rod bolt has to be changed every time without
exception.

The bolts have to be tightened by base torque then 2 stage angular torque. The angular torque’s
ensures that the bolts are torqued up to yield point. And the 2 stage ensures that the clamping load
for each bolt is within a very close tolerance.

• Cylinder head bolts- 10 nos. Check the bolts length and for crack, rust if any.
• Main Bearing Bolts- 10 nos. Check the bolts length and for crack, rust if any.
• Connecting rod bolts- 8 nos. Replace every time.
• Flywheel bolts- 6 nos. Check the bolts length and for crack, rust if any.

Cylinder block – Top face.

Ensure that the tapping for the cylinder head bolt as well as the crankshaft’s main journal is fine.
Ensure that no water or oil after cleaning is in the bolt holes (esp. the cylinder heads.). If found
please remove them, if necessary using cotton cloth (not cotton waste).

If the oil /water is not removed then it is possible that while tightening the bolt. It may not allow
complete tightening of the bolts and one will get a false reading.

Cylinder head gasket:

It is a multi layer steel gasket type. Do not use any oil or shellac on the cylinder head gasket or on the
block face or the cylinder head face. The gasket has to be fitted dry.

The gasket can be assembled any face up or down. However it is suggested that the face with the
numbers should be facing up.

Piston & Rings:

While fitting the piston rings ensure that the rings end gap are staggered in 120°.
The first ring end gap should not be on the thrust axis but the minor axis i.e. on the gudgeon pin axis.
Please note that the first ring is keystone shaped hence the top mark has to face up. The 2nd ring is
taper faced. The face, which should be on the top, has to be facing up. The 3rd ring is the
conformable type oil ring. It can be assembled either way.

While assembling the piston on to the liner- apply clean oil liberally on the liner surface.

Bearing shells:
Before fitting the bearing shell ensure that the parent bore of the block/connecting rod are clean.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 94
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Wipe with a clean cloth the back end of shells before assembling on to the block or connecting rod.
Ensure that the bearing shells are located properly in the notches.

Oil seals:
Ensure that -
 The oil seals lips are not damaged while fitting.
 Always ensure that the lip is coated with grease before fitment.
 Apply engine oil on the outside diameter of seal. The receiving bore should be free of burrs, dent.

Testing:
It is recommended to reassemble the engine on the engine stand only.
Assemble the engine back to the vehicle. Ensure all the connections are made. Then -

 Start the engine

 Run at idle for 5 minute. Observe for leaks.
 Drive the vehicle at 50% of the maximum speed in each gear for about 10 to 30 Km each (Aprox.)
 Retighten the cylinder head bolts after engine cools.
 Reset the tappets.
 Hand over the vehicle to customer to drive with speed limitation for 2000 Kms.
 After 5000 Kms. Readjust the fan belt and tappet clearance. Change the engine oil.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 95
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications & Wear Data -

Figure Description Value

Bore 88.9 mm

101.6 mm
Stroke

Power- Max 46.3 kW @ 3200pm

Torque-Max 195 Nm@1500-1800
Firing Order 1-3-4-2

Direction of rotation Clockwise from fan side

Emission limits BS III & BS IV

Idle RPM 825 ± 75
Fly up RPM 3700 ± 100
Compression Pressure Standard Service Limit
28-30 bar <25 bar
Variation between cylinder
permissible 3.0 bar Max.
Piston Re-entrant Bowl
Full floating. Surface hardened &
Piston Pin
ground

API grade CF4

Oil grade & Quantity Viscosity Index 15W40 : 07 ltrs.
Mahindra Maximile Premium
Replaceable wet type Cast Iron
Cylinder liner

Tappet clearance
Inlet 0.4 mm (0.016 thou)
Exhaust 0.5 mm (0.020 thou)

Inlet valve
OPENS 9°BTDC
CLOSES 35°ABDC

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 96
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Exhaust Valve
OPENS 42°BBDC
CLOSES 10°ATDC

13.5 Lpm@ 875 rpm (pump) 2.0

Oil pump capacity
bar outlet pressure

130 °c Max.
Oil temperature

Oil filter bypass opening pressure 0.8 to 1.0 bar

3.5 bar
Relief valve opening pressure

Oil pressure at
Idle ( 60 to 80°C) 1.6 bar
Max speed( 60 to 80°C) 2.5 bar

Piston ring to groove clearance Standard Service Limit

1st ring
2nd ring 0.135/0.08 0.2
3rd ring 0.095/0.06 0.15
0.075/0.03 0.15

Piston ring end gaps Standard Service Limit

1st ring 0.40/0.20 0.80

2nd ring 1.0/0.80 1.40
3rd ring 0.50/0.250 0.80

Gudgeon pin O.D  28.00/27.995

Connecting rod – Small end bush I.D Standard

in assembled condition 32.041/ 32.025

Gudgeon pin to connecting rod small Standard Service Limit

end bush clearance. 0.047/0.025 0.05
Gudgeon pin to piston pin hole Standard Service Limit
clearance 0.017/0.004 0.03

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 97
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Piston weights grading <5.0 gms

A 710-714 gms
B 715-719 gms
C 720-724 gms
D 725-729 gms
E 730-734 gms
Connecting rod grading as per
<10.0 gms
weights
>1050-1059 gms
A
1060-1069
B
1070-1079
C
1080-1089
D
1090-1099
E
1100-1109
F
1110-1119
G
1120-1129
H
1130-1139
J
1040-1049
L
1030-1039
M
1020-1029
N
1010-1019
P
1000-1009
Q
>20 gms
Recommended for service
replacement
Standard Service Limit
Connecting rod bend or twist
0.05/25 mm 0.1/25 mm

Standard Service Limit

Connecting rod end play
0.15/0.35 0.5

Standard Service Limit

Crankshaft end play 0.3 / 0.1 0.5

Standard Service Limit

0.4/0.2 0.6
Camshaft end play

Standard Service Limit

FIP End play
0.6 1.0
Piston projection from crankcase top Standard Service Limit
surface 0.65/0.35 0.80
Liner projection from crankcase top Standard Service Limit
surface +0.02/-0.09 +0.04/-0.04
Injector projection from crankcase Standard Service Limit
top surface 4.0/3.6 4.0/3.6

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 98
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Standard Service Limit

Cylinder head bottom face distortion
<0.04 <0.1

X Axis- Along C/s Standard Service Limit

Y Axis- Perpendicular to cranks shaft
A- 25 mm ID 88.9/88.92
B- -86.6 mm
C- 113 mm Roundness
D- 163 mm <0.012 <0.03
Roundness/Ovality- Difference in X
& Y plane at any pt. Cylindricty
<0.012 <0.03
Cylindricity/Taper -Difference in
same plane x/y at any point Runout 0.05

Liner/ block grade

(Flange thickness)
RD 0 MAX MIN
RD 1 5.750 5.730
RD 2 5.730 5.710
RD 3 5.710 5.690
RD 4 5.690 5.670
Standard Service Limit
Crankcase top surface flatness
<0.05 <0.1

Height of cylinder head from top to Standard Service Limit

bottom face 92.5 Machining limit 0.3mm

Rocker lever bush I.D ( in pressed Standard

condition) 22.021/ 22.000

Standard
 Rocker shaft O.D
21.980/21.959
Standard Service Limit
Rocker to shaft clearance
0.062/0.020 0.10

Standard Service Limit

Push rod bent
<0.25mm >0.5mm
Valve spring Standard Service Limit
Free Length 25.5Kg +/- 5% @ 42.0 mm
Squareness 49.2Kg +/- 5% @ 32.6 mm
Installed Load/Installed length (Service limit 10% less)
Valve seat angle 44°45’ to 45°

Valve stem O.D

Inlet 8.710/8.695
Exhaust 8.690/8.675

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 99
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Valve to Valve guide clearance

Inlet 8.760/8.740
Exhaust 8.760/8.740
Standard Service Limit
Thickness of the valve head
0.065/ 0.030 0.100
Inlet 0.085/ 0.050 0.120
Exhaust

Timing gear Backlash Standard Service Limit

Crankshaft/Idler 0.2/0.06 <0.3

Idler/Cam gear 0.2/0.06 <0.3
Idler/ Injection pump 0.2/0.06 <0.3

Difference between Cam height & Standard Service Limit

base circle diameter
Inlet 6.282 5.582
Exhaust 6.344 5.844

Front 46.825 - 46.850

Camshaft Bush I.D Center 46.062 – 46.088
Rear 38.138 – 38.163
Front 46.762 - 46.787
Camshaft Journal O.D Center 46.000 – 46.025
Rear 38.075 – 38.100
Camshaft bush to cam journal Standard Service Limit
clearance 0.088 / 0.037 0.140
Camshaft bend 0.05 <0.10
1.17+/- 0.02 mm Plunger lift @
Static timing
TDC
Tappet OD 14.600/ 14.570
Tappet bore ID crankcase 14.650/ 14.612
Standard Service Limit
Tappet to tappet hole clearance 0.02/0.075 0.15

Crankshaft pin Standard Service Limit

OD 53.993 / 53.975
Roundness/Ovality <0.006
Cylindricity/Taper <0.010

Standard Service Limit

Main Bearing oil clearance
0.102/0.032 0.150

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 100
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Standard Service Limit

Crankshaft journal
53.993 / 53.975
OD
<0.006 0.03
Roundness/ Ovality
<0.010 0.02
Cylindricity/ Taper
Undersize of the c/s journal pin OD Dimensions of the journal
0.25mm US 58.75/58.371
0.50 mm US 58.50/58.481
0.75 mm US 58.25/58.231
Standard Service Limit
Crankshaft bend
< 0.05 <0.10

FILLETS ARE HARDENED. DO NOT

CAUTION
ATTEMPT TO STRAIGTEN

Standard Service Limits

Crankshaft fillet radius
3.15 - 3.43 3.0 – 3.5

Crankshaft Hardness Minimum 50 HRC

Connecting rod big end Bearing oil Standard Service Limit
clearance 0.091/0.036 0.150
Connecting rod small end Bearing oil Standard Service Limit
clearance 0.046/0.025 0.070
The Maximum length of bolts after
which they have to cannot be used

Cylinder head bolts 136.6/135.4 mm

Main Bearing Bolts 90.6/89.4mm
Connecting rod Replace every time
Flywheel bolts length 29.58/30.42 mm

Thermostat
Starts opening at 80 - 85°C
Fully opens at 96°C
Lift 7.5 mm

Water pump pulley ration 1.28

Water pump flow ratio 1308 lpm @ 1200 rpm.
Standard Service Limit
Flywheel width from mounting face
57.785 +/- 0.1 2mm
to clutch face
NGT 43.00+/- 0.1 2 mm
Flywheel Standard Service Limit
Flatness <0.05 <0.1
Runout <0.05 <0.1

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 Page 101
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Lubricants & Sealants

Mahindra Maximile Premium Or any other engine oil conforming to API grade CG4 or above and a
viscosity Index of 15W 40.

If any oil conforming to CF4 grade is used then the oil change interval is 7000 Kilometers. Oils of
MIL 2104 C or below are not acceptable

RTV silicone sealant- RHODOSEAL. Part number 0024532 to be used:

 Between Rear oil seal retainer & Block
 Between ladder frame & block

All other places Loctite 547.

• Hard gaskets are used only at: -

 Cylinder head Gasket.

 Turbocharger to Exhaust manifold mounting.
 Exhaust manifold to cylinder head.

Rust cleaning solution (For the Turbocharger mounting nuts):

Brand Name: WD-40

Manufacturer- WD-40 COMPANY
MARKETEDBY—Hardcastle & Waud Manufacturing Co. Ltd.
Brabourne Stadium,
87, Veer Nariman Road
MUMBAI-20.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 102
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tightening Torque’s -
Description Torque Value in Nm
Main bearing bolt 120 ~ 130
Connecting rod nut 65 ~ 70
Cylinder head bolt 35 Nm + 90 dg.
Flywheel bolt 90 ~ 100
Crank pulley bolt 180 ~ 200
HP pump gear mounting bolt 90 ~ 95
HP injector mounting bolt 50 ~ 60
Engine mounting 80 ~ 90
Clutch housing mtg. bolts 80 ~ 90
Water pump mounting bolt 30 ~ 40
Oil pump mounting bolt 30 ~ 40
Rocker arm bracket stud/ nut 30 ~ 40
Rocker arm adjusting screw nut 35 ~ 40
Camshaft thrust plate mounting bolt 30 ~ 40
Exhaust manifold stud/ nut 30 ~ 40
Exhaust manifold to turbocharger mtg. bolt 20 ~ 25
Turbocharger to turbo outlet pipe 20 ~ 25
EGR Valve to air pipe 20 ~ 25
Air intake manifold bolt 20 ~ 25
HP pump mounting stud/ nut 20 ~ 25
Front cover mounting bolt 20 ~ 25
Oil sump mounting bolt 20
Rear Oil seal retainer bolt 20 ~ 25
MOG plug M10X1.0 10 ~ 15
MOG plug M13X1.5 15 ~ 20
Water drain plug 30 ~ 40
Oil drain plug 20 ~ 25
Adapter dipstick 15 ~ 20
Water temp sensor 20 ~ 25
Rocker arm cover nut 5 ~7
HP pump cover bolt 8 ~ 10
Oil strainer bolt 8 ~ 10
EGR Valve/ pipe bolt 20 ~ 25
AC Compressor mtg. bolt 30 ~ 40
AC Compressor brace mtg. bolt 30 ~ 40
Alternator mtg. bolt 30 ~ 40
Alternator brace mtg. bolt 20 ~ 25
Engine lifting hook bolt 20 ~ 25
Oil filter mtg. adapter 15 ~ 20
Turbo oil inlet banjo 20 ~ 25
Turbo oil return nipple 25 ~ 30
Thermostat hsg. cap bolt 20 ~ 25
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 103
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

AIR INTAKE SYSTEM

Contents…

• Description…………………………………………………………………………….
• Trouble Shooting………………………………………………...............
• Care of the System….……………………………………………………………
• In Car Repairs……………………………………………………………………….
• Specification………………………………………………………………………….
• Tightening Torques……………………………………………………………..

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 104
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description —

AIR FILTER AIR FILTER ASSEMBLY

HOSE DIRT
SIDE AIR FILTER CHOCK
INDICATOR

AIR FILTER HOSE

CLEAN SIDE

TURBOCHARGER
ASSEMBLY

AIR INTAKE SYSTEM IN BOLERO m2DICR

The air is sucked through a dry type air cleaner. The air enters the air cleaner housing and due to the
cyclonic effect induced inside; the heavier particles settle at the periphery of pre cleaner. Mushroom-
headed dust outlet valves at the bottom ensure that such heavier particles are discharged. The dust
outlet valve is on the non-clean side. The air is further filtered when sucked from outside to inside of
the element. Air filter service indicator is fitted on the hose between the air filter and engine to
indicate if the air filter is choked or not. After filtration the air is compressed by an axial inflow
compressor, which is driven by radial inflow turbine. The boost pressure in the turbocharger is
controlled by the waste gate mechanism. A diaphragm senses the boost being generated.

Once the boost pressure goes above the specified value it actuates the waste gate through a push
rod. It ensures that the excess gas instead of entering the turbine side is directly connected to the
exhaust pipe hence preventing any further increase in boost. The waste gated turbocharger controls
the boost to 1.6. It enters the Cast iron cylinder head through the inlet valves having a 45-degree
angle.

In case of BS-IV engine, the EGR system cooler is equipped to EGR cooler; it cools the exhaust gases
before entering into the inlet manifold.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 105
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

Symptom Causes Remedial action

Engine will not start & emit 1. Air intake obstructed  Clean the element or replace
black smoke the element when the Service
Indicator shows red band/ LED
on dash glows even after
cleaning. Refer to the care of
the system also
 Check for free operation of
Turbocharger
Engine does not give full 1. Air intake restricted.  Clean filter, replace if required.
power. 2. Air leaks in system after  Plug the leaks, replace hose or
turbocharger clip if required.
3. Turbocharger damaged.  Get the Turbocharger repaired
at authorized TEL dealer.

Black smoke. 1. Air intake restricted.  Check for hoses, clean or

replace element.
2. Air leaks.  Check for leaks between
Turbocharger & inlet manifold
 Remove restriction or replace
parts.

Excessive oil consumption 1. Clogged air filter element.  Clean or replace elements.
2. Restriction in air intake to  Locate & remove restriction.
compressor duct.
3. Air leak between the  Locate the leaks, change hose or
Turbocharger to intake clamp if required.
manifold.  Remove the restriction in the
4. Restrictions in turbocharger drainpipe.
drain line.
5. Thick oil/sludge or coke in  Change oil, filter, service the
the turbocharger’s central Turbocharger & use
housing. recommended oils & drain
intervals. Follow the
recommended procedure while
shutting down.

6. Turbocharger damaged.  Repair Turbocharger.

Whining noise clearly audible 1. Indication of air leak esp. in  Tighten the clamps at the
after 2000 RPM between: Turbocharger to Turbocharger inlet & outlet.
inlet manifold.  Check the hoses for leak

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 106
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System –

The Air cleaner element should be cleaned at each service interval and can be reused. The air cleaner
element should be replaced first at 35,000 Kilometers, and then at every 40000 kms. On dusty roads,
change the air cleaner element earlier if required or when chock indicator shows.

It should be noted that if the engine is run with clogged air cleaner, then it will lead to seepage of oil
from turbocharger into the air intake system.

The vehicle is fitted with Turbocharger; hence the following additional points have to be taken care.

Ensure that the recommended engine oil only is used and the specified drain intervals are
maintained.

Check the operation of the waste gate valve by blowing compressed air with 1.6 bar in the valve
hose. The valve should open, pressing the turbocharger stem and opening the exhaust valve (flap
valve).

• Do not attempt to disturb length of the waste gate controlling actuator rod.
• If the Turbocharger is removed, please do not lift the turbocharger using the actuator rod
as a lifting handle.
• Check the oil separator system, in particular for vacuum leaks. Any vacuum leak will lead to
high pressure build up and then will go through the intake system and give a signal of high
blow by or be confused with compressor oil leak.

Refer following job descriptions while carrying Air intake system maintenance activities –

• AIR FILTER ELEMENT – CLEAN & REPLACE

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 107
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 AIR FILTER ELEMENT - CLEAN

Nut/ Bolt description Quantity Nos. Spanner Size Torque Value –

Nm.
 Hose clamps – air cleaner to 02 11 mm. 2.5 ± 0.5
manifold 02 11 mm. 4.5 ± - 0.5

Schematic – Air Intake

Vacuum Modulator with hoses connected

Check
Modulator
nipples
for
blockage

AIR FILTER ELEMENT – CLEAN Refer illustration.

1. Open the dirty side hose clips & clean Hose clips & separate the hoses.
2. Loosen & remove the mounting bolt.
3. Unlock the clips.
4. Take out the air cleaner element & clean with compressed air. Always apply the
compressed air from inside out of the air cleaner element.
5. Reassemble the air cleaner element & complete the assembly in reverse order of dis-
assembly. Air Cleaner Mounting Bracket torque – 18 ± 3 Nm.
6. Reset the ‘air cleaner clog indicator’ after the assembly is complete.
7. Check the EGR Vacuum Modulator nipple, ensure that it is not blocked.
8. Ensure that the vacuum hoses are fitted and not left open. Refer illustration.

 Clean Air filter element at every service interval.

 Follow the standard process for cleaning the Filter to avoid damages.
 Clean the air filter element at every service interval.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 108
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 AIR FILTER ELEMENT - REPLACE

Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
 Hose clamps – air cleaner to 02 11 mm. 2.5 ± 0.5
manifold 02 11 mm. 4.5 ± 0.5

Schematic – Air Intake

Check
Modulato
r nipples
for
blockage

Vacuum Modulator with hoses

connected

AIR FILTER ELEMENT – REPLACE

Refer illustration shown above –
1. Open the dirty side hose clips & clean Hose clips & separate the hoses.
2. Loosen & remove the mounting bolt.
3. Unlock the clips.
4. Take out the air cleaner element & replace with a new one.
5. Reassemble the air cleaner element & complete the assembly in reverse order of dis-
assembly. Air Cleaner Mounting Bracket torque – 18 ± 3 Nm.
6. Reset the ‘air cleaner clog indicator’ after the assembly is complete.
7. Check the EGR Vacuum Modulator nipple, ensure that it is not blocked.
8. Check the vacuum hoses are fitted and not left open. Refer illustration.

 Replace Air filter element at 40000 kms or early if required.

 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 and ensure that setting height is correct after job
complete.
 It is recommended to replace the air filter element at every 35000kms or when the air filter
chock indicator glows if vehicle running in very dusty conditions.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 109
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –

1. Air cleaner Removal

2. Turbocharger removal & Refitment

1. Air cleaner removal & Refitment –

• The removal of the air cleaner is to be avoided as much as possible. Whenever the element is
removed, it gives opportunity for the entry of foreign particles at the inlet.

• Any improper handling of the air cleaner element during service will do more damage to the
element than increase the life of the element.

Any damage to the element, practically means no filtration or at the best partial filtration which
will reduce the life of the engine & turbocharger by up to 50%

• It is advisable to restrict the element change period to 20,000 KM in adverse working conditions
and attend to the element only when any of the following events happen :
a) Restriction indicator repeatedly shows the red band.
b) Loss of power / Pickup.
c) Heavy black smoke.

This will definitely increase the life of the engine as well as the Turbocharger.

• Air Cleaner Element Change –

 Refer the Air filter element replacement procedure prescribed above.

 Reset the ‘air cleaner clog indicator’ after the assembly is complete.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 110
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

2. Turbocharger Removal & Refitting –

Refer Engine Repair section for ‘Turbocharger Removal procedure’.

• Working Principle, Inspection & Fitment procedures of the Turbocharger –

The Turbocharger is basically an axial inflow air compressor, which is driven by an exhaust gas driven
turbine.

The exhausts gases coming out of exhaust manifold impinge on the turbine blade give the drive to
turbine shaft. At the other end of the turbine shaft the compressor is assembled. The whole
assembly is supported on a floating bush. The bush gets an oil supply directly from the engine and
has oil film between the shaft and bearing as well as the bush and the central housing.
The exhaust gases from the Turbine impinge on the turbine blade & rotate the shaft. The compressor
blades at the other end suck the air from the air filter.

The turbocharger is matched to give an optimum boost for the desired engine speed band. A waste
gate controls the boost. The waste gate is used to bypass the excess exhaust gas away from the
turbine and thus maintain the boost as well as control the backpressure. A spring-loaded diaphragm
controls the waste gate.

A flap valve is installed in the turbine housing just before the turbine blade. Opening the valve allows
the excess gases to bypass the turbine. The flap movement is controlled by a push rod, which is
controlled by a spring-loaded diaphragm. At the other end of the diaphragm the compressed air is
sensed through a hose which is connected at a tapping in the compressor housing.

The length of the pushrod, functioning of the diaphragm and the hose connection are essential for
the precise operation of the push rod. Any air leak from the hose connecting the compressor housing
to the waste gate-controlling diaphragm will also affect the performance of the turbocharger/
engine.

Inspection

 Inspect the suction side (i.e. up to the air cleaner) for oil traces.

In a close crank case ventilation system it is normal to have oil in this area. These oil particles are
carried from blow bye of the engine, which gets condensed from gas to oil. Look for any undue
gumming of oil, hard carbon particles in this area. If such an observation is present then all the
causes for excess blow symptoms have to be checked and eliminated.

 Inspect the compressor and turbine blades for any damage caused by foreign object. The
inspection can be done through the compressor housing inlet and turbine housings outlet.

 Inspect the blades outer edge and observe if any rubbing marks are noticed on the housing.

 Rotate the shaft wheel assembly by hand and check for freeness, and any binding.
 Push the shaft to side and rotate to check for wheel rub. It should turn smoothly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 111
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Lift both end of shaft up and down at the same time and feel for excessive journal bearing
clearance. If clearance is normal then very little shaft movement will be detected.

 If all the above checks are satisfactory then the turbocharger can be reused.

♦ If the turbocharger parts are damaged, wheel rubbing marks present, shaft not rotating freely
or binding or excessive journal clearance then the Turbocharger should be serviced.

 Do not attempt to service or overhaul the Turbocharger. It should be done only at the authorized
Turbo Energy Ltd service center. Any attempts to attend without the use of special tools or
procedure can damage to turbocharger or personnel!

• Turbocharger Installation –

• Do not mishandle, tumbled, dropped or keep any ports open.

• Do not use the actuator control rod for lifting or carrying.
• Do not disturb the setting of the actuator.

 Check

The inlet connection & outlet exhaust connection to turbocharger for foreign material, cracks,
blockages, sand particles, loose nuts etc. This check should be done more thoroughly if any damage
has been noticed in compressor or turbine blades as under normal operating conditions the blades
can damaged only if a foreign object hits them.

Check all the hoses and pipes from turbocharger outlet to inlet manifold for crack, aging, leaks. Check
the hose clips for proper functioning. If in doubt – replace.

The oil supply pipe should be checked carbon deposits, crack, distortions etc. Clean the supply pipe
before fitting.

Do not attempt to change the orientation of turbocharger and ensure the correct gaskets are used.

Do not re-use any of metallic gaskets even if they appear to be good. It will lead to leakage & drop in
the performance of the engine.

Installation –

Once a new turbocharger is being installed –

i. Fill fresh clean oil from the oil supplies port and after that gives the shaft few rotations.
ii. Fit the supply pipe.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 112
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

iii. Without fitting the drain oil pipe, disconnect the FIP solenoid.

iv. Crank the engine till a steady stream of oil comes out through the drainpipe. (CAUTION: Do not
crank the engine for too long. Excessive cranking will result in emptying of the pump cavity
causing the plunger to run dry.)

This will ensure that the oil supply line to Turbocharger is purged of any air pocket.

After this, fit the return line from turbocharger to sump, taking care to avoid any kinks.

With engine running condition, check the air, exhaust and oil connections for leaks.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 113
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications –

Turbocharger Model K 03
Turbocharger specifications K0 3-0095
Turbocharger supplier Turbo Energy Ltd.
Air velocity between the Air filter compressor inlet 35 mbar ( Max)
Maximum static back pressure at downstream of 200 mbar ( Max)
turbine
Oil pressure at upstream of turbocharger 1.6 bar at 800C oil temperature and engine at
idle.

• Tightening Torques –

Bolt location Torque Values (lbf-ft)

Turbocharger Mounting stud/ nut 25 ± 5 Nm (18 ± 4 lbf-ft)
Inlet manifold 25 ± 5 Nm (18 ± 4lbf-ft)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 114
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

COOLING SYSTEM

Contents…

• Description…………………………………………………………………………….
• Trouble Shooting………………………………………………...............
• Care of the System….……………………………………………………………
• In Car Repairs……………………………………………………………………….
• Specification & Coolant……………………………………………………….
• Tightening Torques……………………………………………………………..

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 115
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The cooling system is designed to cater to the following functions:

Remove & dissipate excess heat from the combustion process.
• To maintain the optimum temperature for complete and uniform combustion.
• To provide heating for the heater system.( In the models where the Heater is provided)

The cooling system includes the following components/ sub system:

 Radiator
 Radiator Pressure cap
 Coolant
 Cooling fan Fan drive
 Fan shroud & Thermostat
 Water pump
 Thermostat housing, cover thermostat.
 Recovery tank
 Hoses & their clamp.

The functional system is shown in the block diagram.

Broadly speaking the water flows from the water pump to the cylinder block and from the block to
the cylinder head and then to the bottom of thermostat. Once the thermostat opens the water goes
to the radiator and after getting cooled the water is again fed to the water pump.

Water pump & cover -

The coolant from the outlet elbow of the cross flow type radiator enters the inlet of the water pump.
The centrifugal water pump delivers the water the cylinder block.

Bolero m2DiCR – Cooling System Schematic To HVAC

Radiator Cap
Coolant Hose

To HVAC

Coolant Hose

Hose to
Recovery
Tank
Radiator Assembly
Recovery Tank

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 116
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Cylinder block & cylinder head –

In the block the water enters a main cooling passage which runs along the length of the block in one
side (inlet manifold side). The top passage ensures that the maximum cooling is provided to the
hottest zone of the cylinder liners i.e. the top portion.

At the same time a passage at the front end connect the inlet to another gallery at the bottom of the
liner. In between the top and lower passage in the block the coolant flows between the block & liners
due to the thermos siphon effect. The water then goes to the cylinder head and from there to
bottom of the thermostat.

Radiator & No loss tank -

The radiator cap controls the system pressure to 0.9 bar. Once the pressure exceeds 0.9 bar the cap
lifts off the seat and the coolant is allowed to escape into a no loss tank.

As the engine cools down the system pressure falls and vacuum is formed .The vacuum valve in the
radiator cap opens and allows the water from the no loss tank to go back into the radiator. Thus the
system does not have any coolant loss during normal operation.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 117
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting -

Before going into the specifics of the cooling system it is worthwhile to find out under which driving
conditions the complaints is present.

Some of the causes are:

• Prolonged /excess idling.

• Very high ambient temperature
• Slow traffic
• Traffic jams
• High speed
• Steep Gradients.

• Refer following chart for detailed Trouble Shooting -

Symptom Causes Remedial action

Noise  Reposition the shroud and inspect
Fan shroud the engine insulators.
1. Fan contacting the
shroud  Replace the water pump.
 Replace water pump.
Water pump  Tighten mounting bolt
1. Loose water pump
impeller.
2. Water pump bearing
worn/ failure.  Tighten belt
3. Loose mounting of pump  Replace serpentine belt,
 Replace pulley.
Belts
1. Belt loose  Check the belt alignment & rectify.
2. Glazed/stretched fan
belt.
3. Rough surface on drive  Replace alternator bearing
pulley.
4. Belt alignment

Alternator/Water pump

1. Alternator bearing
failure

Coolant loss- boil over Coolant

1. Overfilled recovery tank.  Reduce the coolant level.
2. Insufficient coolant  Add the additive.
additive causing lower
boiling points.
3. Additive deteriorated

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 118
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

due to aging/  Replace the coolant

contamination.
4. Low coolant level.
Hot shut down  Add coolant
1. Quick shut downs after a
long and hot run.
Leakage’s  Allow the engine to run at idle for
1. Leaks due to loose hose some time before stopping.
clamps.loose nuts, bolts  Find the area of leaks , replace hose
drain plugs, faulty hose or if necessary the clamp also
or leaking radiators.  Pressure test the system to check
for leaks and then repair as
necessary.
Blockages  The flash may be visible by
1. Casting flash in the removing the cooling system
block. components or the core plugs.
Repair or replace.
 Flush radiator.
2. Casting flash in the
cylinder head.  Purge the system.
3. Blocked radiator causing
under filling of the  Purge the system.
cooling system.
4. Air trapped in system.
5. Air in the system causing  Replace the cap/ pipe.
occasional burping.
6. Faulty expansion bottle
cap or pipe.
Coolant loss- boil over Gas mixing
1. Cylinder head gasket  Replace the cylinder head gasket
failure.
Pressurization
1. Defective radiator cap.  Replace the cap.

Timing
1. Improper engine timing  Check the engine timing, FIP timing,
injector pressure and also the
tappet clearance.
Belt
1. Slipping belts  Adjust belt tension.
2. Belt failure water pump  Replace belt
1. Water pump shaft  Replace water pump
broken or damaged
impeller.

Thermostat
1. Faulty Thermostat.  Replace Thermostat.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 119
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Hoses.

1. Radiator hoses collapsed

 Replace hoses.

Fan
1. Fan blades broken

Air flow  Replace fan

1. Air flow reduced to
choked fins
2. Airflow reduced due to  Clean the radiator fins.
obstruction.  Remove the obstruction.
Vehicle
Brakes dragging.  Check the brake system
High Temperature Indication
Improper indication  Replace the sensor.
1. Faulty sensor  Replace the gauge
2. Faulty gauge
Coolant entry into Crankcase 1. Low cylinder head  Replace the cylinder head gasket,
or cylinder torque. torque as per procedure.
 Replace the cylinder head gasket
 Replace the affected part.
2. Faulty head gasket.

3. Blow hole in crankcase,

head , liner
Low Temperature Gauge 1. Thermostat stuck open  Replace thermostat.
Indication- Under cooling 2. Faulty sensor.
3. Faulty gauge.  Replace sensor.
 Replace gauge.
Coolant reserve system 1. Coolant level low  Replenish coolant to FULL level.
inoperative  Pressure test to isolate & repair.
2. Leak in system  Remove clogging

3. Overflow tube clogged  Clean vent.

or leaking.
4. Recovery bottle vent  Change the cap.
blocked.
5. Radiator cap defective.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 120
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System

- Unless there is loss of coolant the coolant additive added is adequate for 80,000 of
the vehicle.
- The recommended coolant additive is given in the chart below.
- The fan belt tension should not fall below 450 N.

Cooling system details:

1. Liquid cooling system Yes
2. Nature of liquid and capacity Water Opt. Water + Ethylene Glycol (70:30)
Capacity - 7ltr.
3. Circulating pump yes/no Yes
4. Characteristics of Circulating pump or make(s) &
type(s) Centrifugal Pump, Autolec Industries
5. Drive ratio 1.28
6. Thermostat type and setting Starts Open at 78⁰ C and fully open at 92⁰ C

Refer following Job descriptions and illustrations while carrying cooling system maintenance –

1. Coolant Level & Leak Check.

2. Coolant Replacement.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 121
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 COOLANT LEVEL & LEAK – INSPECT

Coolant – MAXIMILE ULTRA COOL Capacity – 8 Litres.

New Bolero
Coolant – Engine
Level & LeakCompartment
- Inspect 1view 1

.....MAX........
2
2

1
…MIN…...

COOLANT LEVEL - INSPECT

Refer illustrations shown.
1. Check the coolant level when the engine is cold.
2. Check the coolant level in the recovery tank [1] – 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 [2] 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.
 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.
 Coolant level and leaks to be checked first at 5000kms and then at every 10000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 122
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 COOLANT – REPLACE

Coolant – MAXIMILE ULTRA COOL Capacity – 8 Litres.

New Bolero – Engine Compartment View

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.
 Coolant to be replaced from the system at every 45000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 123
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car repairs

Following are the removal & refitting are covered in this section –

• Fan belt tension adjustment,

• Fan belt replacement.

• Fan Blade removal & fitment.

• Water pump removal.

• Radiator removal

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 124
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Fan belt tension adjustment -

Loosen the alternators lower bolt.

Loosen the brace mounting at the block

Adjust the fan belt tension by first loosening the

check nut and then tightening the outer nut.

After the setting is completed, tighten the check

nut and the bottom support nut.

Check and confirm the belt tension within

recommended value.

If not, repeat the setting again.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 125
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Fan Belt Removal -

• Water Pump Removal -

For both the above removal procedures, refer Engine repair section.

• Radiator Removal & Refitting -

Refer schematic for Radiator disassembly -

Radiator Cap

Coolant Recovery
Tank

Radiator Assy

Drain
plug

Coolant Hose
Radiator Shroud Assy
Coolant Hose

 Do not remove the cylinder block drain plug or the radiator drain cock with the system hot and
pressurized. Serious burns from the splashing coolant can occur.
 Before draining the system. The system pressure has to be relieved.
 Holding the radiator cap with a rag slowly open the radiator cap.
 The water may splash upward causing injury

• Remove the radiator inlet and outlet hose

• Remove the fan shroud.
• Remove the radiator mounting bolts and remove the radiator along with the pipe connecting it
to the no loss tank.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 126
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Dismantling & Assembly of the Cooling System -

 Water Pump

Do not remove the radiator drain cock or the Engine coolant drain plug with the engine in hot
condition.

Always remove the pressure on the system by removing the radiator cap before undertaking any
work on the cooling system.

If the coolant is not contaminated then collect the coolant in a clean container so that it can be
reused. Replace coolant as per recommendation

Water pump

A centrifugal water pump is used to circulate the coolant through the water jackets, cylinder head,
hoses and radiator. The water pump is belt driven by the engine main pulley.
The water pump impeller is pressed onto the shaft. The shaft is supported on two bearings that are
integral to the shaft. The water pump pulley is also pressed on to the shaft.
The water pump seal is located between the impeller and the housing. The housing has a small hole
to allow the seepage to escape. That also acts as an indication point if the water pump seal fails.

Water Pump Removal & Refitting -

It is suggested that the water pump should not

serviced.

This is so because when the seals have to be

changed, then both the impeller as well as the
pulley needs to be changed. (Interference fit,
removal will make them oval.)

Further when assembling the water pump

seals the dimension of the impeller from the
seating face as well as the pulley pressing is
critical. (If not maintained will have low seal
life and low belt life.)

• The fan belt tension has to be measured between the alternator & water pump pulley.
• Always replace with new gasket while removal and refitting water pump.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 127
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications -

Radiator capacity 2.0 liters

Cooling system capacity, total 10 liters
Coolant BASF’s-GLYSANTIN G45-23
/ Mahindra Maximile
Ratio 30%- Glysantin G45-23
Mahindra Maximile is premixed.
Coolant to be added after draining/flushing 10 liters- Mahindra Maximile
3 liter if Glysantin G 45-23
Radiator pressure 0.9 bar
No of fan blades 8
Fan Belt tension
Water pump- Alternator 400-450N
AC compressor 500-550N

• Tightening Torque’s -

Bolt location Torque in Nm ( Lbft)

Water pump mounting bolt M10X1. 5 30-40 ( 22-29.5)
Water drain plug - M12X1.5 30-40 ( 22-29.5)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 128
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

FUEL SYSTEM

Contents…

• Description……………………………………………………………………………
• Trouble Shooting………………………………………………...............
• Care of the System………………………………………………………………
• In Car Repairs……………………………………………………………………….
• Specification…………………………………………………………………………
• Tightening Torques………………………………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 129
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description -

Fuel System – New Bolero m2DICR

The fuel system can be divided into following subgroups.

 Fuel filling.
 Fuel supply from tank, Electronic feed pump to Fuel Filter to HP Pump.
 HP Pump, Common Rail & Injectors including the High pressure pipes.
 Return lines from Injectors, venturi to fuel tank.

The fuel is filled from the opening provided at rear left. The fuel cap is ventilated and threaded type.
(Threaded type of fuel caps are used in Bolero model family of the cap is locked in place when further
turning action results in clicking of the ratchet).

When filling the tank, the air entrapped inside is vented by the vent tube, which is connected at the
mouth of the inlet pipe. The venting is done from the highest point in the fuel tank. The fuel tank has
a capacity of approx. 60 liters.

The Electronic Fuel feed pump is fitted inside the Fuel tank; it has got inbuilt fuel reservoir. The float
unit is integrated and can be replaced. Electronic Fuel pump supplies Fuel to Fuel filter through the
polyamide fuel lines. The HP fuel pump is assembled with Unit Pump and Cam box assembly. Unit
Pump is not recommended to do any service whereas Cam Box can be repair.

The excess amount of fuel from the HP Pump and the injectors is sent back to the Fuel tank. The
Venturi is added in the fuel return line from injectors to fuel tank. The function of venturi is to create
depression (Vacuum) at the injector back leak connection. The front portion of the fuel tank is
protected at the bottom by a stone guard.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 130
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting -

Symptom Causes Remedial action

Engine will not start & emit 1. Clogged fuel filter/ fuel  Change fuel filter
black smoke lines  Check fuel supply line.
2. Defective injectors  Calibrate injectors.
3. Engine timing.  Check engine timing.
4. Defective HP Pump  Replace HP Pump,
Noisy engine & black smoke. 1. Improper injection timing.  Check & correct the Timing.
2. Seized injectors.  Replace injectors.
3. CR system  Refer diagnostic manual.

Engine speed falls off. 1. Clogged fuel filter/ fuel  Change fuel filter
lines  Check fuel supply line.
2. Solenoid supply  Check the supply to solenoid and
intermittent or loose the solenoid.
3. Defective HP Pump  Rectify the HP Pump.

Engine does not give full 1. Clogged fuel filter/ fuel  Change fuel filter
power. lines  Check fuel supply line.
 Replace filters.
2. Injection pump timing.  Check & correct timing.
3. Defective injectors.
4. Air leak in pipe – manifold  Calibrate injectors
to HP Pump
5. Return pipe blocked.  Plug the leaks, replace hose or
6. Defective HP Pump clip if required.
 Replace the hose or tighten
 Tighten the HP pipe to the
correct torque.
 Locate the kink/block in return
pipe and rectify.
 Replace the HP Pump.
 Check the pipe, washer & rectify.
Irregular idling 1. Solenoid supply  Check the connection or replace
intermittent or loose solenoid
2. Leaking HP unions.  Tighten the unions or replace the
High-pressure pipes.
3. Air entering fuel system.  Replace all the banjo washers
and check for the cracks in fuel
4. Idling stop out of line particularly from Tank to FIP.
adjustment  Adjust the idling stop.
5. Defective HP Pump  Repair or replace HP Pump.
6. Wrong High pressure  Replace with original pipes.
pipes.
7. Fuel return line Venturi  Replace venture.
damage/ jammed.
Engine stalls when 1. Improper anti stall setting.  Refer to idling setting procedure.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 131
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

accelerator pedal is released 2. Water contamination Set on vehicle.

causing partial seizure of  Find the cause of water
HP Pump contamination & take corrective
action
Black smoke. 1. Defective injectors  Check injectors.
2. Defective HP Pump.  Rectify or replace HP Pump.
3. Defective CR System  Refer diagnostic manual.

White smoke. 1. Clogged fuel filter/ fuel  Replace fuel filter cartridge.
lines
2. Improper engine timing.  Check & correct timing.
3. Defective CR System  Refer diagnostic manual.

Engine will not start 1. Weak battery  Check the battery specific gravity.
2. Corroded or loose battery  Clean & tighten battery
connection connections.
3. Faulty starter.  Repair starter.
4. Defective HP Pump  Check connection or replace
solenoid/ no supply to solenoid
solenoid.
5. Improper earthing.  Rectify/ correct earthing.
6. Faulty Unit Pump  Replace Unit Pump assembly.
Low Fuel Average Check Fuel return line venture  Replace venture.
for damage/ clogged

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 132
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System –

The fuel injection system depends on supply of clean diesel fuel for the proper functioning of the fuel
system.

To ensure that FIP receives clean fuel all the times it is advisable that the fuel filters are replaced at
the specified intervals.

Fuel filter should be changed at 5,000 Kms, 25,000 kms and then at every 20,000 kms. If the
operating conditions are poor then reduce the change interval. The fuel filter should be of paper type
and genuine Delphi product only.

It should be understood that when the filters get choked then the filtering efficiency that is the size
of particle they are able to stop improves. However, if it gets fully choked then the flow of the fuel is
very less and inadequate at higher speed. Hence if only one filter is changed at a time then the fuel
flow is also adequate and maintains a higher filtering efficiency. The working clearance of the FIP
components are in order of few microns, hence the importance of the above procedure is high.

The internal components of the Fuel Injection pump depend on the lubricating properties of diesel
for lubricating them. Hence, if water is present in the fuel then lubrication between the component
break down and there is seizure. The commonly affected components tend to be either the
distributor head & the piston or the control sleeve getting jammed.

To avoid such an occurrence, it is recommended that at every 5000 kms water be drained from the
bottom of the filter bowls. During monsoons, the frequency can be increase to every fortnight.

The procedure, which should be followed, is:

• Loosen the drain bolt.
• Loosen the filter mounting bolt.
• Drain the water at the bottom of the bowl.
• Close the drain bolt and then the mounting bolt.

The injectors are zero sac type. The injector tips are not hardened, hence can get easily damaged
while handling.

Do not remove the injector as normal maintenance (Unless the fuel is found to be extremely
contaminated with water/kerosene). If taken out, immediately before putting on the tray it-self
cover the tips with protective caps.

• Refer following job descriptions while carrying fuel system maintenance job –

1. WATER IN FUEL - SEDIMENTS DRAIN FROM FUEL FILTER

2. FUEL FILTER ELEMENT – REPLACE
3. FUEL TANK – CLEAN

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 133
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• WATER SEDIMENTS DRAIN - FUEL FILTER

Fuel Filter
Assembly

Fuel Filter water drain socket removal

Fuel Filter Assy. & Water Drain Socket

Fuel Filter – Drain Water Sediments

Refer above illustrations –

1. Water in Fuel drain plug is fitted at the bottom of the fuel filter assembly.
2. Loosen Water in Fuel drain plug by rotating it in anticlockwise direction [2]
3. Allow the Water accumulated in the filter to drain out.
4. Hand tight the Water in Fuel Sensor in clockwise direction to refit it.
5. Check and ensure for no fuel leak after job completion; if any.

• Water sediments to be drain from Fuel filter at every 5000kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 134
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

FUEL FILTER ELEMENT – REPLACE

Bolero m2DiCR is fitted with single Fuel filter
unit having paper type cartridge inside.

Put the tray below, before attending removal of

the fuel filter assembly.

Remove the fuel inlet and outlet hoses from fuel

filter.

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.

‘Torx’ type screw driver or ratchet can be used

for removal & refitting of Torx screws fitted on
top cover.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 135
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

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.

 Always use recommended filters only.

 The fuel filters to be replaced first at 5000
kms and then at every 20000kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 136
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 FUEL TANK – CLEAN

Electronic Fuel
Feed Pump

Fuel Tank
Electronic Fuel Feed Pump
Hose - Fuel Tank
to Filler Neck

Fuel Filler Cap

Fuel Tank Guard

Fuel Lid Assembly

Schematic – Fuel Tank & Hoses

FUEL TANK – CLEAN Refer above illustration –

1. Loosen & remove the Fuel Tank Drain Plug* & drain the fuel to empty the tank.
- *If drain plug is not fitted, remove fuel tank carefully and avoid fuel wastage.
2. Remove the Fuel Tank Skid Plate by loosening & opening the mounting bolts. Loosen the
fuel tank mounting bolts.
3. Lower the tank & remove all the Electrical as well as pipe connections on the top face.
4. Remove the Electronic Fuel feed pump carefully by removing its top mounting screws.
5. Take the tank out & clean with diesel and compressed air.

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

 Do not waste the fuel.
 Check and arrest leakages through fuel hoses, if any observed after installation.
 Check for proper alignment and installation of Electronic Fuel feed pump.
 Check and confirm no leakage through electronic fuel feed pump mounting gasket and/ or any
part of fuel supply system after installation and during engine start.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 137
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –

The In Car repairs which can be carried out are:

• Removal of Injectors

• Removal of HP Pump

Refer SOP’s prescribed in Engine Repair section for above two procedures.

• Removal of the fuel tank

Refer SOP’s prescribed in Fuel System Maintenance section for above procedures.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 138
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Dismantling, Inspection & overhaul of the Fuel Injection Equipment –

The Unit Pump part of HP Pump, Injectors and Common Rail Assembly are high precision equipment.

It is recommended that they are serviced in the OEM’ dealers or their authorized workshops only,
where the necessary equipment for dismantling, testing and calibration is available along with
trained personnel.

The high-pressure fuel pipes also form an integral part of the injection system. Hence, the use of non-
genuine pipes whose lengths or thickness or inner diameter may vary from the original will adversely
influence the performance. Any one of the parameter changes affects the fuel being injected into
cylinder in terms of the quantity and timing.

The Injector sealing washer also forms an integral part of the injection system. Hence, the use of non-
genuine washers whose thickness or inner diameter may vary from the original will adversely affect
the performance.

Refer illustration for schematic of fuel system in Bolero m2DICR -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 139
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Refer below illustrations for more clarity on fuel system components & location -

FUEL TANK –

Fuel tanks are fitted with

Electronic Fuel feed pump.
To have continuous fuel
supply up to 2.5 bar to the
HP Fuel pump. Fuel feed
pump gasket is critical and
need to take care while
pump removal.

Feed pump is connected to

the HP fuel pump with
polyamide lines.

Bolero m2DICR Fuel Supply - Fuel Lines to

Schematic Fuel Filter

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 140
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Fuel Level Sensor Removal –

Pre-removal activities –
• Remove the Fuel tank from vehicle.
• Remove the electronic Fuel feed pump from fuel tank; take care and avoid damages.
• Avoid fuel wastage.

Remove the connector from cover.

Remove the lock of black color connector by

pushing it in the downward direction.

Improper pulling of the connector from the

snaps may cause damage to the connector /
wire.

Lift the snap towards front direction,

Push the frame towards down direction (force

should be applied from back side of the frame)

Remove the wires from slots.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 141
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Guide the fuel level sensor along with the path

as shown and push until the “Click” sound is
heard (locking with the snap)

Improper guiding can cause the uneven

assembly of the level sensor to the reservoir and
improper function of the fuel sensor assembly.

Assemble the wires to the slot as shown.

Assemble the connector to the cover (push the

connector until “Click” sound heard)

Assemble the Fuel Level Sensor without

dropping down.

Improper assembly may cause discontinuity/

intermittent working of the fuel level sensor.

Post installation –
• Assemble the fuel tank and fill the fuel inside the tank*
*In case of removed.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 142
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Refer below illustrations for Fuel System components -

High Pressure Fuel Pump –

HP Fuel pump has got two separate

components; Unit pump assembly is
assembled with Cam Box assembly.

Refer illustration for Cam Box Assembly –

The lubricating Oil is supplied from main oil

gallery to Cam box. The oil hose is
connected with banjo bolts on cylinder
block and Cam Box housing.

Refer cut section views for more info. -

Refer below cross sectional view for Cam Box assembly -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 143
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1
UNIT PUMP ASSEMBLY

UNIT PUMP ASSEMBLY CUT-SECTION VIEW

UNIT PUMP ASSY.

COMPONENTS

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 144
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

UNIT PUMP & CAM BOX

DISASSEMBLY – EXPLODED
VIEW

HP PUMP ASSEMBLY –

Refer illustrations for –

• HP Pump top-view and

side-view.

• Unit pump mountings and

Cam box plate mountings.

COMMON RAIL –

• It is a single piece
construction.

• No welding joints which

can avoid fuel leakages.

• Higher fuel pressures can

be operated.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 145
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Common Rail Schematic – m2DICR

Fuel Injectors –

These injectors are smaller in size; its 17mm

base body diameter. Nozzle: ISO Protrusion,
micro-sac. ‘O’ ring is provided for protecting
from rust. Phosphate type deposition has done
to protect from corrosion. These injectors are
provided with 7 holes with 620 ml/min throw
flow nozzle.

Refer illustrations for more clarification on

injector components & coding.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 146
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

1. Venturi - Functions
 It is the part of CRS Kit.
 The function of venturi is to create depression (Vacuum) at the injector back leak connection.
 Venturi connection is provided in Page no - 2.
2. Significance
• The absence of Venturi will affect the following functions.
• Shot to shot variation of the injector will be high which will lead to vibration.
• The characteristics curve of the injector will be different which will lead to wrong injector
trims learning and subsequently affects the injection quantity/FE.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 147
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Dos and Don’ts -

HP Pipe, Injector, Common rail, and HP Pump:

• Do not mix lubricating oil in fuel tank.

• Do not try for air bleeding from injector by loosening HP Pipes in CR System.
• Flushing of CR Components shouldn’t be done as it introduces dirt.
• HP Pipe shouldn’t be bent, use them according to cylinder no.
• Compulsorily follow high pressure diagnostics for CR Component investigation.
• Clean the HP Pipe fixing nuts surrounding area, by compressed air before dismantling.
• Do not remove/scratch identification sticker/marks on Injector & HP Pump.
Particularly take care while removing injector claw bolt, as the tool itself will damage I2C label if not
hold in perpendicular position to bolt.
• Do not reuse HP Pipes.
• Discard new HP Pipes if found without protective caps.
• Safeguard CR Components with protective caps in clean area, when removed for some other
engine related jobs.
• Fit back the injector in original position, when removed for some other jobs.
• If found carbon deposit on injector tip, do not replace injector. Clean it according service
information.

ECU:

• Do not remove ECU connection unnecessarily and ensure proper/firm fitment on vehicle.
• Do not replace ECU for Fault codes (DTC), go for root cause analysis.
• Record the environment details along with fault codes before erasing.
• Direct spray of pressurized water (Water wash) on ECU must not be done. Also water shouldn’t be
sprayed in engine compartment in engine hot condition.
• Software ID must be checked for relevant applications, before replacing ECU.
Do not test the vehicle with different SW ID ECU.
• Cross verify I2C values while entering for particular injector to cylinder no.
• Do not rewrite I2C values unnecessarily.
• ECU shouldn’t be disconnected while ignition is on or Engine is running.
• Do not remove any sensor connection while ignition is on or engine is running.
• Do not perform welding job on vehicle with battery & ECU connected.
• ECU shouldn’t be dropped on ground or water.
• Blown out fuses shouldn’t be reused.
• Do not cut & join the wiring harness for extra connections/vehicle accessories.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 148
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications –

COMPOENET DESCRIPTION
HP FUEL INJECTION PUMP BS3/ BS4
Features in FIP
FBB ( Lock timing bolt) Not Applicable
PLA unit (Controls the idling to the specified band Not Applicable
when the AC is switched ON)
LFG (Avoids the fuelling to become zero during gear Not applicable
changing thus improving driveabiility.)
Potentiometer (Is used to give the input of the engine Not Applicable
load to the controller for EGR)
Injector F002 C8Z 889
Identification Grey
NOP ( Nozzle Opening Pressure) 250+8 bar
Specification (No of holes x hole dia. x Spray angle 6X0.155X 150°
Nozzle holder F002C80014
Nozzle DSLA 150 P1584
High Pressure pipe (OD x Thickness x length) 6 x 1.8 x 500

• Tightening Torques –

Location Torque Value Nm(lbf-ft)

FIP Lock screw 12.5 ± 2.5 Nm (9 ± 2 lbf-ft)
All M5 nuts/ Bolts on FIP 2~3 Nm ( 1 ~ 2 lbf-ft)
High Pressure Pipe Nut 27.5 ± 2.5 Nm (20 ± 2 lbf-ft)
Injector holding clamping stud 25 ± 3 Nm (18 ± 2 lbf-ft)
Injector Overflow pipe Banjo nut 6 ± 1 Nm (4 ± 1 lbf-ft)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 149
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

EMISSION CONTROL

Contents…

• Description…………………………………………………………………………….
• Catalytic Converter………………………………………………………………
• Trouble Shooting………………………………………………...............
• Care of the System……………………………………………………………….

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 150
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The Bolero m2DICR engines meet the BS-III as well as BS-IV emission norms. For the BS-III emissions,
to control the NOx an Exhaust gas recirculation is used. Catalytic converter is also introduced in
exhaust system. For BS-IV emission, to control the NOx an Exhaust gas recalculated are cooled
through EGR cooler equipment provided in the system.

• Exhaust Gas Re Circulation – Schematic

During acceleration and in higher loads the engine generates high combustion temperatures. The
high combustion temperatures increase the NOx generation. The higher percentage of NOx
generated in the combustion chamber come out through the tail pipe in the atmosphere.

To reduce the amount of NOx coming through the tail pipe the EGR system adds exhaust gases into
the fresh air that is going into the combustion chamber. Since the exhaust, gas is already burnt hence
when mixed with fresh air acts as an inert gas. The role it does is that it reduces the amount of
oxygen available for combustion. The net effect is that it reduces the peak combustion temperatures.
This results in lower amount of NOx being generated.

To control the amount/percentage of exhaust gases to be circulated back to the combustion

chamber the ECU, which is already controlling the common rail functions, is used.

The ECU monitors the air flow, coolant temperature, engine speed, and accelerator pedal position.
Based on the above parameters the ECU operates a switch that in turn controls the amount of
vacuum going to the EGR valve. The amount of vacuum applied controls the lift of the EGR valve. The
lift of the EGR valve is sensed.

A catalytic converter is a device used to reduce the toxicity of emissions from an internal combustion
engine. A catalytic converter works by using a catalyst to provide an environment for a chemical
reaction in which toxic combustion by-products are converted to less-toxic substances.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 151
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Functional diagram of the controller Unit –

The inputs of the engine speed (from the alternator W terminal); Throttle position (from the
potentiometer) are continuously monitored. The change in throttle position is correlated in terms of
the acceleration. The water temperature input is also sensed. These 3 inputs together are fed to logic
circuit in the controller, which decides the signal for the EGR pressure modulator. The EGR system is
bi-state i.e. EGR is either ON or OFF, and no intermediate positions of EGR valve permitted. The EGR
cut-off is above a certain speed value for preventing the engine stalling at high speeds.

If the water temperature is less than 25°C or more than 95°C, the EGR will not be operated. This
prevents problems in engine cold starting and excessive smoke when the engine is operating at full
load.

Working of Catalytic Converter –

A two-way catalytic converter is used in m2DICR BSIV Engine, it has two simultaneous tasks:

1. Oxidation of carbon monoxide to carbon dioxide: 2CO + O2 → 2CO2

2. Oxidation of unburnt hydrocarbons (unburnt and partially-burnt fuel) to carbon dioxide and
water: CxH2x+2 + [(3x+1)/2] O2 → xCO2 + (x+1) H2O (a combustion reaction)

This type of catalytic converter is used on diesel engines to reduce hydrocarbon and carbon
monoxide emissions.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 152
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Refer below brief details on the Emission control system components and their function –

Accelerator Pedal Sensor

Location : In the accelerator pedal

Type : 6 wire, double track potentiometer
Function : Informs ECU about driver’s pedal
Purpose : To transmit driver’s pedal request
to ECU.

Boost Pressure And Temperature Sensor

Location : On the intake hose

Type : Piezo resistive & Thermistor
Function : Monitors the air flow
Purpose : To correct air flow map and
regulate EGR flow.

Coolant Temperature Sensor

Location : On the cylinder Head

Type : 2 wire, resistor with negative
temperature coefficient
Function : Monitors the coolant temperature
Purpose : To determine the temperature of
the engine.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 153
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

EGR Position Sensor –

Location : On the EGR valve

Type : 2 wire, resistor with negative temperature coefficient
Function : Monitors the Position of EGR valve
Purpose : ECU to Understand the opening Of EGR Valve

EGR vacuum modulator -

Location : Near Air filter

Type : Solenoid controlled vacuum modulator
Function : To supply desired level of vacuum to EGR valve
Purpose : To control EGR flow

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 154
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

OBD Lamp

Location : On the instrument cluster

Type : Tell tale lamp.
Function : Lights up when a fault related to emission is detected in engine
Management System.
Purpose : To inform the driver about engine status / fault status.

Electronic control unit [ ECU ]

Location : Behind glove box

Type : DELPHI DCM 2.5 -16 Bit
Function : Receives information from various sensors on the state of the engine /
requirements and manipulates the engine functioning through actuators.
Purpose : To run the engine as per desired mapping.

Electronic Control Unit

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 155
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

Symptom Causes Remedial action

Engine does not give full 1. Gas leak between  Change the gasket or the
power. EGR pipe joints. hose.
2. EGR pipe leak.  Change the pipe.
3. EGR valve  Check the EGR using the blink
Improper functioning. codes. Proceed appropriately.
 Ensure vacuum connections at
4. Vacuum hose vacuum modulator, reservoir,
crack, loose, and alternator.
fallen off

Noisy engine & high 1. Cylinder head gasket  Replace the cylinder head
smoke defective. gasket.
2. Worn out or damaged valve  Lap the valve seats or regrind.
seats.  Check the FIP timing.
3. FIP timing.  Tighten the injector holder.
4. Leaking injector holder.  Confirm & check Gasket
5. Leakage at EGR condition
Valve flange  Bolt torque.
face, exhaust manifold and
EGR pipe end.

Black smoke 1. EGR valve stuck Check the EGR valve using the
open blink code & confirm.

Excessive oil 1. Cracked vacuum  Check the vacuum line from

consumption line hoses the alternator to
2. Restriction in  EGR valve - check for leaks,
Crankcase breather crack. Replace cracked hoses
3. Bend/kink in any  Locate & remove restriction.
of the oil return  Check the crankcase
pipe’s/vacuum ventilation & rectify.
hoses  Change the vacuum hoses.
 Remove the bend or kinks.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 156
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System -

To meet the emission norms it is essential that the Fuel system, Air intake system & cooling system
be maintained as per the schedule. For details refer to the particular section.

If the engine is running below the optimum temperature (happens when thermostat is removed)
then tailpipe emissions in particular the particulate increases (up to 30%). Similarly a wrong grade or
poor quality of fuel increases the emissions. A blocked air cleaner or restriction in intake system
increases the emissions

EGR:

On vehicles fitted with EGR system the following additional points check have to done during
scheduled maintenance.
• Check for any exhaust gas leakage through sealing faces, EGR pipe. Formation of any black
soot indicates leakage.
• Check the vacuum hoses for any leaks, cracks.
• Retighten all nuts and bolts as per the recommend torque.

While doing the tappet clearance, in case of vehicle fitted with EGR system ensure that the EGR pipe
is not bent or overstress the pipes, elbow.

If the pipes are removed then it is essential that while fitting back new gaskets is used. Do not open
the pipe from one end only; it will cause the pipe to twist. If the EGR pipe has to be removed, then
open from both the ends.

The ECU/controller controlling the EGR operation is an electronic device. Hence it is prone to get
damaged if spikes are generated in the system.

It is advised that the following precautions be taken.

 If any welding work is being carried out on the vehicle then the battery terminals are
removed. Similarly, the practices of shorting the battery to check the battery have to be
avoided. (It can cause a spike.)
 The practice of changing battery with a running engine is also not acceptable. Again, the
resultant spike can damage the controller beyond repairs.

EGR Cooler –

 Check EGR cooler hoses and joints for leakages and arrest it if any leakage observed.
 Check for any exhaust gas leakage through sealing faces, EGR pipe.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 157
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Checking the System –

EGR System –

Do a simple check, if the EGR is functioning…

• Check if the engine temperature is between 25 to 95 degrees C.
• Remove the outlet of the vacuum modulator (connection to EGR valve).
• Check for the vacuum- there should not be any vacuum when at low speed, nor at high idle.
Check for the vacuum at around 1500 to 1800 RPM- without accelerating at steady throttle
condition.
• If no vacuum, then check for the vacuum connection, electrical connection, controller, and
modulator.

EGR Valve –

Remove the EGR valve and check it valve-sticking, deposition of carbon etc. If excess carbon deposits
and sticky valve noticed then it should be cleaned with a suitable solvent, so that the correct valve
seat is ensured.

After cleaning the valve blow air from the bottom side of the valve and check for any leakages.
To check for the functioning of the EGR valve apply vacuum on the vacuum connection of the EGR
valve. The lift of the valve at the required vacuum should be achieved.

EGR Pipe –

Remove the EGR pipe and check for gas leakage, damages etc. Clean the gasket seating area from
any carbon deposits burrs etc. Spray WD 40 rust cleaning spray on the nut.

To check the pipe for any leakages, close one end of flange and from other end blow air at two bars.
Dip the pipe in water and observe if any leakage is observed. If any leaks are observed then the pipe
has to be replaced. Do not attempt to weld/ seal the leakage joint

EGR Vacuum Modulator –

The Modulator does not require any maintenance. For any damage replace the component.

EMS ECU –

It does not require any maintenance.

However, like any ECU care has to be taken that if any welding work is being carried out on the
vehicle then ensure that the battery terminals are removed.

Similarly, the practices of shorting the battery to check the battery; has to be avoided. (It can cause a
spike.) The practice of changing battery with a running engine is also not recommended. Again, the
resultant spike can damage the controller beyond repairs

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 158
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Checking the EGR Valve –

Remove the EGR valve and check it for valve-sticking, deposition of carbon etc. If excess carbon
deposits and sticky valve noticed then it should be cleaned with a suitable solvent, so that the correct
valve seat is ensured.

After cleaning the valve blow air from the bottom side of the valve and check for any leakage. To
check for the functioning of the EGR valve apply vacuum on the vacuum connection of the EGR valve.
The lift of the valve at the required vacuum should be achieved.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 159
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

CLUTCH

Contents…

• Description…………………………………………………………………………….
• Trouble Shooting………………………………………………...............
• Care of the System………………………………………………………………
• In Car Repairs……………………………………………………………………….
• Clutch Overhaul..………………………………………………………….......
• Inspection……………………………………………………………………………..
• Specification & Wear Limit………………………………………………….
• Tightening Torques……………………………………………………………..
• Lubricants…..…………………………………………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 160
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The clutch disc is a single, dry type with cushion springs in the hub. The clutch disc’s friction material
is riveted to the hub.

The clutch cover is a diaphragm type with one-piece construction. A 240-mm clutch disc is used.

In the engaged position (when the clutch pedal is not pressed), the diaphragm spring of the clutch
cover assembly holds the clutch pressure plate against the clutch disc. This enables the engine torque
to be transmitted to the input shaft of the gearbox, without any slip / loss.

The clutch is hydraulically actuated with self-adjusting features. The complete actuation system
comprises of a clutch master cylinder with integral reservoir. The master cylinder is connected to the
clutch actuation or the slave cylinder by hydraulic pipe. The travel of the push rod results in linear
movement of the release bearing through a release fork pivoted on a ball in the clutch housing.

The clutch release bearing pushes the diaphragm spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load on the clutch plate. Steel spring straps riveted to the
pressure plate cover pulls the pressure plate away from the clutch disc. When the clamping load on
the clutch plate is relieved it slides on the splines of the input shaft away from the flywheel thus
disengaging the engine torque from the input shaft & enabling the gears to be changed.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 161
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will require a
road test to confirm that the problem exists. To find out the actual root cause of the problem the
clutch will have to be dismantled and the failed parts examined to determine the cause.

During road test, drive the vehicle in normal operating speeds. Shift the gears and observe the clutch
action. If chatter, grab, slip or improper release is experienced, remove & inspect the parts. However
if problem is noise or hard shift then the problem may not be in clutch only but also the transmission
or the driveline.

If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed (corresponding
to the gear). Keeping the accelerator fully pressed, slowly apply the brake- with your left feet. If the
engine stalls then the clutch is not slipping.

• Clutch Problem Causes –

Fluid contamination is the most frequent cause of clutch malfunction. Oil, water on the clutch
contact surface will cause faulty operation viz. Slip, grab, and judder.

During inspection check if any parts in the clutch are coated with oil or water splash from road.
Oil contamination indicates a leak at either rear main seal or transmission-input shaft. The oil leaks
from either of these areas will normally coat the housing interior or clutch cover or flywheel. Heat
buildup due to slippage between the clutch plate and the flywheel or the pressure plate can result
into the leaked oil literally getting baked. Visually this will result in a glazed residue varying from
amber to black.

Roads splash contamination will mean that the dirt water is entering the clutch housing either due to
lose bolt or torn rubber boot.

Clutch misalignment –

The clutch component i.e. the clutch plate, flywheel and the pressure plate have to be aligned with
the crankshaft and the transmission input shaft. Misalignment caused by run-outs/ warpage will
cause clutch to grab judder as well as improper release (also manifesting as hard gearshift).

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 162
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Flywheel run out –

The flywheel run-out needs to be checked whenever misalignment is suspected. Flywheel run-out
should not exceed 0.10 mm.

To measure the run-out mount the base of the magnetic dial gauge on the block. Locate the dial
gauge’s needle on the outer surface of the flywheel.

Some of the common reasons for excessive run-out are:

 Heat warpage.
 Improper machining.
 Incorrect bolt tightening
 Foreign material on crankshaft flange or flywheel.
 Improper seating on crankshaft.

Clutch cover & Disc runout –

A warped cover or diaphragm spring will result in clutch grab and / or incomplete release of clutch
plate.

If the clutch alignment tool is not used then the misalignment of the clutch plate can cause distortion
of the cover and also disc damage.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 163
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

The cover can also get misaligned due to improper tightening of the cover onto the flywheel. The
only way to avoid is that the bolts must be tightened alternatively (diagonal pattern) and evenly i.e. 2
to 3 thread a time only.

A noisy gearshift operation especially the 1st and 2nd gear can be due to clutch not getting disengaged
completely. To check it, jack up the rear axle. Lift the axle till both the wheels are rotating freely.

Press the clutch pedal completely and start the engine, the wheels should not be spinning. Now
slowly release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If
some spinning is noticed then it indicates improper lift of the pressure plate. First check the bleeding
and the pedal travel then check for the pressure plate lift.

Clutch Housing Misalignment –

The clutch housing has to be aligned with the engine so that the input shaft is aligned with the
crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It
can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also
damage the spline of the input shaft and clutch hub’s well as the clutch splines.

 Normally the clutch housing misalignment is a result of:

 Incorrect seating on the engine/transmission.
 Missing alignment dowel holes.
 Loose or missing mounting bolt.
 Mounting surfaces that are damaged/ not parallel.

To check the clutch housing misalignment bell housing run-out will also need to be checked.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 164
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Clutch slippage –

Observation Causes Remedial action

Disc facing worn out. 1. Normal wear.  Replace clutch disc

2. Clutch riding.  Replace clutch plate
3. Insufficient diaphragm  Replace clutch plate & cover
spring clamp load. assembly.
4. Faulty release  Replace , and bleed/
mechanism.
5. Vehicle being driven  Customer to be informed.
despite slipping clutch.
6. Bad driving practice of  Customer to be informed.
allowing the clutch to
slip far too long.

Clutch disc facing Leak at :  Replace seal & disc. Clean cover
contaminated with oil, 1. Crankshaft rear end oil assembly.
grease or clutch fluid. seal
 Replace seal & disc. Clean cover
2. Leak through the input assembly.
shaft
 Apply less grease. Replace clutch
3. Excess amount of grease disc. Clean cover assembly.
applied to the input
shaft splines

Clutch is running partially Release bearing carrier  Replace bearing / carrier.

disengaged. sticky.

Flywheel height incorrect. 1. Improperly machined

flywheel.  Replace flywheel in both case.
2. Excess machining done.

Wrong disc or pressure plate Use the correct parts  Replace the parts after comparison.
used.

Clutch disc/ cover or 1. Improper tightening or  Replace the parts and tighten as per
diaphragm spring warped. loosening procedure. sequence.
2. Rough handling of clutch  Replace the parts, ensure that the
plate or cover assembly rough handling is avoided

Flywheel side clutch facing Flywheel surface ,scored and  Reduce the scoring and nicks by

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 165
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

surface – torn/ nicked/ worn having light notch sand paper. Reduce if scoring
deeper.

Clutch disc facing burnt. 1. Frequent operation  Roughen the flywheel face with
Excessive glazing of the under high loads or hard sandpaper. Replace clutch plate &
flywheel & pressure plate. acceleration conditions cover assembly.
2. Frequent clutch riding by  The driver has to be alerted to avoid
the driver. repeat failure.

Clutch facing broken Improper storage- clutch  Replace.

plate dropped prior to
fitting.

Fouling marks on the torsion Improper fitment-  Rectify.

damper. assembled the wrong way
around.

Clutch grab/chatter –

Observation Causes Remedial action

Clutch disc facing Leak at :
contaminated with oil, 1. Crankshaft rear end oil  Replace seal & disc. Clean cover
grease or clutch fluid. seal assembly.
2. Leak through the input  Replace seal & disc. Clean cover
shaft assembly.
3. Excess amount of grease  Apply less grease. Replace clutch
applied to the input disc. Clean cover assembly.
shaft splines

Clutch disc / pressure plate 1. Incorrect or substandard  Replace disc and cover with the
warped. parts. correct parts.
2. Improper tightening or  Replace the parts and tighten as per
Disc facing show unusual loosening procedure. sequence.
wear
3. Rough handling of clutch  Replace the parts, ensure that the
plate or cover assembly rough handling is avoided.

Partial engagements of 1. Clutch pressure plate  Replace clutch cover & clutch plate.
clutch disc (One side worn – position setting incorrect
opposite side glazed and or modified
lightly worn.) 2. Clutch cover, spring or  Replace clutch cover & clutch plate.
release fingers bent or
distorted due to rough
handling or improper
assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 166
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

3. Clutch disc damaged or  Replace clutch plate.

distorted.
4. Clutch misalignment.  Check alignment and runout of
flywheel disc or cover.
 Replace the clutch plate & cover
assy. (if required. Correct the
alignment)

No fault found with clutch Problem related to  Further diagnosis required. Check
components. suspension or driveline engine & transmission mounting
components. insulators. U Joint, tyres, body
attaching parts.

Clutch master cylinder or Piston/ bore damaged or  Overhaul the master & slave
slave cylinder piston corroded cylinder.
jammed/ scuffing.

Tangential strap connecting 1. Incorrect driving  Advise the customer of the

the pressure plate to the practice consequences.
diaphragm cover broken.  Mostly due to tow
starting in 1st or 2nd
gear

Or
 Incorrect gear
selection

Withdrawal fork worn out Wear of the fork at pivot end  Replace the fork.
or the release bearing end

Improper clutch release –

Observation Causes Remedial action

Clutch disc warped. New disc not checked before  Check the new disc’s runout &
installation replace it.
Clutch plate is binding on the 1. Clutch disc hub splines  Replace the clutch plate.
input shaft’s splines. damaged during
installation.
2. Input shaft splines rough  Replace input shaft is severely
or damaged. damaged.
3. Corrosion or rust  Replace the clutch plate. Replace
formation on splines of the input shaft if the scaling can
disc and input shaft. not be removed.
Clutch disc-facing sticks to Vacuum may form in pockets  Drill 1/16 inch diameter hole
flywheel. over rivet head. Occurs as through rivets and scuff sand the
clutch cools down after use. clutch disc facing .
Clutch will not disengage 1. Low fluid in the clutch  Top off the fluid and check for
properly. master cylinder. leaks.
2. Air in the hydraulic  Bleed & refill the system.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 167
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

system
3. Clutch cover loose.  Tighten the bolts.
4. Wrong clutch disc.  Replace disc.
5. Clutch cover diaphragm  Replace the cover assembly.
spring bent / warped
during transmission
installation.  Fit the clutch plate correctly the
6. Clutch disc fitted hub should be facing the pressure
backwards. plate side & the flywheel side mark
towards the flywheel

Bush worn out / damaged Vibration / misalignment  Fit new bearings & check for
Clutch misalignment misalignments.

Hard gear shift -

Observation Causes Remedial action

Brake fluid less and or 1. Leaks  Replace fluid.
contaminated 2. Reservoir strainer  Stop leaks and avoid
missing contamination.
Excessive clutch pedal free Wrong adjustment or lock Adjust
plays. nut loosening
Clutch plate warpage 1. Warpage due to handling Replace
or assembly.
2. Warpage due to
misalignment.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 168
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System –

While topping up use the recommended fluid conforming to DOT 3 specifications only. Avoid mixing
different brands.

The clutch fluid is hygroscopic fluids hence tend to collect humidity. The humidity along with the
brake fluid can cause acidic reaction & seizure of the master & slave cylinders. The clutch fluid should
be replaced every 30,000 km or one in a year, whichever is earlier. The master & clutch cylinder seals
to be replace every 50,000 Kms.

Refer procedures given below while doing scheduled maintenance of the Clutch System -

• CLUTCH FLUID LEVEL & LEAK – INSPECT

• CLUTCH FLUID – REPLACE

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 169
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 CLUTCH FLUID LEVEL & LEAK - INSPECT

Clutch Fluid – SAE J1703 FMVSS No.116 DOT 4 or IS 8654 Type-2

Clutch Master
Cylinder with
Reservoir MAX
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 –
CASTROL UNIVERSAL BRAKE FLUID “CUBE” or TVS Girling DOT3.
 Do not mix different brand fluids.
 Clutch fluid level and leak to be inspected at 5000, then at every 10000 kms.
 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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 170
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 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, & then at every 30000 kms.
 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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 171
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –

• Adjustment of clutch pedal height

• Clutch bleeding.

Adjustment of clutch pedal height –

Loosen the lock nut of master cylinder’s push rod

fork.
Slide back the dust cover.

Rotate the master cylinder push rod till desired

height of pedal is achieved.
Tighten the lock nut of push rod fork.
Screw in pedal stopper bolt completely.
Press pedal fully till the pedal bottoms on the floor.
Now screw out the pedal stopper bolt till it touches
the pedal lever, release pedal.
Screw out the bolt further by one turn. Tighten the
locknut.
Recheck pedal height.

Bleeding the clutch system –

Clean the external areas of the clutch slave cylinder

and remove the dust cap of the bleeder screw.

If the bleeding operation is done by without

connecting by a tube and in the open air then the
chance of air remaining trapped is high.

Connect bleeding tube, to bleeding screw on slave

cylinder.

Ensure that the other end of the tube is fully

immersed in the bottle having clean clutch /brake
fluid.

Fill the Reservoir clutch master cylinder up to the top

level with recommended clutch fluid.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 172
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Operate clutch pedal 3 or 4 times slowly to the full

stroke.

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.
Repeat the exercise till no air bubbles appears in the
bottle.

During this operation ensure fluid level in reservoir.

Tighten the bleed screw properly.

Remove bleeding tube and place the dust cap o bleed

screw.

Check the fluid level in container and need be top up

to the ‘max’ level.

Clutch Actuation Mechanism –

The clutch actuation is hydraulic actuation. The clutch pedal actuates a master cylinder. The hydraulic
fluid is transmitted to the slave cylinder through Bundy tubes.

The slave cylinder actuates a fork, which is pivoted on a ball pivot. The other end of the fork; a
release bearing on a carrier actuates the diaphragm springs.

1. Clutch Master Cylinder overhaul

2. Slave cylinder overhaul.

3. Slave cylinder and Concentric bearing Overhaul

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 173
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

1. Clutch Master Cylinder overhaul –

Remove the outlet pipe connection.

Remove the clevis pin lock & the clevis pin.

Remove the clutch push rod fork & the clutch pedal.
Remove the master cylinder from the firewall.

1. Pull back the dust cover.

2. Remove circlip.

3. Remove the push rod assembly with

retainer washer.

4. Remove the piston assembly by gently

tapping the Clutch Master Cylinder body
on a wooden block.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 174
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Using a screwdriver, lift the leaf spring retainer.

Remove spring assembly from plunger.

Take care, while lifting the spring otherwise the spring

and the stem will fall off.

Compress spring to free valve stem from eccentrically

positioned hole in the end face of spring retainer. This
will separate spring retainer from valve stem.

Remove spring, valve spacer and spring washer from

the valve stem.
(While assembling hold the spacer between fingers
such that the valve stems hangs down vertically. Pull
down the stem downwards as far as possible. Observe
if the valve stem has moved freely upwards. If
movement is not free replace valve spacer.)

Remove the valve seal from the valve stem.

The bore and the plunger should be checked for

scoring, scuffing uneven wear marks, corrosion and
excessive clearance between plunger & body
Check the condition of dust cover for cut,
deterioration if damaged replace.
The assembly procedure is the reverse of the
dismantling procedure.
While fitting the plunger lubricate it with brake fluid.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 175
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

2. Slave cylinder overhaul –

Remove the Bundy pipe from the inlet port of slave

cylinder.

Remove the slave cylinder from the mounting bracket.

1. Remove dust cover.

2. Remove circlip.
3. Remove plunger with gland seal and plunger spring from body by lightly tapping it on wooden
block.
4. Remove gland seal from plunger.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 176
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

The bore and the plunger should be checked for

scoring, scuffing uneven wear marks, corrosion and
excessive clearance between plunger & body
Check the condition of dust cover for cut,
deterioration if damaged replace.
The assembly procedure is the reverse of the
dismantling procedure.

While fitting the plunger lubricate it with brake fluid.

Make sure that the push rod end is firmly located at

the fork.

Clutch overhaul –

Block the front wheels, so that the vehicle does not

move forward.

Disconnect the negative cable of the battery.

Remove the electrical connections to the starter

motor.

Remove the starter motor.

Remove the clutch slave cylinder from the gearbox

mounting.

Remove the propeller shaft from the gearbox end.

Do not allow the propeller shaft to hang. Support it.

Remove the speedometer cable from the gearbox

end.
Remove the electrical connection for the reverse
lamp switch.

Support the engine suitably at rear.

Remove the gearshift lever grommet.
Remove the gearbox lever upper half.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 177
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Support the gearbox using a suitable stand.

Remove the gearbox mounting insulators.
Remove the clutch housing mounting screws to the
engine rear face & the ladder frame.
Move the gearbox away from the engine.
Remove the clutch release bearing with sleeve.
Remove the clutch fork.

If the original cover will be reinstalled then mark

position of cover on the flywheel for assembly
reference. Use paint as a marker for this.
If the cover assembly may be reused then loosen the
cover bolts evenly and in tightening sequence to
relive the spring tension equally.
The bolts should be loosened few threads at a time –
so that the warping is avoided.
If the cover assembly is not going to be reused then
this precaution is not essential.
If the pilot bearing has to be removed then the
flywheel has to be removed and then the bearing
removed.

The assembly sequence is the reverse of the dismantling (except the precautions mentioned.)

Inspection:

All the components should be inspected for wear. Any components, which are beyond the wear
limits, have to be replaced.

Over & above the wear limits: The following points also need to be ensured.

Flywheel run-out --

The flywheel run-out needs to be checked whenever misalignment is suspected. Flywheel run-out
should not exceed 0.10 mm

To measure the run-out; mount the base of the magnetic dial gauge on the block. Locate the dial
gauge’s needle on the outer surface of the flywheel.

Some of the common reasons for excessive run-out are:

 Heat warpage.
 Improper machining.
 Incorrect bolt tightening
 Foreign material on crankshaft flange or flywheel.
 Improper seating on crankshaft.

If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it
back ensure that:

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 178
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 No dirt and grease present on the mounting face (it can cause cocking & run out)

 The flywheel bolts have been replaced.

 Torque tightened as per sequence and also the angular tightening as per the specification is
done.

Absence of any of these requirements may result in bolt loosening causing flywheel runout.

Clutch cover & Disc runout --

Check the clutch disc run-out before fitting. It should be within the specifications. If it is more than
the specification- use a different clutch plate.

A warped cover or diaphragm spring will result in clutch grab and / or incomplete release of clutch
plate.

If the clutch alignment tool is not used then the misalignment of the clutch plate can cause distortion
of the cover and also disc damage.

The cover can also get misaligned due to improper tightening of the cover onto the flywheel. The
only way to avoid is that the bolts must be tightened alternatively (diagonal pattern) and evenly i.e. 2
to 3 thread a time only.

Clutch Housing Misalignment –

The clutch housing has to be aligned with the engine so that the input shaft is aligned with the
crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It
can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also
damage the splines of the input shaft and clutch hub’s well as the clutch splines

 Normally the clutch housing misalignment is a result of:

 Incorrect seating on the engine/transmission.
 Missing alignment dowel holes.
 Loose or missing mounting bolt.
 Mounting surfaces that are damaged/ not parallel.

Before fitting the clutch housing ensure that no dirt, debris or foreign parts are trapped between the
mating surface of the transmission & the clutch housing.

Flywheel --

If the flywheel is found to be having minor scoring then it can be resurfaced. However the maximum
allowed cut is 0.076 mm. If scoring is deeper than 0.0076 than the flywheel has to be changed.
(Excessive material removal will cause the flywheel to either crack/ warpage after installation/ drop

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 179
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

in clamping load and will affect the proper clutch release as the travel of release bearing gets
affected.)
If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it
back ensure that:

 No dirt and grease present on the mounting face (it can cause cocking & run out)

 The flywheel bolts have been replaced.

 Torque tightened as per sequence and also the angular tightening as per the specification is
done.

Absence of any of these requirements may result in bolt loosening causing flywheel runout.

Starter/ flywheel ring replacement: Unless the provision of properly heating & fitting is available. It
is not recommended to replace the starter ring. It is worthwhile to replace the ring along with the
flywheel.

If the starter ring is only going to be replaced then:-

• Do not use a gas flame to cut. It can cause local overheating of flywheel.

• The ring gear has to be heated in an oven to get uniform expansion. (Nearly 191°C)

• Do not uses flame to heat the ring – it can cause annealing of the ring teeth and premature
failure.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 180
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications & Wear Limits –

Figure Description Value

Clutch control type- Hydraulic- self adjusting

Pressure plate Diaphragm

Clutch Disc Progressive

Outer Dia (mm) 240 ±1
Inner Dia ( mm) 160 ± 1

Disc Thickness ( mm) 8.0 mm (free)

Clutch disc run out --
Minimum thickness from 1 mm
outer face to rivet head.

Clutch pedal Suspended Type

Clutch pedal Ratio 7.12

Clutch pedal free play ( 10 to 20 mm

including push rod play at
pedal top)

Master Cylinder 19.05 mm

Bore diameter

Slave Cylinder 23.81 mm

Inner diameter

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 181
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Clearance between 0.13 mm

The piston & the bore
( Both cylinders)

Flywheel Standard Service

Limit
Flatness ≤ 0.05 0.1
Runout ≤ 0.05 0.1

Flywheel
Width from Mounting face to 72 mm
clutch face
Clutch release point from
pedal full stroke end position 25 mm from Bottom position
Pressure plate finger height ( 47.6 ± 1.0 mm
mm)

Diaphragm spring tip non 0.8 mm ( finger to finger)

alignment.( Max)

Diaphragm spring finger wear Max depth 0.5 mm

Max width 5 mm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 182
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tightening Torque’s –

Location Torque Value

Pressure plate bolts 23.5 ± 3.5 Nm (17 ± 3 lbf-ft)

Hydraulic clutch Bundy tube connections pipes 15 ± 1Nm (11 ± 1 lbf-ft)
Clutch master cylinder mounting nut 18.5 ± 3.5 Nm (14 ± 3lbf-ft)
Clutch slave cylinder bolts 37.5 ± 2.5Nm (28 ± 2lbf-ft)
Flywheel Bolts 95 ± 5Nm ( 70 ± 4 lbf-ft)
Clutch pedal pivot bolt and nut 27.5 ± 2.5 Nm ( 20 ± 2 Lb-ft)

• Lubricants Recommended –

Specification: DOT 4/ SAE J1703

Replacement interval: First 30,000 kms and then 40,000 kms.

Castrol Brake Fluid

Hindustan Petroleum: HP Super Duty Brake Fluid

Indian Oil: Servo Brake fluid Super HD

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 183
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

TRANSMISSION (NGT 520)

Contents…

• Description………………………………………………………………….
• Trouble Shooting…………………………………………………………..
• Care of the Transmission…………………………………………………
• In Car Repairs………………………………………………………………
• Transmission Dismantling…………………………………………………..
• Transmission Component Inspection…………………………………….
• Sub-assemblies……………………………………………………………….
• Assembly Inspection…………………………………………………..

• Specification………………………………………………………………..
• Tightening Torques………………………………………………………..
• Sealant Recommendation………………………………………………..
• Special Tools……………………..…………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 184
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description –
It is a 5-speed gearbox. All the forward speed is synchromesh type. The reverse gear is having sliding
mesh type.

The gear selection is by a direct shift lever tongue operating in between shift rail gate. The accidental
operation of two gears is avoided by an interlocking mechanism. To avoid vibrations passing on to
the shift lever, the shift lever is a two-piece with rubber isolation provided on to the top half.

The gearbox housing is tunnel type Cast iron with an intermediate plate. The Gearbox is mounted
directly on the engine through the integral clutch housing and supported at bottom below the rear
housing. The output shaft is fitted with companion flange which is bolted to propeller shaft in case of
2 wheel drive. If vehicle is equipped with 4 wheels drive the output shaft is splined and is mated to
the transfer case.

Refer illustrations of –

1. NGT520 transmission cross sectional view of 2WD.

2. Synchroniser pack assembly cross section view used in NGT 520 Transmission.

CLUTCH HOUSING INTERMEDIATE

PLATE
SHIFT LEVER
MAIN DRIVE SHAFT SYNCHRO PACK
RD TH
RELEASE 3 &4 4TH
BEARING SLEEVE SYNCHRO
ST
PACK 1 &
BREATHER ND
2 REAR HSG. ASSY.
FRONT
HOUSING COMPANION
FLANGE

SYNCHRO TH
ST 5 REVERSE
COUNTER SHAFT PACK 1 &
SUB-SHAFT
2ND

NGT 520 TM (2WD) Cross-sectional View

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 185
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

SYNCHRONIZER
Synchronizer ASSY.Cross
Pack Assembly – NGTSection
520 View

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 186
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Service Diagnosis / Trouble Shooting –

A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an
incorrect lubricant level check.

Leaks can occur at the mating surface of the gear case, intermediate plate and adapter or extension
housing or from the front/rear seals. A suspected leak could also be result of an overfill condition.

Leaks at the rear of the extension or adapter housing will be from the housing oil seal. Leaks at
component mating surface will probably be the result of inadequate sealer, gaps in sealer, incorrect
bolt tightening, or the use of a non-recommended sealer.

A leak at the front of the transmission will be from either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is
severe, it may also contaminate the clutch disc causing slip, grab and chatter.

A correct lubricant level check can be made only when the vehicle is level, use a two post or a four
post hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These
recommendations will ensure that an accurate check and avoid an under fill or overfill conditions.

Hard Shifting

Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants,
component damage, and incorrect clutch adjustment or by a damaged clutch pressure plate or disc;
or worn out brass synchro ring.

Substantial lubricant leak can result in gear, shift rail, synchro and bearing damage. If a leak goes
undetected for an extended period the first indications of a problem are usually hard shifting and
noise.

Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear, internal bind and hard shifting.

Improper clutch release is one of the most frequent causes of hard shifting. Incorrect adjustment of a
worn damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced
then gear clash during shifts can be resulted. Incomplete travel of the clutch pedal due to restrictions
at the end of stroke (upturned carpet, extra carpet or cover or bend clutch linkage can also cause
improper clutch release and hard shift.)

Worn or damaged synchro rings can cause gear clash when shifting any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In
most conditions this will decline as the rings wear in.

Transmission noise

Most manual transmissions make some noise during normal operation. Rotating gears can generate
slight whine that may only be audible at extreme speeds.
Severe obviously audible transmission noise is generally the result of a lubricant problem.
Insufficient, improper or contaminated lubricant can promote rapid wear of gears, synchros, shift
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 187
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

rail, forks and bearing’s. The overheating caused by a lubricant problem can also lead to gear
breakage.
Summarizing the common faults and their cause:

PROBLEM POSSIBLE CAUSES CORRECTION

Gear Whine • Low oil level  Top up oil.
• Worn teeth gears  Replace gears
• Worn bearings  Replace bearings.

Knocking or ticking • Chipped gear teeth  Replace gears.

• Foreign matter inside  Remove the foreign matter
transmission. and locate how the foreign
matter came inside e.g.
missing breather and rectify
that also to avoid recurrence.
 Replace the bearings.
• Defective bearings.
Jumping out of gear • Defective detent springs.  Replace the detent springs.
• Worn out grooves in shift rail.  Replace the shift rails.
• Shaft misalignment.  Check & Correct it.
• Worn dog teeth in gear  Replace the gears
• Worn out fork/ fork pads  Replace the fork/ pads
• Worn out synchronizer body.  Replace the body
• Gear lever fouling.  Check & correct.
• Bottom lever slot worn out.  Replace bottom lever.

Unable to select gear • Clutch defective  Rectify the clutch/ clutch

withdrawal mechanism
• Worn out selector mechanism.  Rectify the gear selector
mechanism.
• Worn out brass synchro ring.  Replace synchro ring.
• Gear clutch teeth damaged.  Replace gear.

Hard gear shifting • Clutch defective  Rectify the clutch/ clutch

withdrawal mechanism
• Improper or contaminated  Replace the lubricant with the
lubricants specified lubricant.
• Worn out brass synchro ring.  Replace synchro ring.
• Gear clutch teeth damaged.  Replace gear.

NOTE:
• Transmission assembly steps given below consist of Problems, Causes and Precautions while
assembling of sub components and main assembly.
• For more details on various problems and probable causes refer the assembly procedure section
prescribed in this manual.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 188
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the Transmission –

Use lubricant meeting oils specification of API GL4 and viscosity 80W90 Synchro. Recommended
brand name is MAXIMILE GO 80W90 Synchro. Recommended fluid replacement interval first is
10000 kms, then every 30000 kms. The fluid capacity/ quantity in NGT520 Transmission are 2 Liters.

TRANSMISSION OIL – REPLACEMENT PROCEDURE

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.

CAUTION: While replacing the transmission fluid ensure that –

• Vehicle is parked on level ground/ 2 post/ 4 post lift.

• If the activity is done on a 2 post lift and vehicle is fitted with LSPV, 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 completion.
• The lubricant level should be at the lower edge of the filler plug.
• The filler plug and drain plug on NGT 520 TM to be tightened to 27.5 + 2.5 Nm.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 189
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –
Rear Oil Seal Replacement –

• Remove the Rear propeller shaft from

companion flange*

( Only rear propeller shaft in case of 2 wheel

drive vehicle)

• Refer section ‘ removal and installation of

propeller shaft’

• Remove the Speed sensor* from Transmission assembly (*optional)

• Remove the Locking nut from companion flange assembly. Hold the companion flange
while removing nut.
• Remove washer form companion flange.

• Remove the companion flange from

Transmission assembly.

• Use flange puller in case it found jam.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 190
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Remove dust cover.

• Remove rear oil seal using tool.

• Always replace with a new seal once it has been removed.

Installation –

• Before installation apply multi-purpose grease to lip of oil seal.

• Install new seal, press until it stops.

• Refit propeller shaft assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 191
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Gear Position/ Gear Neutral Switch Check -

Micro hybrid vehicles are equipped with ‘STOP START’ system. The Gear neutral Switch is located on
the Adaptor Pivot Plate. Refer illustration below.

• Check continuity, refer below chart.

Switch Gear Position Continuity

Reverse Yes
Reverse lamp switch
Except Reverse No
Neutral Yes
Neutral Position Switch
Except Neutral No

Neutral switch should be fitted with 6 mm gap with sensor; Sensor is fitted on bottom gear
lever.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 192
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Transmission Rear Insulator Removal –

NGT 520 Transmission

(2WD)

Rear Insulator

Cross Member below

transmission

• Before separating the transmission from the engine, remove the crankshaft position sensor
(OBD) from the clutch housing.
• Support transmission while removing it from vehicle.
• Remove battery –ve terminal.

• To prevent oil spills, drain transmission oil before removing transmission.

• Ensure and take care of rear oil seal while removing propeller shaft.
• Lift vehicle on four post.
• Remove battery terminal.

• Remove Clutch Slave Cylinder from clutch

housing.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 193
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Remove Gear Neutral switch connector*

from transmission.

• Remove reverse light switch connector on

TM assembly.

Refer illustration for locations of Reverse light

switch on NGT 520 Transmission.

• Disconnect and remove speedo cable from

speedo sleeve fitted on Transmission.

• Remove starter motor from transmission.

• Remove Rear propeller shaft.

• Remove gear knob and shift lever- upper part.

• Remove insulator below TM and the Cross member below the TM assembly.

• Support to the TM assembly bottom side for safety purpose and to avoid TM damage.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 194
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Support engine by placing a jack under oil pan; before removing Bell housing mounting bolts.
• Do not place jack under oil pan drain plug.
• Remove bell housing mounting bolts and separate transmission from engine.

• If vehicle is equipped with 4 wheel drive, ensure to –

• Disconnect and remove four wheel drive

Shift link.

• Put tray below the transfer case, remove

drain plug to drain the Transfer Case oil.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 195
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Disconnect and remove the speedometer

cable connector on Transfer case.

• Disconnect and remove the front propeller

shaft.

• Remove the transfer case insulator by

removing its mounting bolt.

Put spanner through cross member hole to

access the mounting bolt of insulator.

Support to the TM assembly bottom side for

safety purpose and to avoid TM damage.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 196
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Transmission Case Components –

• Transmission Gear Components –

• Main Drive Gear –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 197
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Main Shaft Drive Gear & Synchronizer–

• Counter Lay Shaft Gear & Synchronizer –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 198
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Shift Control Components -

PLUNGER

POPPET PLUG

• Selection Biasing and Shift Lever Components –

• Transmission Components Disassembly –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 199
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

NGT 520 2WD Assembly

SCHEMATIC OF NGT 520 TM DISASSEMBLY

• Remove Clutch release bearing and fork.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 200
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Remove clutch housing from transmission

assembly.

NOTE:
• Use mallet for slight tapping on bell housing
while removing from transmission.

• Remove the bellow and bottom lever

mounting bolts.

• Lever and locating pin removal.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 201
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Use a lengthy screw driver and put gear in

neutral position for ease of removal of gear
components.

• Remove the Speedo gear along with adaptor.

• Remove Companion flange lock nut and

washer.

• Remove the companion flange from

Transmission end.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 202
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Rear housing Removal -

• Rear housing should be in straight position

while removing.
• To avoid oil spillage, check and drain
remaining oil residuals from housing.
• Be careful not to damage of rear oil seal.

Front housing removal –

• Remove the counter shaft front bearing

spacer.
• Remove Circlip, Bellevelle washer, Snap ring
and Adjuster shim from end of MD Gear
assembly.
• Remove front release brg. Sleeve.
• Use brass hammer while removing the front
housing from intermediate plate.

• Remove 5th drive gear bearing using puller. Remove Shim and Spacer.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 203
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Remove 5th gear driving gear by removing roller bearing, using Special tool.

• Move sub shaft in forward direction.

• Reverse gear fork to be taken forward and
remove Circlip and bearing using puller.
• Remove 5th driven gear with bearing.

Remove 5th and Reverse hub assembly -

• Be careful not to lose pin, shifting inserts.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 204
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove poppet plug fitted on intermediate plate and shaft rail assembly of 5th and reverse.

• Be careful not to lose ball & spring while removing shaft and rail assembly.

• It is differ as in 2WD and 4WD.

• Output shaft in 4WD provided with lock nut where as in 2WD it is plane OD.
• Output shaft in 4WD is having splines throughout the shaft where as in 2WD it is fitted with
companion flange.

Removal of Shift Rail and Fork assembly -

• Remove insert pin using dolly.

• Remove fork shaft by hand.
• Remove insert pin on 1st/2nd shift rail.
• Remove fork shaft by hand, use mallet if required.
• Remove fork on 3rd/4th and 1st/2nd

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 205
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• 2WD output shaft is having Companion

flange and nut fitment arrangement at the
shaft end.

• Take out reverse gear from output shaft

 Sub-Plate and Drive Shaft Removal –

• Remove sub plate fitted on intermediate plate assembly.

(It is located on output shaft side).

• Remove circlip on output shaft main bearing.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 206
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Separate drive shaft from intermediate plate -

• Use mallet to remove the main drive shaft

from intermediate plate.

• Remove main drive gear assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 207
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Remove counter shaft bearing and cone from

intermediate plate. Use puller, refer
illustration.

• Remove main shaft main bearing using puller.

MD Gear dismantling –

• Remove synchro ring.

• Remove circlip and bearing using tool.
• Remove roller bearing by hand.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 208
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Main Shaft Drive Gear & Synchronizer dismantling –

• Separate Counter shaft from Intermediate

plate.

• Counter shaft front bearing can be removed by

using bearing puller.

• Counter shaft rear bearing can be removed by

using bearing puller.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 209
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Remove the circlip.

• Remove the Hub assembly.

• Be careful not to lose synchro key.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 210
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Transmission Components Inspection –

1. Shift Control Rod and Fork Inspection:

• Check contact and sliding surfaces of Shift Rod and Fork for wear, scratches and damage if any.

2. Gear Components Inspection:

• Check gear shafts for cracks, wear and

bend if any.

• Check gears for excessive wear, cracks,

tooth breakage and chips if any.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 211
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

3. Synchronizers:

• Check splines portion of coupling sleeves,

synchronizer hubs, and gears for wear,
chips, and cracks.

• Check shifting synchro key for wear and

deformation.

• Check synchro key C-spring for

deformation.

4. Bearings:

• Ensure that all bearings are roll freely.

They are free from noise, cracks, wear
and pitting.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 212
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Transmission Components Assembly –

• Assembly of the Transmission is the reverse of its disassembly. While assembling following care
should be taken.

• Ensure that front housing, intermediate plate and all components are free from dirt, dust before
assembling.
• Transmission bearings life will reduce in case use of unclean gear components used.
 Assembling Synchronizers (Strut type) -

• Ensure fitment of both sides.

• Check all three key for proper fitment.
• Ensure free movement of hub & sleeve.
• Ensure proper C-spring fitment.

 MD Gear Sub assembly -

• Ensure circlip groove on the bearing to be on

the top side. Refer illustration.
• Circlip to be assembled after bearing fitment.

NOTE:
• In case circlip is missing/ not fitted properly;
excessive play in MD gear will be observed
which can lead to gear slippage.

 Counter Shaft Sub assembly -

• Ensure direction of inner race as shown in

illustration.

• Press bearing as shown in illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 213
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Press bearing to the full depth.

• Maintain run out of counter & sub-shaft within 0.05 mm. (extended countershaft with subshaft)
• Mark counter & sub-shaft with marker on spline end for matching at which the run out is within
specification.

• If run out in counter sub-shaft pairing is not maintained then 5th gear slippage can take place.

 Intermediate Plate assembly -

Bearing installation in intermediate plate-
• Main shaft ball bearing installation in intermediate plate.

• Ensure counter shaft bearing is pressed such that bearing should be flushing with the rear face of
the plate.
• Ensure torque on M10 bolts for idler shaft. Torque value 43 ± 7 Nm.

•In case Idler shaft is not fitted properly or not torque as per recommended value, the 5th gear
failure issue may come, or 1st gear teeth will foul with idler shaft.
• Insufficient bearing pressing can restrict lever to and fro movement/ gear slippage may occur.
• Over torque or under torque to the idler shaft bolt may lead to reverse gear failure due to
support loosening.
 Front housing sub assembly -
• Ensure that rail end caps are fitted.
• Ensure that dowel slot is inside while entering into front housing.
• Ensure that dowel is pressed fully.
• Place the filler plug.
• Ensure that rail and cap flushed with housing cap.

• If end cap not fully pressed then dust can go inside the tm before clutch housing fitment.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 214
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Bearing Retainer/ Clutch Release Bearing Sleeve Sub Assembly -

• Ensure that oil seal direction is correct before

assembly.
• Ensure proper pressing and fitment of oil seal.

• In case oil seal not fitted properly or gets

damage while fitting, the oil leak complaint
may come.
• Apply oil on seal lip for initial lubrication
purpose.

5th Reverse Hub Sub assembly (Double DOP) –

Do entire assembly of 5th/Rev hub on press fitted hub along with sub shaft or do separate sub
assembly of 5th/Rev hub & then press it on sub shaft.

In case assembly is not proper, hard shifting or reverse gear failure may occur.

• Match the sleeve in hub with respective

direction. (Plain side of sleeve & grooved side
of hub on upper side.

• Insert three struts. Small length on rev side &

big length on 5th side.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 215
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Insert the C-SPRING covering all three struts.

• Place the BELLE VELLE WASHER in hub with

tapper angle down side.

• Place the PROTECTOR & fix the circlip by

hammering using dolly.

• Rotate entire assembly on opposite side i.e.

5th side & fix the C-SPRING.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 216
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Check the entire assembly for the fitment.

• Use Double DOP hub having groove on OD.

• In case synchro key is missing or fitted in wrong direction, no shifting will takes place or synchro
will damage in running.
• If sleeve is fitted in opposite direction, no shifting will takes place.
• In case C-spring missing or if it is not covering one key, crash shifting occurs.
• If belle velle washer is missing gear box noise may come.
• Gear box will jammed in case of circlip is missing.

 Speedo Sleeve Sub Assembly –

• Ensure proper direction of oil seal during assembly.

• Ensure proper pressing of oil seal.

• In case oil seal is not pressed properly or damages while assembling, oil leak issue may occur.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 217
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Rear Housing Sub Assembly –

• Tighten the drain plug with nut runner & torque with wrench - (27.5 ± 2.5 Nm)
• Use freudenkeg seal (brown colour) for sub assembly & locate it on floating dolly for pressing.
• Check and ensure circlip for proper fitment.

• Ensure proper direction of oil seal.

• Ensure bearing for fully pressed.
• Ensure oil deflector below the outer race of
cylindrical roller bearing.
• Ensure dowel for pivot fitment.

• Oil leakage takes place in case oil seal is missing or seal lip is damaged or cut.
• Over torque to the drain plug lead to crack on rear housing drain plug side and oil leak start.
• Under torque to the drain plug lead to drain plug falling off and oil leaks.
• If circlip is missing or not fitted properly, 5th driven gear & outer race will come out and get
damage.
• Gear box noise may come in case bearing outer race is missing.

 Output Shaft Sub assembly -

• Put output shaft spline side into fixture.

• Fit the needle cage, put the oil drops and fit
the 3rd gear. Fit the brass ring over it.
• Fit the hub into the spline. Ensure the
direction of hub, refer illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 218
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Put the BELLE VELLE washer and fix the circlip

on it.
• Use oil on cone of brass ring.
• Check snap ring for its proper sealing using
the gauge provided. Paint mark on the shaft
after checking.

• If 3rd gear circlip is not fitted properly, circlip

will come out resulting in lever too & fro
movement and 3rd gear slippage.

• In case of 4 WD, the output shaft will have internal threading.

• Ensure end play of 0.175 - 0.375 mm in 1st, 2nd and 3rd gear; in case wrong shims put or shims
missing, 1st/2nd or 3rd/4th gear slippage may occur.
• Ensure brass ring placement on each 1st, 2nd and 3rd gear.
• Ensure proper direction of bearing. (Snap ring groove should be above, away from 1st gear)
 MAIN ASSEMBLY -

 Power Train Assembly -

• Put MD Gear into fixture.
• Place the pilot bearing in MD Gear / Input
Gear.
• Apply grease to the pilot bearing.
• Insert 4th gear brass ring on MD Gear.

• Ensure that MD Gear and output shaft are

free.
• Put counter gear sub assembly on fixture.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 219
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Adaptor Plate/ Intermediate Plate and Bearing Retainer Plate Fitment -

• Ensure that the pilot bearing is fitted.

• Put locator on counter gear and then fit the
intermediate plate by tapping on plate.
• Ensure that the bearing is flushes with the
rear face of the adaptor plate.
• Ensure that the snap ring fitment before
placing the bearing retainer plate.

• Apply ANABOND 111 sealant on M8 bolts.

• Torque value for retainer plate bolt is 31 ± 4
Nm.

• Ensure fitment & torque tighten of 4WD lock nut over reverse driven gear @ 60 ± 10 Nm. (Ensure
spacer sleeve fitment in 2wd models)
• Ensure circlip fitment under 5th driven gear in 4wd models
• Ensure crimping of nut with hammer & dolly.
• If snap ring is not fitted or bolts are not torque properly, crash shifting may occurs.
 SRSF Fitment -

• Ensure that Reverse driven gear is placed

before 1st/2nd rail is inserted.
• Put the grease before 3rd/4th interlock plunger
is placed.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 220
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Fix the fork and insert 1st /2nd rail.

• Fix the ball and insert 3rd/4th rail.
• Press the 1st/2nd split pin. Ensure that 1st/2nd
split pin is not fouling with 3rd/4th rail.
• Ensure that 1st & 2nd split pin flushes with fork
boss.
• Ensure that both pins are pressed.
• Insert the plunger.
• Insert 5th & Reverse fork along with 5th &
Reverse synchro assembly and Reverse sliding
gear.
• Ensure ball and spring insert after 5th/Reverse
rail assembly.

• Tighten the vibra-seal 516 pre coated puppet plugs & torque (25 ± 5 Nm) with use of angle nut
runner.
• In case of 4WD Transmission, put nut above reverse driven gear and torque tighten it.
• In case of 4WD Transmission, put snap ring above 5th gear and circlip below 5th driven gear.

• Shifting will not happen in case split pin not pressed.

• Crash shifting will occur if split pin is fouling.
• In case of ball & spring missing the shifting will be effortless and gear slippage issue may occur.
• In case of brass ring in 5th/reveres synchro assembly is missing, 5th crash shifting may occur.
• In case of no torque/ less torque to puppet plugs may lead to gear slippage; and high torque may
lead to thread slippage and then gear slippage.
• Puppet plug sealant application missing will lead to fluid leakage through poppet plug.
• In case 1st/2nd pin fouling with 3rd/4th hard shifting may occur.
• In case pin is partial pressed or missed out or pin direction is wrong, gear slippage will occur and/
or gear will not shift or double gear engagement will occur.
• If fork is tight in rail, gear shifting will not happen.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 221
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Use mallet to check and ensure that double

shifting is not taking place.

• If there is no gap at the rail end, it may foul

and hard gear shifting may happen.

• Apply sealant LOCTITE – 574 on front

housing face.

 5th Gear Pair Assembly -

• Put roller bearing on 5th driven gear.

Ensure cone is on bottom side.
• Ensure fitment of brass ring below 5th
driving gear.
• Match the 5th gear couple and press it.
• Ensure output shaft sleeve is not rotating
freely after pressing 5th driven gear.
• Ensure placing of spacer on 5th driving
gear and sub shaft.

• Use 5th driving gear without worm for 4WD Transmission.

• Ensure circlip fitment on gear in case of 4WD Transmission.
• If 4WD circlip is not used then it may lead to gear slippage/ seizure.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 222
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Front Housing Tunnel Insertion -

• Ensure that loctite-574 is applied on front

housing face.
• Ensure ball and spring insertion in the
detent holes.
• Ensure torque tighten both the poppet
plugs.
• Ensure intermediate plate is located in
place.
• Put the assembly in front housing; tap the
intermediate plate if required.

• If sealant not applied properly Oil leakage

issue may come.

• Gear shifting problem-Synchro ring

damaged during insertion/improper
insertion.

 Rear Housing Shimming – (In case Housing is being replaced with new)

• Tighten 2 bolts to clamp front housing

and plate.
• Ensure that the front housing bottom face
is resting properly on the locating faces.
Use filler gauge of 0.05 mm to confirm no
gap. Gauge should not pass.
• After shimming put the ball bearing on
sub shaft & press with impact of dolly.
Shim selection procedure:
Dimension B= Intermediate plate face to Sub
shaft collar face.
Dimension A= Rear Housing face to lower
face of bearing bore.
Shim size =A - B -( 0 to 0.120 mm)

• Gear slippage will take place if Shim/spacer or both are missing.

• Gears jam/ not engage /bearing seizure will take place if Shim selection is not proper.
• If rear housing with bracket not used then wire routing on vehicle can't be done.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 223
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Rear Housing Insertion on Main Assembly -

• Ensure torque on M10 bolts - 8 numbers. - 55 ± 5 Nm.

• Ensure one number M10 bolt with hole.
• Use sealant FEVICOL- 171 on external thread of the Speedo sleeve.
• Apply torque on Speedo sleeve - 39 ± 4 Nm.

• Apply sealant Loctite-574 on rear housing.

• Ensure that shim is fitted on sub shaft.

• Put dolly on the splines of output shaft for

rear housing insertion & check for 5th
driven circlip fitted.

• Put the rear housing and tighteen the mounting bolts.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 224
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Fit the rear housing and 8 nos. mounting

bolts.
• Tighten filler plug and drain plug.
• Assemble Speedo sleeve and Speedo
gear.
• Insert ball and spring in detent hole.
Ensure both ball and springs are inserted.
• Tighten the vibra seal 516 pre coated
puppet plug & torque @ (25 ± 5 Nm) with
use of Angle Nut Runner.
• Fit the dust shield on the rear housing
with 4 bolts.
• Torque the dust shield bolts with angle
nut runner at 25 ± 5 Nm .

• Fit companion flange on the output shaft

splines.

• Put the plane washer before fitting

companion flange nut.
• Apply Sealant (Anabond 111) on output
shaft spline/ nut ID.
• Torque the companion flange nut to -
191 ± 21 Nm.

• Remove the dolly after fitment of Rear housing assembly.

• Put the washer and Lock nut on output shaft.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 225
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Apply Sealant (Anabond 111) on output

shaft thread/ nut ID; before fixing it on
shaft.

 Bearing Retainer / Clutch Release Bearing Sleeve Fitment -

• Ensure shim of MD gear fitment and snap

ring fitment on MD gear bearing.
• Ensure grease application on oil seal in
bearing retainer.
• Place belleville washer on the bearing
retainer before insertion on the MD gear.

• Place the counter shaft spacer before

retainer fitment.
• Use oil seal locator for retainer insertion
on the MD gear spline.
• Torque the m8 bolts to 24 ± 4 Nm.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 226
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Apply the Loctite 243 on small side of stud before stud fitment.
• Use new front end Retainer which has groove on OD & suffix ‘O’ ring. Refer sketch.
• If snap ring or spacer is not fitted then gear slippage will take place.
• If M.D gear shim is not fitted then 4th to 2nd crash shifting will take place.
• If torque or tightening of retainer bolts is not done then Oil leakage will take place.
 Adaptor Pivot Assembly / Lever Sub Assembly -
• Adaptor pivot dowel fitment.

• Apply silicon sealant on pivot before inserting dowel. Inadequate sealant application on the
pivot will cause oil leakage.
• In case dowel pin is missing, no proper alignment of lever sub assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 227
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• After adaptor dowel fitment, put the

adaptor pivot on fixture/ assembly table.

• If pivot not entering s/a fixture fully then

check whether the pivot pin is inserted
fully.
• Torque 3 M8 Bolts. - 24 ± 4 Nm.

• Assemble the gear bottom lever into the

Transmission assembly.

• The TM bottom lever assembly differs

from vehicle to vehicle as the NGT 520
Transmission is used for Xylo mDICRDe,
Bolero M2Di, and in Bolero variants.
• Bottom lever shown in Illustration
belongs to Bolero M2Di model.

• Assemble the correct gear bottom lever into the adaptor pivot assembly. Refer illustrations -

• Assemble the nylon bush, spring and retension plate. Refer illustartions.

• Ensure bush fittment. In case bush is missing, improper shifting or lever rattling may occur.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 228
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• After placing retension plate, press it and

then install the plunger and spring.

• Plunger and Spring fittmnet.

• In case plunger or spring is missing, biasing will not takes place.

• In case wrong spring used the biasing force will not ok.

• Side cover plate fittment. Ensure proper bolt fittment and torquing.
NOTE:
• In case bolt is missing or not torqued properly, the incorrect biasing may occur.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 229
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Torque the side cover bolts to the torque

value 8 ± 2 Nm.

• Lever Fittment -

• Apply inadequate sealant on the adaptor

pivot bottom side mating face.
Refer illustration.
• Put the rubber below over bottom lever
and adaptor pivot.

• After fitment of Bottom lever assembly into the Transmission, torque the adaptor pivot to 24
± 4 Nm torque.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 230
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Ensure proper location of pivot assy. with

help of dowel. - Pivot pin facing
downwards.
• Fit pivot pin with pivot insertion &
pressing impactor dolly.
• Apply silicon sealant on pivot.
• Fit pivot by tapping it.

• Use new Rubber grommet along with new

metal clip.
• Keep the clips of the metal tie clip
towards 5th/rev gear side.

• Apply sealant (Anabond 413/ Loctite 648)

on breather cap.

 Adapter Pivot & Gear Neutral Switch Fitment -

• Place the sensor on retainer plate.

• Put two lugs of sensor on plate hole and
press it.
• Fit two bolts of M8 40 on sensor lugs and
fit one bolt of M8 20 on plate. Torque
them 29 ± 2 Nm.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 231
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Put 6 mm gauge between Magnet and

sensor while fitting to ensure gap (6 mm)
between them.
• Fit the Allen screw with help of screw
driver; apply 2.5 ± 0.5 Nm torque.
• Fit the grommet on pivot.

 Assembly Inspection -
Make sure that the following check points to be carried out after completion of Transmission
assembly and before fitting it on vehicle –
• Check for presence of railed caps.
• Check for presence of breather.
• Check for static shifting.
• Check for biasing.
• Check for presence of countershaft spacer.
• Check for presence of one number M10 flange bolt with hole.
• Check for reverse lamp switch lead damage.
• Check for drain plug torque (check if it is loose by hand)
• Check for presence of filler plug.
• Check for free rotation of MD Gear.

Recommendation –

Mahindra & Mahindra recommends that after the fitment of Transmission assembly on vehicle,
check all the parameters ensure all the fitments are completed and do vehicle drives test to check
Transmission behaviour as well as vehicle performance.

Vehicle to be run in neutral condition for 5 to 10 min for proper churning or lubrication of oil.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 232
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specification –
Figure Description Value
Type Mechanical
Description NGT 520
Gears 5 Forward and one reverse gear
Gear shift Direct shift with rubberized lever
Gears Helical- toothed

1 3 5 Gear Engagement Block synchro ring type synchronizer

on 1,2,3,4 & 5th

2 4 R
Gear Ratio
1st 3.778
2nd 2.087
3rd 1.379
4th 0.789
5th 3.524
Reverse
Oil grade/ quantity 80 W90; GL 4
Oil Capacity: 2.0 litres.

Counter shaft bearing One ball bearing/ one Cylindrical roller.

Input Torque capacity 20 Kg-m.
Weight 68 Kg

Play Limit (mm) Service limit(mm)

1st 0.175 0.375
2nd 0.175 0.375
 Kg
3rd
4th
0.175 0.375
0.175 0.375
5th 0.18 0.30

Fork to groove clearances/ 0.1 to 0.4 mm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 233
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tightening Torques –
Description Torque in Nm (lbf-ft)
Plug - Shift Rail Poppet Spring 25 ± 5 Nm ( 18 ± 4 lbf – ft )
Flange Bolt / Nut – Clutch Hsg. To Main Hsg. 43 ± 7 Nm ( 32 ± 3 lbf – ft )
Flange Bolt – Front Intermediate & Rear Hsg. 55 ± 5 Nm ( 40 ± 4 lbf – ft )
Drain plug 27.5 ± 2.5 Nm ( 20 ± 2 lbf-ft)
Filler plug 27.5 ± 2.5 Nm ( 20 ± 2 lbf-ft)
Reverse light switch 30 ± 5 Nm ( 18± 4 lbf – ft )
Bolt – Clutch Release Bearing Support Sleeve 24 ± 4 Nm ( 18 ± 3 lbf – ft )
Bolt - Idler Shaft 43 ± 7 Nm ( 32 ± 3 lbf – ft )
Bolt - Bearing Retainer Plate 31 ± 4 Nm ( 23 ± 3 lbf – ft )
Lever Retention Bolt 24 ± 4 Nm ( 18 ± 3 lbf – ft )
Companion Flange Nut 191 ± 21 Nm ( 140 ± 15 lbf – ft )
Speedometer Sleeve 39 ± 4 Nm ( 29 ± 3 lbf – ft )
Bolt – Gear Box to Transfer case 55 ± 5 Nm ( 40 ± 4 lbf-ft)
Nut – Reverse Driven Gear 60 ± 10 Nm ( 44 ± 7 lbf-ft)

*also refer the torque values mentioned during the Transmission assembly and sub-assemblies where
ever applicable.

• Sealant Recommendation –
Sr. No. Location Sealant / Thread Locks Applicability
1 Ft. Hsg. & Intermediate Plate Loctite 574 

2 Intermediate Plate & Rear Hsg. Loctite 574 

3 Clutch Hsg. & Front Hsg. Loctite 510 

Anabond 413
4 Breather 
( Retaining Grade )
RTV Sealant Metlock 920
5 Pivot locking Option 1 – Rhodorseal 
Option 2 – Pidiseal 3P
Between Clutch Hsg. & OD of Ft.
6 Loctite 510 
Bearing Retainer
Clutch Release Bearing support
7 Loctite 510 
sleeve

8 Poppet Plug M 12X1.25 Loctite 542 

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 234
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Special Tools –
Description/ Part No./ Sketch Usage View

Dolly to press countershaft roller

bearing.

0703AD0900H002

Dolly to press countershaft roller

bearing

0703AD0900H001

Dolly for pressing bearing on

output shaft

0703AD0900H011

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 235
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Intermediate plate bearing pressing

dolly.

0703AD0900H005

Dolly for pressing ball bearing in

rear housing.

0703AD0900H015

Fixture to press bearing on output

shaft.

0703AD0900H007

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 236
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Assembly fixture.

0703AD0900H004

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 237
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

PROPELLER SHAFT

Contents…

• Description…………………………………………………………………………….
• Trouble Shooting………………………………………………..............................
• Care of the System………………………………………………………………….
• In Car Repairs………………………………………………………………………..

• Specifications & Wear Limits……………………………………………………..

• Tightening Torques…………………………………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 238
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The function of the propeller shaft is to transmit power from one point to another. The shaft is
designed to transmit torque from transmission / transfer case to the axle.

The propeller shaft has to operate through constantly changing length while transmitting torque. The
axle rides suspended by spring in floating motion. The propeller shaft must be able to change the
transmission angle when going through the various road surfaces. This is done through Universal joints
which permit the propeller shaft top operates at different angles. The slip joint or the yokes allow the
contraction or expansion of the propeller shaft thus allowing the length to change.

The propeller shaft is built with the yoke lugs in line with each other, which is called phasing. This
design produces the smoothest running condition. An out of phase shaft can cause a vibration.

Propeller Shaft – Front end/ Transmission end Propeller Shaft – Rear end/ Differential end
joint joint

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 239
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble shooting –

Tyres that are out of round or wheels that are out of balance cause a low frequency vibration.
Brake drums that are unbalanced cause a harsh low frequency vibration.
Driveline vibrations can also result from loose or damaged engine mountings.

Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft
does not cause a vibration that is present only in a narrow speed range.

Drive condition Possible cause Correction

Propeller shaft • Undercoating or other  Clean exterior of shaft & wash
foreign on the shaft. with solvent.
• Loose companion flange  Tighten the mounting bolts.
mounting bolts.  Replace the joint/yoke.
• Worn out yoke/slip joint.  Check runout- replace shaft.
• Excessive runout.  Correct angularity.
• Incorrect drive line  Replace the UJ.
angularity.  Replace the propeller shaft.
• Worn UJ bearings.  Replace the rear springs.
• Propeller shaft damaged or  Reindex the propeller shaft by
bent. 180°, test and correct as
• Broken rear springs. required.
• Excessive runout or  Reindex the propeller shaft by
unbalanced condition. 180°, test and correct as
• Excessive pinion shaft required
runout.
Universal Joint Noise • UJ worn out  Replace the UJ

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 240
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System –

Refer following procedure while carrying scheduled maintenance of the system –

PROPELLER SHAFT SLIDING JOINT - LUBRICATE

Grease Grade –MAXIMILE LCG, NLGI 2/3

Propeller
Bolero – Shaft – BoleroShaft
Propeller Zlx Schematic
Joints

Propeller Shaft Front end - Yoke Propeller Shaft Rear end - Yoke

Differential Oil – Replace (Refer illustration 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 5000kms.
 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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 241
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In car repairs –

 Unbalance
 Runout

1. Unbalance –

If the propellers shaft unbalance is suspected then it can be verified by the following procedure.
Removing & rendering the propeller shaft by 180° may eliminate some vibrations.

Clean all the foreign material from propeller shaft and the universal joint.
Inspect the propeller shaft for missing balance weight, broken welds and bent areas.
If the propeller shaft is bent then it must be replaced.
Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the
propeller shaft
Check the companion flange mounting bolts.
Raise the vehicle.
Remove the wheel & tyres.
Install the wheel nuts to lock the brake drum.
Mark & number the shaft 6 inches from pinion end at
four positions 90° apart.

Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the
vibration occurs.

Install a screw clamp at position “1”

Start the engine and recheck for vibrations. If there is little or no change in vibrations then move the
clamp or of the other 3 positions.
If there is no difference in vibration at the other position then the vibration is not due to the
propeller shaft imbalance.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 242
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

If the vibration decreases, install a second clamp and

repeat the test.

If the clamps cause an additional imbalance, separate

the clamp (¼ inch above & below the mark.). Repeat
the vibration test.

Increase the distance between the clamps until the

vibration is at the lowest level.

At this position bend the slack end of the clamp so that

it does not loosen.
Install the wheel & tyres. Lower the vehicle.

If the amount of the vibration remains unacceptable then repeat the exercise at the Gearbox end.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 243
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

2. Runout –

Remove dirt, rust, paint & undercoating from the

propeller shaft surface.

The dial indicator must be installed perpendicular to

the shaft surface.

Measure the runout at the center and at the ends – 75

mm away from the weld.

Replace the propeller shaft if the runout is beyond the specified limit.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 244
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• UJ Repairs --

Lift the vehicle,

Follow recommended procedure.

Put aligning marks on the flange, UJ and propeller

shaft before removal.

Do not use a punch to mark impression.

Remove the mounting bolts at the pinion end

Remove the mounting bolts at the gearbox end.

It is important to protect the machined, external

surface of the yoke from damage after propeller
shaft removal. Any damage in the machined
surface will lead to damage of the seal and cause
a leak.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 245
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the circlips holding the UJ in place.

Applying the socket wrench on the outside of the

propeller shaft flange, force out one end of UJ
using a vice as shown.

While assembling- insert both ends then hold &

press fit them with special tool.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 246
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specification & Wear Limits –

Description 2WD
Length (Joint to Joint) x O.D x thickness in mm 972 X 63.5 X 1.60
Runout 0.4 mm MAX TIR at centre & 75 mm away
from the yoke weld

• Tightening Torque –

Location Torque Nm (lbf-ft)

Companion Flange nuts at Transmission & Axle end 38.5 ± 3.5 Nm (28 ± 2.5 lbf-ft)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 247
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

REAR AXLE

Contents…

• Description……………………………………………………………………………………………..
• Trouble Shooting……………………………………………….............................
• Care of the System…………………………………………………………………………………
• In Car Repairs………………………………………………………………………………………….
• Rear Axle Overhaul………………………………………………………………………………..
• Specification…………………………………………………………………………………………..
• Lubricants…..………………………………………………………………………………………….
• Tightening Torques………………………………………………………………………………..

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 248
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The rear axle is of the hypoid, full-floating type using shim adjustment to obtain bearing pre-loads. The
full-floating design is used in medium and heavy-duty trucks. A full-floating axle can be identified by a
protruding hub to which the axle shaft flange is bolted. These axles are able to carry more weight than
a semi-floating or non-floating axle assembly because the hubs have two bearings riding on a fixed
spindle. The axle shafts themselves do not carry any weight; they serve only to transmit torque from
the differential to the wheels. Full-floating axle shafts are retained by the flange bolted to the hub,
while the hub and bearings are retained on the spindle by a large nut.

The differential case with Crown wheel and the drive pinion are mounted in opposed taper roller
bearing in one-piece rear axle carrier. The rear axle pinion receives its power from the engine through
the Transmission and driveshaft. The drive pinion rotates the differential case through the
engagement with the crown wheel, which is bolted, to the differential case flange. Inside the
differential cages are four differential pinions mounted on the differential pinion shaft which is splined
to the housing. These gears are engaged with the side gears, to which the axle shafts are splined.
Therefore as the differential housing turns, it rotates the axle shaft and the rear wheel. When it is
necessary for one wheel to rotate faster than the other is, the faster turning gear causes the pinion to
roll on slower turning gear to allow differential action between the two axle shafts.

The axle shaft is connected to the full floating hub. The hub is mounted with help of two tapper roller
bearing and a spacer in between the bearing. The spacer controls the hub play and also supports the
inner race.

All operations other than the removal of the axle shafts and the replacement of the wheel bearing oil
seal should be carried out with the axle removed from the vehicle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 249
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres
and other parts of the Vehicle. For this reason be sure that the cause of the trouble is in the rear axle
before adjusting, repairing or replacing any of the axle parts.

• Rear Axle Noise Diagnosis –

Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures.
Slight axle noise heard only at certain speed or under particular conditions must be considered
normal. Axle noise tends to peak or be more pronounced at particular speeds and the noise is in no
way a sign of the trouble in the vehicle.

Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to
isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to
eliminate a slight noise may baffle even the most experienced mechanic/ technician.

Axle noise fall into two basic categories: gear noise and/ or bearing noise.
 Axle Noise - Gear Noise
 Bearing Noise
 Others Noise
The most important characteristic of the gear noise is that it is usually sensitive to accelerator
position. E.g. noise audible under drive condition will often disappear under coast condition (i.e.
driving in neutral with the clutch released and engine running) at the same vehicle speed and vice
versa.

Axle gear noise whine will always occur at the same road speed and throttle setting i.e. drive or coast
(i.e. driving in neutral with the clutch released and engine running). Gear whine is usually a fairly high
pitched pure tone as opposed to a low-pitched rumble caused by a spalled bearing.

Some noises, which can be confused with axle gear whine, are: -

…. Whine from an engine component; this will always occur at the same engine speed irrespective of
which transmission gear is used

…. Whine from an indirect Transmission gear (e.g. 5th gear on some vehicles produces a whine
comparable with axle whine) however this will disappear when the direct transmission ratio is
selected.

…. Whine from tyres or wind noise from a rack or aerial. These noise generally occur over a very broad
speed range and do not change with driving mode i.e. drive or coast (i.e. driving in neutral with the
clutch released and engine running)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 250
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Remember -

Before diagnosing the whine as axle gear noise, ensure that the whine:

• Occurs in direct transmission ratio (4th gear)

• Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the
clutch released and engine running)
• Always occur at the same road speed and not engine speed, Occurs over a limited vehicle
speed. (This can vary over a wide band should the axle be in extremely bad condition.)

Bearing Noise –
Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide
speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in
pitch as speed increases and is not directly affected by changing from drive to coast (i.e. driving in
neutral with the clutch released and engine running) and visa versa.

(a) Rear wheel bearing noise tends to be low pitched grumble, which can normally be detected
and confirmed when driving on a smooth road at constant speed, with the noise most audible
while swerving sharply from left to right. If the noise increases or a decrease as the car is
swerved, it is probable that a wheel bearing is faulty. Driving close to a wall or a curb at a
suitable speed can carry out a further check for wheel bearing noise.
(b) Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not
affected by the swerve check referred to previously.
(c) Pinion bearing noise is normally at a higher pitch than wheel or differential bearings and is
often slightly sensitive to throttle position, although not to the same extent as gear noise.

Other:
1. A further condition, which can exist, is due to a worn bearing that allows the gear set to move
out of its correct mesh cause gear noise. This condition is usually throttle sensitive, with the
noise frequently disappearing on a “drive” condition. Any amount of or endplay in either the
pinion bearings or differential carrier bearings are detrimental to the gears and bearings and
will cause axle noise.
2. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a
ticking or light knocking noise over a restricted range of throttle position. The frequency of the
noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring
gear. The severity of the noise indicates the size of the defect. A light “tick “is seldom
detrimental and usually occurs in new axle and will normally disappear once the axle has been
run in.
3. Louder noise usually indicates a more serious defect and a knock occurring in an axle which
was previously free from this type of noise must always be investigated.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 251
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the axle –

The lubricant level should be checked every 10000 Kms with the vehicle unladen and in a level ground.
The lubricant level should be at the lower edge of the filler plug. Use lubricant meeting oils
specification of GL 5 and viscosity of SAE 90 .The brand names have been specified in the lubricant
section.

Note: Unless otherwise specified the assembly procedure / guidelines is the reverse of the
disassembly procedure.

• IN VEHCILE ADJUSTEMENT & REPAIR –

The works in axle that can be done without removing from the vehicle are:

Replacement of pinion seal -

Remove the propeller shaft from

the companion flange

Using the MST 203, Lock the companion flange.

Unlock the pinion nut

Remove the companion flange along with the dust cover

Using screwdriver take out the old oil seal- take care not to damage the seating / contact areas.
Fit the new seal using the dolly.
Apply oil on lip and ensure that seating area has been wiped clean and free of burrs

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 252
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• The backlash adjustment –

GEAR TOOTH CONTACT

The backlash adjustment should not be done on the vehicle - This is due to the fact that the spreader
usage in vehicle is difficult if the vehicle isn’t being attended in a pit. Further after adjustment it may
be necessary to adjust pinion height. (Any change in backlash indicates wear- hence though shim
adjustment may compensate for gear teeth wear. It will not compensate the pinion wear and pinion
bearing wear and loss of preload)

However it is suggested that the tooth contact be checked on the vehicle taking decision to open/
overhaul. It is recommended that after draining the oil and opening the rear cover. Put paint marks in
four different places. Then push the vehicle forward and backwards at least 15 feet. This will give a
much better tooth contact under load. (It should be remembered that with load the tooth contact
moves away from toe to heel. The tooth contact without load is given in the specification sheet.)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 253
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Rear axle Overhaul – Comprises of the following major steps –

1. Removal & refitting of the rear axle shaft.

2. Removal & refitting of the hub and the brake carrier and oil seal.

3. Removal of the differential assembly.

4. Pinion height adjustment and preloading of pinion bearings

5. Assembly of the crown wheel.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 254
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Removal of the axle assembly from the vehicle –

Raise the rear end of the vehicle with a hoist and

safety support the frame.

Support the rear axle assembly on stand and

remove the wheels.

Disconnect the propeller shaft rear end at the

universal joint companion flange.

Disconnect the brake hydraulic hoses.

Remove the shock absorber.

Remove the spring to axle ‘U’ bolt clips and side

the assembly from underneath the vehicle.

Remove the brake pipe ‘T’ clamp from axle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 255
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Removal & refitting of the rear axle shaft & hub –

Dismantling –
Jack up the vehicle & remove the wheel.

Remove the drum.

Loosen & Remove the hub cover bolts. Remove

the hub cover using a screwdriver.

Remove the axle shaft.

Unlock the lock washer.

Using the MST 221, remove the outer locknut.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 256
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Take out the lock washer and the inner nut.

Pull out the hub along with the bearings.

Remove the Oil Seal.

Remove the bearings, cones & spacer.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 257
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Inspection –
1. Inspect the rollers and the inner races of the bearings for Scoring, pitting/ or spalling.
2. If any damage is noticed – inspect the outer races also.
3. To remove & refit the outer races, use MST.
4. If the outer race / cup are found to be loose in the housing then it is advisable to replace the hub.
Trying to recondition the hub bore is not recommended.
5. If the bearing seating area/ the oil seal seating area in the hub is worn then replace the hub.

Assembly –

Apply the MAXIMILE LCG3 grease on the bearings.

Locate the inner bearing cone in the hub. Fit the spacer & the inner bearing.
Press the new oil seal.

The lip of the oil seal should be coated with grease. Also fill grease in the cavity where the oil seal
spring is present.
Press the hub assembly & fill the grease. Fit shim & washer.
Locate the inner cone of the outer bearing & fit the bearing.
Torque Tighten the inner nut to 95 ± 14 Nm torque. The hub play should be within - 0.020 (i.e. It can
be in preload zone & do not have any free play) to + 0.040 mm. (Since it is recommended to be in the
preload zone; hence the Step 9 is critical). 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.
Put the locking washer & tighten the outer nut to
the torque 95 ± 14 Nm.

Fit the Axle shaft.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 258
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

CHECK: Rotate the hub using a spring balance & the pulling force should not exceed 2.5 Kgs. (Check
when the drum is not fitted) If found more; the shim setting should be checked once again. – OR -
Follow the below mentioned hub play checking procedure by using dial gauge –
NOTE: To be check without axle shaft.
Use dial gauge along with stand.

Preloaded the dial gauge and fix the stand on the

axle hub through hub cap mounting screws. Set
the dial gauge pointer on the sub shaft.

Pull and push hub outside and inside respectively

and note the dial gauge readings to know the
play.

If the play is more, the shim needs to be added.

If play is low shims to be removed.

Check the play once again to get correct play

reading.

Fit the axle shaft.

Check and ensure correct fitment of brake

assembly, parking brake cable.

Fit the drum.

Fit the wheel.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 259
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Removal of the differential carrier/ Centre assembly –

Remove the drain plug and Drain the oil from

differential.

• Ensure that vehicle is firmly supported on chassis frame before starting the job.
• Remove the both side wheels.
• Disconnect both side suspensions from axle housing tube assembly.
• Remove the parking brake cable, rear drum brake parts, and wheel cylinder bundy tubes.
Ensure no brake fluid spillage on vehicle components.
• Remove the rear axle shafts assembly from the housing assembly.
• Remove axle housing tube out of the vehicle. It is recommended to use fixture for
overhauling the differential centre assembly.
• Remove the differential cover set screws.
Remove the differential side bearing
Cap bolts.
Make sure they are matching letters or other
marks on the cap or on the housing so that each
cap can be reinstalled in the same position from
which it was removed.

Remove the side bearing caps.

Using MST 205, expand the differential.

It is necessary to spread the carrier as the
differential bearing has initial preload. Use
Housing Spreader Tool Install, hold down clamps,
on a dial indicator. From the side, measure the
carrier spread. When the spreading force is
applied, do not exceed a limit of 0.5 mm (0.020”).
Remove the dial indicator. Carefully pry the
differential case loose using pry bars at the head
of the gear bolts and the carrier casting.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 260
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Pull out the crown along with the

Bearings.

 Remove the spreader tool to prevent the possibility of the carrier taking a set.

• Should the spreader tool be unavailable, use two pry bars, one on each side of the
differential case opening.
• If the differential carrier bearings are to be removed, use bearing pulle.
• Turn down the lock strap tabs and remove the screws and lock straps holding the differential
ring gear to differential case.
• The differential shaft is held in place by a lock pin. Use a small punch as shown in to drive
out the lock pin. Remove the differential shaft.

Using MST 203, lock the companion flange.

Unlock the pinion nut.

Remove the companion flange along with the

dust cover.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 261
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Using care not to lose the pinion thrust washers remove the differential pinion gears.
• Remove the axle shaft gears and thrust washers.
• To remove the drive pinion, first remove the universal joint end yoke assembly. Use Tool to hold
the shaft while removing the nut. Use puller, to remove the end yoke.
• With a hammer and brass drift, drive on the end of the pinion shaft to force the pinion into the
differential housing so it can remove.
• Remove the pinion shaft oil seal.

Differential Carrier Bearing Cups

To remove the outer and inner differential carrier bearing cups, use a puller. Oil the puller screw
threads with clean engine oil or machine oil. Remove the inner bearing cup first. To replace the
bearing cups, the puller is used for the inner bearing cup and driver is used to install the outer
bearing cup. Procedure for removal is given below:

• Remove the hex, nuts from each end of the puller.

• Carefully insert the round adapter with two flat sides through one of the bearing cups and
position it behind the inner bearing cup shoulder.
• Insert the short threaded end of the main puller screw through the hole in this adapter and
secure the adapter with hex, nut.
• Position the plate across the open face of the differential housing and secure it with a hex, nut.
• Make sure the adapter plate sets flat against the pinion inner bearing cup adjoining shims. Turn
down the screws to remove the bearing cup.
• Reposition the puller to remove the outer bearing cup. The adapter should be seated firmly
against the shoulder of the cup with long threaded end of the main puller screw through its
centre. The plate is positioned against the front seat of the differential housing.
• Make sure the adapter plate sets flat against the pinion outer bearing cup. Turn down the screw
to remove bearing cup.

Remove Differential and Pinion Bearing -

Use of the above puller ensures easy removal of bearings without damage to cages or rollers as
pulling pressure is applied directly to the bearing cones.
Install the inner pinion bearing on pinion. To install the differential case bearing on differential case
use driver See Fig. 20.
Adjusting Differential Side Gears (Not Applicable for Limited Slip Differential) (Ref. Page No. 07-20)
Clearance between the differential side gear and differential casing should be 0.00 to 0.15mm (0.00”
to 0.006”) Use the following procedure to check the clearance.

• With the differential positioned as shown in Fig.10, bounce the differential slightly so the
differential gears settle.
• Measure the clearance between side gears and the case as illustrated.
• If the clearance exceeds 0.15mm (0.008”) add shims between the side gear and the case. To
bring the clearance within specified tolerance, shims in these thickness are available:
0.10mm (0.004”), 0.15mm (0.006”) and 0.20mm (0.008”).
When shims are required, there must be at least one shim on each side. Also, keep the shim packs as
equal as possible. After adding shims, repeat the clearance check.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 262
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Assembly of the crown/ Centre assembly –

Sequence of Operation:

a. Sub assembly of the differential gears in the Differential cage

b. Sub assembly of the crown wheel with the differential cage
c. Pinion assembly (including the preloading)
d. Crown Wheel backlash setting
e. Crown wheel side bearing preloading
f. Crown wheel tooth contact checking

• Sub assembly of the differential gears in the Differential cage –

Normally the classification of axle in semi floating or full floating is based on the wheel end bearing.
However there is an impact in differential also.

The full floating axles the side loads of the wheel / hub are taken by the bearings at the wheel end-
hence no load come through the axle shaft to the differential. So normally no spacers are used
between the pinion in the full floating axle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 263
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Sub-assembly of the crown wheel with the differential cage –

Pinion assembly (including the preloading) –
The pinion assembly is subdivided into:
a. Pinion height setting.
b. Pinion preloading. Pinion Height Setting

Without using any gauge Using depth measuring

(limitations apply, look at
the details in the write

2.1 All UV’s.

Look at the old pinion Z Use the MST to measure

value (etched on top the pinion height.
face) and the new pinion (NOTE: Do not use the
Z value. For the shim older MST 200, the C
value refer to the chart clamp type of MST)
• Pinion height setting without using the gauge –
This procedure can only be used when only the Crown wheel & pinion is being replaced.
In case the bearings are also replaced then the use of gauge method is recommended.
In case the bearing seating area damages/ distortions or the axle housing replacement is taking place
then the gauge method has to be used. (Please take care that if the bearing seating bore is having
distortion then first that has to be corrected then only the gauge to be used.) The chart to be used is
given below –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 264
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Pinion height setting in Bolero Maxi Truck CNG –

• Fit the dial gauge in the MST

• Place the MST along with the dial gauge on the MST and make the dial gauge zero.
• Ensure to preload the dial. Please note that this MST acts as master blocks hence handle it
with care.
• Place the pinion along with the inner bearing on the pinion bore.
• Place the MST on the crown bearing bores. Note the dial gauge value. The dial gauge value
versus the Z value etched gives the shim to be added between the pinion and inner bearing.

- Crown wheel side bearing preloading

- Refer photo of the embossing shown:

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 265
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Adjustments of the crown preload & tooth backlash –

Install the crown, in the carrier.

Instead of using the bearings use MST,
- One on each side.
The advantage of using the MST (dummy bearings)
instead of bearings while setting is that as the
outer race does not keep getting tilted hence we
get accurate reading further the bearings do not
get damaged when they are removed after
checking the values of shims required.

Push the crown assembly towards the pinion so that the backlash is zero.

In this position find the shim pack which has to be

inserted on right (Back of crown) side and also on
the teeth side.

Move shims from teeth side to back of the crown side so that the backlash is achieved.

After the backlash has been set. Add shim of 3 thou on both the sides.
This give a total preload of 6 thou & each bearing preload is 3 thou.

After the CWP preloading the crown bearing bolts have to be torque tightened.
Please note that the bearing caps should not be interchanged.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 266
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Previously the bearing cap & differential used to have punch marks.
However to reduce the errors the L & R are embossed on cap and also on the differential.
Add an additional 0.075mm (0.003”) of shim on the both the side so that the crown teeth get
preloaded.
Take out the assembly; keep the selected shim packs correctly.
Remove the MST (dummy bearings).
Insert the bearing assembly along with the selected shim pack.
Use MST 205 to spread the carrier.

While using the spreader, ensure that the expansion is not more than 0.5 mm. If more it can cause
permanent deformation of the carrier.

While assembling the cap, ensure that the markings match with each other.
Torque- 109 ± 15 Nm ( 80 ± 10 lbf-ft)

Check the backlash, if less or more then the shims should be moved from one side to the other.
Note: Approximately 5 thou shim is equal to 3 thou of backlash.
Check the backlash. 0.13 to 0.25 mm ( 0.005”-0.010”)

Check the runout in four places it should be less than 0.15 mm ( 0.006”)

After the backlash has been achieved, check the

tooth contact on both the drive and the reverse
side.
Note: since the crown wheel is without load hence
the contact should not be exactly at centre but as
shown in the sketch.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 267
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications –

Description Value
Full floating single reduction without differential lock.

No of teeth on crown N1 41
No of teeth on pinion N2 11
Axle reduction ratio N1/N2 3.73

Pinion Pre load 23 to 45 Kg.cm.

Preloading of differential bearings 0.075 mm ( 0.003”)

Crown-pinion backlash Maximum variation of (0.005 to 0.008”)

backlash in a crown wheel & pinion (0.003”)

Run out of the ring 0.15 mm ( 0.006”)

gear / crown wheel

Hub end play -0.0020 mm ( preload of 20

microns) and upper limit of
+0.3 mm ( 0.0012”)

Hub rotational torque < 2.5 Kg.

Check for correct tooth contact on Check on both the driving & reverse flank. This
both the forward and reverse direction contact is for checking without load.

Clearance between and side( sun) gears and diff 0.20 mm (0.008”)
case

Rotational torque of differential case with sun & 5 Kg cm

pinion gears

Inner race interference Outer race clearance 0.125 mm (0.005 to 0.007”)

Oil grade/ Viscosity/ Quantity GL 5/ SAE 90/ 1.65 litres

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 268
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tightening Torques –

Brake carrier mounting bolts 40 ± 7 Nm (30 ± 5 lbf-ft)

Pinion nut 230 ± 13 Nm(170 ± 10 lbf-ft)
Crown mounting nuts 61 ± 7 Nm (45 ± 5 lbf-ft)
Differential side bearing bolts 108 ± 13 Nm (80 ± 10 lbf-ft)
Differential disc cover bolts 18 ± 2 Nm(12 to 15 LB FT )
Hub lock Nut 95 ± 14 Nm (71 ± 10 lbf-ft)

• Recommended Lubricants –

Specification: GL 5; SAE 90

Brands –

Maximile : Recommended Maximile DO

Other options -
IOC SERVOGEAR HP 90
HP HP GEAR OIL XP 90
BPCL BHARAT SPIROL HD 90
BHARAT SHELL SPIRAX HD 90
CHEMOLEUMS CHEMOLEUMS TURBO GL5 SAE 90
GULF MP GO 90
CALTEX THUBAN GL5-90
VEEDOL VEEDOL MULTI GEAR 90 HD
CASTROL CASTROL HYPOY B 90

• Sealant –

Differential cover sealant: Loctite 587 / Gasket.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 269
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

STEERING SYSTEM

Contents…

• Description………………………………………………………………….
• Trouble Shooting…………………………………………………………..
• Care of the Axle………..……..……………………………………………
• In Car Repairs………………………………………………………………
• Working principle of the Steering Pump………………………………
• Specifications………………………………………………………………
• Tightening Torques………………………………………………………..
• Sealant Recommendation………………………………………………..
• Special Tools……………………..…………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 270
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The power steering system is a rack and pinion type. The engine driven hydraulic –pump supplies oil to
a control valve situated in housing that supports the pinion shaft. Movement, imparted to the control
valve from the shaft in the steering column is via a torsion bar. This sensing bar moves the control
valve, which in turn directs the oil to one side or the other side of the ram piston inside the steering
rack.

The control valve is a rotary type spool valve controlled by the torsion bar interposed between the
steering shaft and pinion of the steering box. The spool valve is a shaft with six flutes and a sleeve,
which has six internal axial grooves, encases this. Radial ports in the sleeve and shaft pass the oil from
the supply to the lines connected to the ram chamber.

New Bolero (R&P) Power Steering Assy. - Schematic A series of the splines between the
shaft and the sleeve limit the twist of
the torsion bar to about 7 degrees in
each direction; This fail-safe feature
provides a mechanical drive from the
steering shaft to the pinion in the
event of any power system failure.

When the wheel is in straight-ahead

position, all the ports are open so oil is
allowed to flow through the valve and
return to the reservoir.

As soon as the wheel is turned, the

torsion bar is deflected; this allows the
spool valve to rotate relative to the
sleeve, cutting off the oil flow both to the reservoir and one side of the ram. At the same time the
other side of the ram is subjected to oil pressure, which builds up sufficiently to move the road wheel
and return the torsion bar to no – torque position. During this stage the oil displaced from the
uncompressed side of the ram is returned to the reservoir.

On occasion when the resistance to road wheel movement is excessive, the oil pressures build up to
its maximum. At this pressure a relief valve fitted inside the pump opens and allows the oil to return
to pump inlet.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 271
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

The rack and pinion design is a simple design. However it is still susceptible to various problems in
particular to leaks. If the bellows are ripped or are unable to keep the contaminant’s away then it can
cause damage to oil seal and subsequent leaks.

One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold
and as the vehicle is driven/ warmed the power assist gradually comes back. It normally indicates that
grooves worn into the bore of the pinion aluminum housing by hard control valve seals.

Wear in the centre housing causes the fluid to leak around the rack piston causing either steering
wander or lack of straight-ahead stability. Another cause of steering wander and erratic control often
accompanied by clumping, thumping noise is the deterioration of rack mounting bushings.

Fluid levels can be hard to locate. Sometimes you will see a low level in the pump reservoir but no
evidence of escaping liquid. Squeeze the bellows and you will probably find that they are full of liquid.
To confirm if that side of the rack is the culprit, then remove the both the bellows, clean the rack
housing and then operate the system to observe the seepage directly.

It should be mentioned that a rusty input shaft U joint or deteriorated flexible textile/rubber coupling
could imitate rack problems.

After attending the repairs it is critical and the system to be flushed completely. Disconnect the return
line from the pump and put in a container, then disable the injection (remove the wire from the shut
off solenoid) and crank the engine. Add fresh fluid until you get a clear flow from the line. Take care
that the reservoir does not run dry during the flushing. Failure to do so will result in premature failure
of the repaired unit.)

The possible causes for the power steering complaints are tabulated below:

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 272
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Chart foe Trouble Shooting –

Problem Possible Causes Corrections

Objectionable Hiss • Noisy relief valve in There is some noise in all the power
hydraulic pump. Steering steering system. One of the most
gear noise valve noise is common is a hissing sound most
transmitted through the evident at stand still parking. Hiss is
steering column or open-air a high frequency noise that is
passages in the area where present in every valve and results
the column or controls pass from high velocity fluid passing valve
through the floor into the orifice edges. There is no
engine compartment. relationship between this noise and
the steering gear performance. DO
not replace the intermediate shaft
or the steering gear unless the noise
is too objectionable. Check the
dashboard seals between the drivers
area and under hood to eliminate
open space/ gaps.
Rattle or chuckle noise in • Gear loose on frame.  Check the gear mounting bolts.
Steering Gear • Steering linkage looseness.  Torque the bolts to
• Pressure hose touching specifications.
other parts of the vehicle.  Check the IBJ and OBH for wear.
• Loose IBJ or OBJ
• Improper over centre-  Adjust the hose position.
clearance. A slight rattle  Do not bend the tubing by hand.
may occur on turns because  Replace, if required.
of increased clearance off  Adjust to specification
the high point. This is
normal and clearance must
not be reduced below
specified limits to eliminate
this slight rattle.
Excessive wheel Kick Back or • Air in the steering.  Add oil to the pump reservoir
Loose Steering and bleed.
• Steering Gear Mounting  Tighten attaching bolts to the
loose. specified torque.
• Front wheel Bearings  Replace loose parts.
Incorrectly adjusted or
worn.  Adjust the wheel bearings or
• Steering Gear Improperly replace as required.
adjusted.  Adjust to specifications
• Damaged or worn steering  Dismantle and assemble the
Gear. steering gear as specified.
• Worn or damaged rubber  Replace the rubber bushings.
bushing for mounting
steering gear

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 273
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Vehicle leads to one side or • Front end misaligned.  Adjust to specifications.

the Other (keep in mind the • Unbalanced steering gear  Replace the gear Valve.
road condition and wind valve. If this is the cause
conditions.) Test the vehicle steering effort will vary light
, Going in Both directions , in direction of lead and
On a Flat road heavy in opposite direction.
• Steering shaft rubbing with  Align the column.
the ID of the shaft tube
• Steering linkage not level.  Adjust as required.
Momentary Increase in • Low oil level in Reservoir.  Add steering fluid as required.
steering Effort When • Pump Belt slipping.  Tighten or replace belt.
Turning the Wheel Quickly • High Internal leakage’s  Refer to pump test.
To the Right or Left ( Steering Gear or Pump)
Poor return of Steering • Tyres under inflated.  Inflate to specified pressure.
• Lower coupling flange  Loosen the pinch bolt and
against the steering gear assemble.
adjuster
• Steering wheel rubbing  Adjust the steering column.
against directional signal
housing.
• Tight or seized steering shaft  Replace the bearings.
bushing/bearings.  Relubricate/ replace the joints.
• Steering joint or linkage  Align the steering column.
binding.
• Steering column misaligned.  Relubricate/ replace the ball
• Lack of lubrication in the joints.
suspension ball.
• Improper front end  Check & adjust to specifications.
alignment.
• Steering gear adjusted too  Adjust the preload.
tight.
• Kink in return hose.  Replace the hose.
Steering wheel Surges or • Low oil level in Pump.  Add fluid as required.
Jerks when Turning with • Loose pump belt.  Adjust tension as per
engine running, especially specification.
during Parking. • Sticky flow control valve.  Clean the control valve or
replace the pump.
• Insufficient pump pressure  Refer to the power steering
System Test.
Hard steering effort in both • Low tyre pressures  Adjust the tyre pressure.
the directions • Lack of lubrication is  Lubricate & re-lubricate at
suspension or ball joint. proper intervals.
• Steering gear to column  Align the steering column.
misalignment.  Tighten or replace belt.
• Pump belt slipping.  Fill to proper level and inspect
for leaks.
• High internal leakage.  Refer to pump Pressure test.
• Sticky flow control valve.  Replace or clean the valve.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 274
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Lower coupling flange  Loosen the pinch bolt and

rubbing against steering assemble correctly.
gear.  Adjust the preload in Straight-
• Steering gear preload high. ahead position.
• Improper front end  Check & adjust to specifications.
alignment
Foaming Milky Looking • Air in the fluid and loss of  Check for leak & correct. Bleed
Power Steering Fluid. Low fluid due to internal pump the system. Extremely cold
Level and Possible low leakage causing overflow temperature will cause aeration
pressure problems if the oil level is low. If
oil level is correct and the pump
still foams then check for the air
leakage caused by loose joint
Low oil Pressure due to • Check for kinks in the hose.  Remove the kinks/ replace hose
Restriction in the Hose  Remove the foreign objet or
• Foreign objects stuck in the replace the hose.
hose.
Chirp Noise in Steering Gear • Pump belt slipping  Tighten or replace Belt
Belt squeal ( Particularly • Pump belt slipping  Tighten or replace Belt
noticeable at Full wheel
Travel & Standstill Parking)
Growl noise in Steering • Scored pressure plate,  Replace Pump.
Pump thrust plate or rotor
• Extreme Wear of cam ring  Replace Pump.
Growl noise in Steering • Low oil level  Add the power steering fluid.
Pump • Air in the oil. Poor pressure  Bleed the system.
hose connection.
Rattle or knock noise in • Vanes sticking in rotor slot  Replace pump, flush system.
steering Pump • Pressure hose touching  Adjust hose position.
other parts of the Vehicle.
Swish Noise in stg Pump • Faulty flow control valve  Replace pump.
Whine Noise In Stg Pump • Pump shaft bearing scored  Replace pump.
Low oil Pressure Due to • Flow control valve stuck or  Replace pump.
Steering pump inoperative
• Pressure plate not flat  Replace pump.
against the cam ring.
• Extreme wear of the cam  Replace pump, flush system.
ring.
• Air in oil.  Locate source of leak & correct.
Bleed the system.
• Low oil level  Add power steering fluid as
required.
• Pump belt slipping  Tighten or replace belt as
required
• Damaged hoses or steering  Replace as necessary.
gear

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 275
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the system

The lubricant level should be checked every 10000 Kms with the vehicle unladen and in a level ground.
The lubricant level should be between the maximum and minimum mark. The fluid level should be
checked with the engine in off condition. If the oil level is excess it will tend to come out from the filler
cap in use lubricant meeting oils specification of ATF (Automatic Transmission Fluid. The brand names
have been specified in the Operators Manual and also in the end of the Section.

This section also includes of –

 Power Steering Fluid – Level/Leak – Check

- Rack and Pinion type

- Worm and roller type

 Power Steering Pump Drive Belt Check

 Power Steering Pump Drive Belt Replace

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 276
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 POWER STEERING FLUID (Rack & Pinion) – LEVEL/LEAK - CHECK

Power Steering Oil (Rack & Pinion) – Specification: DEXRON III

Brand: SHELL Make “SPIRAX S3 ATF MD3”/ CALTEX Make “TEXAMATIC 1888”
Capacity – 0.8 Ltr.

Schematic – Power Steering

(Rack & Pinion) System
.....MAX........

…MIN…...

Fluid Leak Check Points

POWER STEERING FLUID – LEVEL/ LEAK - CHECK

Refer illustration shown above.
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 first 5000 kms then at every 10000kms.
 Brand specific. No other brands recommended.
 Recommended brands:
SHELL Make “SPIRAX S3 ATF MD3”/ CALTEX Make “TEXAMATIC 1888”.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 277
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 POWER STEERING PUMP DRIVE BELT CHECK

(Power Steering Drive Belt- Rolunds AVX 10V)

Water Pump -
Alternator Drive Belt

Steering Pump Drive Belt

AC Compressor Drive Belt

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

1. Cracking
2. Chunk-out

Cracking – Small, yet visible cracks along the length of a rib or across the belt groove.
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.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at every 10000kms.
Replace belt first at 45000 kms & then at every 30000 kms.
 Recommended value for Power Steering drive belt is – 210 + 5/175 + 5 Hz (New/Used)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 278
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 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

Refer illustration shown.
1. Remove Fan, shroud and NVH cover.
2. Remove Water pump-Alternator drive belt. (Refer :709-MAT-0033)
3. Remove AC Compressor drive belt. (Refer :709-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.
 Assembly procedure is reverse to the removal of 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.

 Accessory drive belts to be inspected first at 5000kms, 15000kms and then at every 10000kms.
Replace belt first at 45000 kms & then at every 30000 kms.
 Recommended value for Power Steering drive belt is – 210+5/175+5Hz (New/Used)
 Check belt tension at the point shown as green dot in above illustration.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 279
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car repairs

The following repairs can be carried out without removing the assemblies.

a) Removal of Outer Ball Joint & Tie Rod

b) Greasing of the OBJ (In case the rubber gaiter is torn.)

c) Removal & Refitting of Intermediate Shaft

d) Removal of Steering Gear Rack Assembly

e) Checking of Steering Play.

f) Bleeding the system.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 280
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Removal of Outer Ball Joint & Tie Rod -

• Drive and position vehicle in the two post lift.

• Loosen the wheel nuts. Lift up the vehicle and remove the front wheels.
• Position the pads of two post lift underneath the vehicle, so that they are seated at the
intended jacking location and then raise the vehicle. (Refer “Wheels & Tyre” section for jacking
locations of the vehicle)
• Remove the front wheel nuts and then wheels from the vehicle.

Improper jacking could lead to vehicle slippage and cause damage to the vehicle and person.

• Slacken the track rod end lock.

• Remove the castled nut split pin and remove the castled nut.

• Remove the track rod end using the

special tool

• Remove the track rod end. While removing the track rod end, make a note of the number of
turns required to remove the end.
• While fitting back the end or fitting a new end turn it back the same number of threads
• While fitting back the end or fitting a new end turn it back the same number of threads

Improper installation and usage of the special tool could damage rubber boot of the tie-rod end.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 281
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Greasing of the OBJ (In case the rubber gaiter is torn)

• Refer above procedure for Removal of Outer ball joint.

• After removal of the track rod end -

• Remove the circlip

• Fill the joint with about 10 grams of grease

• Fit a new gaiter and put the lock

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 282
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Removal & Refitting of Intermediate Shaft

• Using a thin bladed short screw driver, remove covering caps of the lower panel lock screws
• Using a Phillips screw driver, loosen (counter clock-wise) the lock screws and remove. Remove
the lower panel from its position.
• Using a 12 mm socket and wrench set, loosen (counter clock-wise) the intermediate shaft
coupling bolt from the steering column and remove.
• Using a 12 mm socket and wrench set, loosen (counter clock-wise) the intermediate shaft boot
cover mounting nuts.
Using a 12 mm socket and wrench set, loosen
(counter clock-wise) the intermediate shaft joint
lock bolts present in the coupling. Remove the
upper shaft from the coupling.

Using a 12 mm socket and wrench set, loosen

(counter clock-wise) the intermediate shaft yoke
coupling bolt. Separate the intermediate shaft
yoke from the steering gear assembly

• Installation –
Insert the intermediate shaft yoke over the
steering gear input shaft. Using 12 mm socket and
wrench set, tighten ( clock-wise) the intermediate
shaft yoke coupling bolt to the torque of 19~25
Nm.

Insert upper intermediate shaft inside the vehicle. Using a 12 mm socket and wrench set, tighten (
clock-wise) the intermediate shaft boot cover mounting nuts with floor panel to the torque of

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 283
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Insert lower end of the upper intermediate shaft in the coupling. Using a 12 mm socket and wrench
set, tighten (clock-wise) the intermediate shaft joint lock bolts present in the coupling to the torque of

Insert the intermediate shaft coupling into the steering column shaft. Using a 12 mm socket and
wrench set, tighten (clock-wise) the intermediate shaft coupling bolt with steering column to the
torque of 19~25 Nm.
Install the lower panel in its position. Using a Phillips screw driver, tighten (clock-wise) the lock screws.
Insert the covering caps of the lower panel lock screws.

After installation, turn the steering wheel to check its free and smooth movement. When turned lock to
lock from home position, number of turns on either side should be same. When the road wheels in
straight ahead position, steering wheel should be in home position. Repeat the removal and
installation of the steering wheel to bring it in home position, when the road wheels are in straight
ahead position.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 284
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Removal & Refitting of Steering Gear Rack

FLUSHING THE POWER STEERING FLUID -

• Drain and flush the PS fluid from the system. (Refer procedure “Power steering fluid flushing” in
this section for instructions)

Avoid spillage of PS fluid on other components. Wipe off immediately, if any spillage is noticed.
Adequately cover the power steering reservoir and lines from the entry of any foreign material/dust.

REMOVAL OF POWER STEERING PRESSURE LINE -

• Remove the Power Steering pressure line hose from the vehicle.

NOTE
Plug the inlet and outlet hole of the PAS rack to avoid entry of any foreign particle. Plug both the ends
of the PAS pressure line hose to avoid entry of any foreign particles.

REMOVAL OF TIE-ROD END -

Remove both the tie-rod ends. (Refer procedure “Tie-rod end” in this section for instructions)

REMOVAL OF STEERING GEAR ASSEMBLY -

Using a 17 mm socket and wrench set, loosen

(counter clock-wise) the intermediate shaft yoke
coupling bolt. Separate the intermediate shaft
yoke from the steering gear assembly.

Using a 20 mm socket and wrench set, loosen ( counter clock-wise) the steering gear assembly
mounting bolt lock nuts from the chassis cross-member. Remove the rack assembly from its position.

INSTALLATION OF STEERING GEAR ASSEMBLY -

Install the PAS gear assembly on the chassis cross member. Using a 20 mm socket and wrench set,
tighten (clock-wise) the lock nuts.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 285
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Insert the intermediate shaft yoke over the

steering gear input shaft. Using 17 mm socket
and wrench set, tighten( clock-wise) the
intermediate shaft yoke coupling bolt to the
torque of 19~25 Nm.

INSTALLATION OF TIE-ROD END

Install both the tie-rod ends. (Refer procedure “Tie-rod end” in this section for instructions)

INSTALLATION OF POWER STEERING PRESSURE LINE

Install one end of PS pressure line in the steering gear and the other end of the PS pressure line in the
pump.

Install the inlet tube and outlet tube of the fluid lines in the intended ports of the steering gear.
Interchanging lines will damage the PS gear and pump.

FILLING OF POWER STEERING FLUID

Fill the power steering fluid (PS) in its reservoir. Check the level from the dip tube to ensure that it is
up to the “MAX” mark.

Check for Steering wheel centralization, correct if required.

Do the Toe-in check, correct if required.
- Toe-in recommended values for Genio is 0 to 1 mm ( 0 to 13’)

Never reuse the Power Steering fluid, if the same is found to be contaminated.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 286
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Checking for Steering Play

After driving the vehicle in a straight road, check

the wheel spokes for angular play.

If more than 25 to 30 degrees then check -Tie-rod

25/30 end ball joint or steering gear inner ball joint or
degrees Lower arm ball joint or universal joint.

Replace the defective part/parts.

While checking ensure that the engine is in off condition and wheels are in Straight Ahead Position
(SAP position)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 287
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Bleeding the system

• Before starting the Bleeding operation, ensure that the Vehicle is on level ground, and the
reservoir is filled to the maximum specified level.
• As with any hydraulic system ensure that the recommended fluids only is used. Ensure that no
dirt enters the system while topping up. Before opening the reservoir cap, wipe the area with
a cotton cloth and open the cap.

• Ensure that the front wheels are jacked up and wheels are lightly touching the ground.
• If this is not done then the steering linkage and components will be under undue stress.
• Even with the wheels partly jacked up; do not hold the steering in fully locked position for
more than 10 second. Failure to do so may damage the pump beyond repairs.
• Start the engine.
• Rotate the steering wheel from lock to lock; 3 to 4 times.
• Check if the oil in the reservoir has dropped down drastically- if so check for any leaks.
• Check if any foaming/ frothing are taking place.
• Repeat the rotation from lock to lock till the foaming subsides
• If the foaming is not subsiding after ¾ of the above cycle, check for the tightness of the hoses in
particular the reservoir to the steering pump and later the steering gear to reservoir. The loose
connection in these pipes will allow air to suck into the system.
• After completing the bleeding operation, ensure that with the engine running the oil level is
between the maximum and minimum mark.

• Close the reservoir cap properly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 288
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Working principle of the Steering Pump –

The steering pump is non-serviceable. Hence it cannot be repaired.

The pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief
valve) and it is gear driven by engine. The power steering pump consists of housing, drive shaft,
cartridge assembly & bearing(s) apart from the valve.

As the pump rotates a vacuum is created at the inlet, which causes atmospheric pressure to force the
fluid in to pump from the reservoir. As the rotor rotates, the inlet port closes and the fluid is trapped
between the vans. Further movement forces the fluid to be pressurized as the profile of the cam ring
constantly reduces the available volume. At the minimum point of the profile the chamber opens into
the outlet port.

The rotor is having 10 vanes, thus each rotation is equal to 5 pumping action. The discharge rate of the
power steering pump increases in proportion to the pump speed increases.. The flow control valve is
provided to maintain the optimum flow of the supplied oil for power steering operation, at all engine
speeds. The relief pressure will open when the system pressure exceeds the set value. This normally
happens when the steering wheel is turned and held in the lock position.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 289
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications

Steering system :
Type (Manual / Power assisted – Manual Steering Opt. Power assisted – Hydraulic
Hydraulic / Power assisted – Electric /
Other)
Steering wheel
Position(center/offset) Offset
Outside dia mm 406 opt. 380
Number of spokes 3
Steering column
Make Rane TRW Seering Systems. LTD.
Rane Madras LTD.
M/s Sona Koyo steering system Ltd.
Type / Model Non Tiltable Type
Intermediate shaft
Make M/s Sona Koyo steering system Ltd.
Rane Madras LTD.
Type / Model Bolero SLX/GLX/SLE/LX/XLS:-Coupling is provided in
Intermidiate shaft
Bolero DI/DIZ/DX/XL:- Without coupling
Maximum No. of rotation of steering For Rigid Axle :- Manual : 4.75 ; Power Stg. :- 3.75 ;
wheel from lock to lock For IFS :- Manual : 5.5;
For IFS :- Power Stg. : 3 Opt.- 3.5
Offset of the steering column with respect 46.5 mm Left of Seat Centre.
to the seat
Steering Gear
Type of steering gear Manual -Recirculating Ball Type
(Re-circulating ball / Worm & Roller /Rack Power Steering - Worm & Roller ;Opt.-Rack & Pinion
& Pinion / Others)
Make For Manual Strg. - M/S.Rane Opt. - Sona Koyo Strg.
Systems Ltd.
For Power Strg - M/s. Rane TRW Power Strg Ltd.
Opt. - Sona Koyo Strg.Systems Ltd.
Steering gear ratio
For Rigid axle: Manual - 20:1 to 23:1; Power Stg.- 18.2
:1 For IFS: Manual - 24:1; Power Stg.: 18.2:1;OPT.
40.1mm/ REV.
For Manual Stg. For Power Stg.
Wheel lock angle(deg) Inner Outer Inner(IFS) (R&P) Outer(IFS) (R&P)
Left Left 35 31 35 34 32 30
Right Right 35 31 35 34 32 30
Power Assistance Power steering worm & Roller type with UJ Optional
Power Steering Rack & Pinion
Type of assistance Hydraulic assistance
Make M/s.Rane TRW power Steering Ltd.
Opt.- Sona Koyo Stg.Systems Ltd.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 290
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Oil Specification For Worm & Roller - Fluid meeting DEXRON II

Specification.
RECOMMENDED BRANDS - CASTROL TQ OR IOC
TRANSDEX II
For Rack & Pinion :- Fluid meeting DEXRON III
Specification; RECOMMENDED BRANDS - SHELL
"SPIRAX S3 ATF MD3" (OR) CALTEX "TEXAMATIC FLUID
1888"
Oil capacity l For Worm & Roller - 1.6 Lit.;For Rack & Pinion.:-1.1 Lit.
Pressure setting, kg/cm2 / bar / kPa Not applicable
Min turning circle diameter mm For 2680mm WB:-
Recirculating Ball Type & Worm & Roller Type - 10800;
Opt. Rack & Pinion - 11600
For 2794mm WB:-
Recirculating Ball Type & Worm & Roller Type -11800
Opt.- Rack & pinion - 12400
Min. turning circle clearance diameter, mm For 2680mm WB:-
Recirculating Ball Type & Worm & Roller Type - 11200;
Opt. Rack & Pinion - 12000
For 2794mm WB:-
Recirculating Ball Type & Worm & Roller Type -12200
Opt.- Rack & pinion - 12800

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 291
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tightening Torques

Description Torque Value Nm (lbf-ft)

Steering Gear Centre Bolt 120 ±10 Nm (88 ± 7 lb-ft)
C Clamp side mounting 85 + 13Nm(62 lb-ft)
Casting side bolt 85 + 13Nm(62 lb-ft)
OBJ- tie rod end 80 + 10Nm(59 lb-ft)
Upper column top mounting 22 + 3Nm(16 lb-ft)
Upper column bottom mounting 22 + 3Nm(16 lb-ft)
Column grommet 22 + 3Nm(16 lb-ft)
Lower I shaft mounting on gear 22 + 3Nm(16 lb-ft)
Connector mounting on upper I shaft 22 + 3Nm(16 lb-ft)
Steering pressure hose 25 + 3Nm(18 lb-ft)
Steering return hose 25 + 3Nm(18 lb-ft)
Hose clamp on pump 22 + 3Nm(16 lb-ft)
Hose clamp on gear 13 + 2Nm(9 lb-ft)
Steering wheel nut 47 + 7Nm(34 lb-ft)
Steering column and ignition lock sub-assembly 14 + 1Nm(10 lb-ft)
Fitment of steering arm to knuckle LH/RH 80 + 10Nm(59 lb-ft)

• Recommended Lubricants

 The recommended brand names are: SPIRAX S3 ATF MD3

 Capacity is 0.8 lts.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 292
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• List of the MSTs –

Description / Part No. / Sketch Usage View

MST – 548
Steering stand

MST – 549
Tie rod end remover

MST – 550
Socket steering pump Nut

MST – 551
Unit wrench –12 mm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 293
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

FRONT SUSPENSION

Contents…

• Description…………………………………………………………………………………
• Trouble Shooting………………………………………………....................................
• Care of the System………………………………………………………………………
• In Car Repairs……………………………………………………………………………..
• Dismantling………………………………………………………………………………..
• Specification……………..……………………………………………………………….
• Tightening Torques………………………………………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 294
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description –

BOLERO m2DICR – IFS & STABILIZER BAR

The front suspension is independent type. The front suspension in

the 2WD vehicle is double wishbone type with helical spring and
telescopically acting hydraulic dampener. The front suspension also
employs stabilizer bar/ anti roll bar with ball joints on the connecting
links as shown in the sketch to transfer the loads to the outer wheel
during turns.

Stabilizer Bar - Schematic

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 295
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

A squeak noise from the shock absorber can be produced if movement between the rubber bushing
and metal occurs. Tightening the attaching parts can usually stop this noise. If the squeak noise
persists then inspect for worn or damaged bushings and attaching components. Repair as necessary if
anything found amiss.
Squeak also happen due to relative movement from suspension arm’s bush inner sleeve (serration
end) and chassis bracket. This situation happens, if torque is not as per specs. Torque tightening the
LCA & UCA bolts normally resolves the issue. The shock absorber bushings do not require any kind of
lubrication. Do not lubricate the bushings to reduce bushing noise. Grease or mineral oil base
lubricants will deteriorate the bushing.
The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must
be replaced. To test a shock absorber hold it upright in fully extended position for 10 minutes. Then
force the piston in and out of the cylinder four or five times. The action throughout each stroke should
be smooth and even.
Refer below trouble shooting chart for causes and remedial action.
Symptom Causes Remedial action

 Check and adjust:

 Hub end play
 Camber to be checked and
adjusted.
One Edge Wear Excessive camber

 Check & correct Toe In

 Check the chassis bend
 If tyre rotation not carried out
as per schedule. Do the tyre
rotation.
Feathered Edge Wear Incorrect Toe In
1. Body Mounts loose.  Tighten the body mounts.
Excessive Vehicle rolling 2. Suspension mounting  Tighten the suspension
loose. mounts.
3. Broken or deteriorated  If broken stabilizer bar-
stabilizer replace
4. Worn stabilizer bush  Replace the bushes & tighten
5. Malfunctioning shock to the specified torque,
absorber  Replace the shock absorber.
6. Stabiliser link bolt loose  Tighten the link bolts
Broken or deteriorated coil  Replace the coil spring
Vehicle inclined spring
1. Parts worn or loose  Tighten the parts or replace
Noise 2. Broken coil spring  Replace the coil spring
3. Shock absorber faulty  Replace the shock absorber

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 296
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the system

Following jobs covers suspension care while doing vehicle regular service intervals -

 Front suspension bolts torque - inspect

 Front suspension bushes ifs (coil spring) – inspect

 Front suspension arms ifs – inspect

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 297
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 FRONT SUSPENSION BOLTS TORQUE - INSPECT

Front Suspension – IFS & Anti roll bar

FRONT SUSPENSION BOLT TORQUE - CHECK

Refer illustrations shown.
1. Check Upper arm mounting bolt on chassis. Check & ensure the upper arm mounting bolt
torque – 90 ± 10 Nm.
2. Check the lower arm mounting on chassis. Check & ensure the mounting bolt torque – 90 ±
10 Nm.
3. Check the Strut bar bushings for cracks/ damage etc. Check & ensure the Strut Bar
mounting bolts for the torque –
• Strut Bar to Lower Arm - 40 ± 10 Nm
• Strut Bar to Chassis - 60 ± 10 Nm
4. Check & ensure shock absorber bar upper & lower mounting fasteners torque
– 35 ± 5 Nm.
5. Check & ensure the following Torque –
• Anti roll Bar Link Mounting nut on LCA: 40 ± 10 Nm
• Anti roll Bar Link nut on Stabiliser Bar: 40 ± 10 Nm

 While tightening the link ensure that wheels are resting on the ground/ 4 post lift. If it is not
done, the ride quality will get adversely affected.
 Front suspension bolt (Coil Spring) torque to be checked at every 15000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 298
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 FRONT SUSPENSION BUSHES IFS (COIL SPRING) – INSPECT

&
 FRONT SUSPENSION ARMS IFS – INSPECT

BUSH - Front
Suspension - IFS

FRONT SUSPENSION BUSH – CHECK

Refer illustrations shown.
1. Check Front Shock Absorber Rubber Bushes (both LH & RH) for wear or damage. Replace if
necessary. Check & ensure shock absorber bar upper & lower mounting fasteners torque –
35 ± 5 Nm.
1. Check Front Anti roll Bar –
• Bushings for wear or damage. Replace if necessary.
• Link Bushes (both LH & RH) for wear, twist or damage. Replace if necessary.
• Link Ball Joints (both LH & RH) for axial play/boot cut. Replace if observed.
2. Check the Strut bar bushings for cracks/ damage etc. Check & ensure the Strut Bar
mounting bolts for the torque.

 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.
 Front suspension bushes (Coil Spring)/ Arms to be inspected at every 15000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 299
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –

Following are the repair jobs covered in this section –

• Front Wheel Bearing greasing

• Wheel Alignment

• Steering Centralization

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 300
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Front Wheel Bearing – Lubricate

Wheel Bearing Grease- MAXIMILE LCG, NLGI 2/3

Front Wheel Hub - Dismantle

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 calliper without straining
the brake hose.

1. Loosen & Remove the hub cover bolts.

2. Remove the hub cover using a screwdriver.
3. Unlock the lock washer.
4. Using the MST 221, remove the outer locknut.
5. Take out the lock washer and the inner nut.
6. Pull out the hub along with the bearings.
7. Remove the Oil Seal.

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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 301
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

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. Torque Tighten the inner nut to 95 ± 14 Nm torque. The hub play should be within - 0.020
(i.e. It can be in preload zone & do not have any free play) to + 0.040 mm. (Since it is
recommended to be in the preload zone; hence the Step 9 is critical).
6. 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.
7. Put the locking washer & tighten the outer nut to the torque 95 ± 14 Nm.
8. Apply Anabond RTV 673 sealant on the gasket & fit the hub cover.
9. Fasten the hub cover bolts & tighten them.
10. Rotate the hub using a spring balance & the pulling force should not exceed 2.5 Kgs. (This
check to be done when the calliper is not fitted) If found more the shim setting should be
checked once again.
11. Assemble the calliper assembly.

 Ensure that the brake hoses are not stretched/ damaged. Put the calliper without straining the
brake hose.
 Wheel bearings to be lubricated at every 45000kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 302
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Wheel Alignment

Before proceding, it is necessary to understand weahther wheel alignment is required to do; Refer
below decision tree to know more on wheel alignement requirement :

Do the wheel
Has the vehicle covered Yes alignment as per the
40,000 Km, process

No

Yes
Any abnormal tyre
wear?

No

Does the vehicle pull to

one side even with
Yes
correct tyre pressures?

No

Yes
Check the front
Front ride height loss suspension bushes
more than 10 mm? and shock absorbers
bushes

No

Yes Torque tighten the

Front suspension bolts and align the
bolts loosened? original marks.

No

Wheel alignment not required

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 303
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Wheel Alignment – Procedure

ADJUSTING
FULCRUM PIN
SHIM

UPPER CONTROL ARM

STRUT BAR

Pre Work for Wheel Alignment Process:

Tyre pressure : Ensure correct tyre pressure before start wheel alignment. Sequence :

LOWER
CONTROL Bolero IFS Exploded View - Schematic
ARM

For adjusting the Castor –

• The values should be within 3° ~ 5°
• The difference between the LH and RH wheels Castor should be within 1°
 Castor angle is set by adjusting the length of the strut bar. Fine adjustment up to 30’ can be
done if required by adjusting the threaded portion of the strut bar end (383 ± 1 mm)

For adjusting the Camber – Refer illustration shown below.

• The value for any given wheel should be + 30’ ± 15’ (i.e. +15’ to + 45’) Camber is adjusted by
adjusting shims.
• To increase the camber, add shims in between fulcrum lever & chassis bracket. To decrease
the camber; remove shims from fulcrum lever & chassis bracket. Difference between left
and right camber value should be within 30’. By interchanging 1 mm of shim camber will
vary approximately 8’.
• Tighten the fulcrum mounting bolt to 90 ± 10 Nm. (Refer to the torque chart).
• 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.
• Cross-confirm the camber value.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 304
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

For adjusting the Toe In - Refer illustration shown below.

Toe is adjusted by adjusting tie rod length. Partial toe in of bolero is: 12’ to 18’. To increase the toe
in reduce the length of tie rod. If the toe in is out of the standard value adjust by turning the right
and left turn buckles of the tie rod to an equal amount. Apply locktite to avoid loosening of tie rod
end nut. The difference between the length of right & left tie rod should not be more than 5 mm.
After adjusting the toe-in confirm the right and left turning angle.

Adjusting the Wheel turning 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 35° (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 35° 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.

• Wheel Alignment Parameters –

PARAMETERS VALUES
Toe in Partial 12’ to 18’ at wheel rim
Toe in Total 3 to 5 mm
Camber +30’ ± 15’
Difference between LH & RH Camber 30’
Caster 3o to 5o
Difference between LH & RH Castor 1o
King pin inclination 9o 45’ to 11o 75’
Wheel turning angle 35o

 Wheel alignment to be carried if abnormal conditions are noticed or at 40000kms, whichever is

earlier.

 The sequence of the wheel alignment, which should be followed, is:

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 305
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Carry out the run out compensation when using the computerized equipment.
 Please note that if the run out compensation is not done correctly/bypassed (by just
entering the enter button) then all the values which will be read may be wrong hence all
the adjustments may be wrong.
 In other words if run out compensation is not done then each time the wheel alignment is
done the value obtained/measured will be different.

1. Steering Wheel Centralize- cross check & adjust.

2. Castor checking & adjustment ( Computerized / Manual)
3. Camber checking & adjustment( Computerized / Manual)
4. Toe in checking & adjustment. ( Computerized / Manual)
5. Wheel Turning Angle, checking and adjustment. ( Computerized / Manual)
6. Check the centralization of the Steering wheel as the final operation

In order to obtain the correct values and avoid complaints. Please note that the following parameters
have to be adhered without fail:

• The tyre pressures in all the four wheels are as per the specifications, refer below chart.
• Vehicle should be unladen and parked on level surface
• Ensure that the wheel hub play is correct.

Check that the chassis and the under body are not coated with mud. If in doubt get the vehicle
cleaned before doing the checking.

• Replace the parts of suspension if found badly damaged

• Before starting the measurement, ensure that the parking brakes are applied and the rear
wheels are blocked
• Before doing the wheel alignment – ensure that the linkages i.e. the ball joint are not worn or
loose. Check the free play in the steering.
• All the tyres and the wheel disc should be of the same type.

This procedure for centralizing the Steering wheel is valid only if the misalignment of the spokes is
less than 10 degrees. In other words this procedure is only for fine-tuning the steering wheel position
not for glaring error. If it is more 10 degrees then remove the steering wheel and initially realign to
less than 10 degrees.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 306
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Steering Wheel Centralization

This procedure for centralizing the Steering wheel is valid only if the misalignment of the spokes is less
than 30 degrees. It is only for fine-tuning the steering wheel position and not for gross error. If it is
more 30 degrees then remove the steering wheel and initially realign to less than 30 degrees.

To check for the centralization of the steering wheel.

Drive the vehicle on a level road surface; note the angular
position (misalignment of the steering wheel spokes.

Raise the vehicle. Keep the wheels in Straight Ahead Position.

Mark the position of the track rods and the track rod
ends.

Slacken the track rod end lock nuts and also remove the
gaiter outer retaining clips.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 307
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Rotate both track rods in the same direction

approximately 30 degrees for every 1-degree of steering
misalignment error.

If the steering wheel has an anti clockwise angular error then both track rods must be rotated
clockwise- when viewed from the left – hand side of the vehicle.

If the steering wheel has an clockwise angular error then both track rods must be rotated
anticlockwise- when viewed from the left – hand side of the vehicle.

 Refer Wheel Alignment procedure prescribed earlier in this section to check below –

1. Castor checking & adjustment

2. Camber checking & adjustment
3. Toe in checking & adjustment.
4. Wheel Turning Angle, checking and adjustment.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 308
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specification -

Suspension : Type and description (Leaf / Coil / Air / Semi-pneumatic / Torsion bar)
Front Rigid Suspension - Leaf Spring
Opt: - 2WD- Coil Spring (For Independent Front Susp.)
Rear Rigid Suspension - Leaf Spring
Make - Front For Leaf Spring - M/s Vikrant; Opt.Jamuna , TOYO
For Coil Spring - M/s Coventry,Opt. M/s.TC Springs
Make - Rear M/s Vikrant Opt. Jamuna Opt. TOYO Opt. MAC
Type of spring Front. - Leaf Spring; Opt. Front - Coil Single Stage
Rear - Leaf Semi Eliptical Two Stage
Bolero; Bolero DI/DX BOLERO XL/XLS
If leaf spring Frt. Leaf Spring Rr. Leaf Spring Rr. Leaf Spring
Main spring
Stack height, at center 28.5 51 57
Width at the center point / stack point 63.5 63.5 63.5
Flat length 921 1219 1219
Free camber 125 130 150
No. of leaves 6 6 7
No. of spacers 0 4 6
Auxiliary Spring/ Stack height, at center Not applicable
Width at the center point / stack point Not applicable
Flat length/ Free camber Not applicable
Suspension- Shock absorber :
Type and Number
Front & Rear Hydraulic Double Acting, Telescopic , 2

Suspension- Stabilizer :
Front Torsion Type
Rear Torsion Type ( For Bolero XL/XLS Only )

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 309
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Recommendations -

• Lubricants –

No lubricants / grease to be used in the suspension bushes. Only soap solution to be used during
assembly

• Tyre Pressure – Refer below chart for correct tyre pressure in New BOLERO Zlx/ Slx & Sle -

COLD TYRE INFLATION PRESSURE – NEW BOLERO Zlx/ Slx/ Sle

215 / 75 R15 185 / 85 R16
TYRE SIZE/
Laden Unladen Laden Unladen
Location
Kg/cm2 (bar) Kg/cm2 (bar) Kg/cm2 (bar) Kg/cm2 (bar)
FRONT 1.6 (23) 1.6 (23) 2.6 (37) 2.6 (37)
REAR 2.4 (34) 1.8 (26) 2.8 (40) 2.6 (37)

• Tightening Torques –

Location Torque Nm
UCA mtg. bolt on frame. 90 ± 10 Nm
UCA ball joint nut 140 ± 20 Nm.
LCA mtg. bolt on frame. 200 ± 20 Nm.
LCA ball joints to LCA 45 ±5 Nm.
LCA ball joint nut 140 ± 20 Nm
Stab bar mtg. bolt on frame. 40 ± 10 Nm
Link mtg. bolts on knuckle & Stab bar 40 ± 10 Nm
Shock absorber upper mtg. bolt on chassis. 40 ± 5 Nm
Shock absorber mtg. bolt on LCA 120 ± 10 Nm.
Wheel Nut 95 ± 5 Nm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 310
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

REAR SUSPENSSION

Contents…

• Description………………………………………………………………
• Trouble Shooting………………………………………………………
• In Car Repairs…………………………………………………………..
• Specification……………………………………………………………
• Tightening Torques……………………………………………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 311
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description –

The front and rear suspension is a progressively rated multi leaf spring with double acting shock
absorber. The front end of the springs is mounted at the pivot end through rubber bushings. The
bushings isolate the road noise and road harshness as the springs move. The rear end of the spring is
connected to the springs through shackle.

New Bolero Rear Suspension - Schematic

The shackles allow the variation of the spring length when the vehicle moves over the different terrain
causing the wheel to move up and down.

The travel of the spring is controlled by bumper, which is mounted on the axle. The springs are
connected to the axle with U-bolts and spring plate. All suspension components that use rubber
bushings should be tightened with the vehicle at normal height. If the springs were not at normal ride
height condition the ride quality would be affected and also the life of rubber will also be affected.
Rubber bushings must never be lubricated.

The ride control is achieved by the use of double acting shock absorbers and leaf springs. The shock
absorbers dampen the jolt and the rebound as the vehicle travels over the various road conditions.
The top end of the shock absorber is connected to the chassis while the bottom end is connected to
axle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 312
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

A squeak noise from the shock absorber can be produced if movement between the rubber bushing
and metal occurs. Tightening the attaching parts can usually stop this noise. If the squeak noise
persists then inspect for worn or damaged bushings and attaching components. Repair as necessary if
anything found amiss.

The shock absorber bushings do not require any kind of lubrication. Do not lubricate the bushings to
reduce bushing noise. Grease or mineral oil base lubricants will deteriorate the bushing.

The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must
be replaced. To test a shock absorber hold it upright in fully extended position for 10 minutes. Then
force the piston in and out of the cylinder four or five times. Also check for any hydraulic oil leakage.
The action throughout each stroke should be smooth and even.

Symptom Causes Remedial action

Suspension Noise 1. Check if mud is between  Clean with pressurized water.
the leaf springs.
2. Check tip insert if broken/  Replace the tip between the leaves.
worn out.
3. Check bushes.  Replace the bushes.
4. Check shock absorber  Tighten the shock absorber mounting
bush worn out/ loose. bolt or replace the bushes.
5. Check leaf breakage.  Replace the spring assembly.

Vehicle ride Jumpy/ 1. Improper tyre pressure.  Keep tyre pressure as recommended.
Jerky  Replace the shock absorber.
2. Shock absorber bushes
worn out.  Replace the bushes.
3. Spring leaf bushes worn
out.  Check the shock absorber and replace
4. Shock absorbers leaking/ if required.
weak.  Check the bump clearance as per the
5. Leaf spring sagging / specified procedure.
broken.  Replace springs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 313
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the System –

• SUSPENSION BOLT TORQUE (SHACKLE & PIVOT) REAR – INSPECT & ADJUST
&
• SUSPENSION BUSHES (SHACKLE & PIVOT) REAR – INSPECT

Suspension – Shackle & Pivot

SUSPENSION BUSHES & TORQUE VALUES (SHACKLE & PIVOT) REAR – CHECK & ADJUST
Refer illustrations shown.

1. Check the Shock Absorber bushes (along with anti roll bar bushings in case of 4 WD / Rigid
Suspension) for wear, cracks & damage.
2. Check & ensure the lower & upper mounting nut torque – 35 ±5 Nm.
3. Check the leaf spring bushes for wear, cracks & damage. Check & ensure the nut torque at
pin end & shackle end – 89 ± 6 Nm.
4. Grease shackle Pins; in case of 4 WD / Rigid Suspension.

 Suspension bushes (Shackle & Pivot) Front & Rear to be inspected at every 15000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 314
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –

This section consists of –

1. Shock absorber removal

2. Leaf spring - bush replacement

- Pivot end bush replacement

- Shackle end bush replacement

3. Leaf spring assembly - replacement

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 315
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• SHOCK ABSORBERS - REMOVAL

• Remove the upper attaching nut and washer.

• Remove the lower attaching nuts, washer and bolts from the axle. Remove the shock
absorber.
• While fitting ensure that they are tightened to a torque of 45 to 55 Nm (33 to 40 Lb ft)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 316
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

LEAF SPRING - BUSH REPLACEMENT

• Pivot End Bush Replacement –

BUSH

Tightening Torque
50 ~ 70 Nm.

• Support the vehicle in chassis

1. Loosen the shackle mounting bolts.
2. Remove the pivot mounting bolts by rotating and pulling.
3. Pull out inner bush by pulling it out.
4. Lower the axle and bring the spring out of pivot.
5. Remove the bush by pulling it out.

While assembling ensures that:

• The rubber bushes are liberally coater with soap water.
• The hole in the centre of the pivot and the hanger bracket are clean and not blocked by
mud.(The hole is provided so that while assembling the air should not get trapped between
the two bushes- preventing proper assembly.)
• The eyes in spring and pivot/shackle are properly aligned before the bushes are inserted.
• After the bushes are inserted, remove the support from the chassis & axle (if used) and then
tighten the pivot and shackle bolts to the desired torque.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 317
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Shackle End Bush Replacement –

BUSH SHACKLE BRACKET

Tightening Torque
50 ~ 70 Nm.

• Support the vehicle in chassis

1. Loosen the shackle mounting bolts.
2. Remove the shackle/pivot mounting bolts.
3. Pull out one bush at a time. Each eye is having two collared bushes. They can be pulled out.

While assembling ensures that:

• The rubber bushes are liberally coater with soap water.
• The hole in the centre of the pivot and the hanger bracket are clean and not blocked by
mud.(The hole is provided so that while assembling the air should not get trapped between
the two bushes- preventing proper assembly.)
• The eyes in spring and pivot/shackle are properly aligned before the bushes are inserted.
• After the bushes are inserted, remove the support from the chassis & axle (if used) and
then tighten the pivot and shackle bolts to the desired torque.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 318
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• LEAF SPRING ASSEMBLY - REPLACEMENT

• The leaf springs need to be replaced only if the springs are broken or are sagging.
• To check for the spring sagging it is recommended that bump clearance in unladen conditions
is measured.

The bump clearance has to be measure after ensuring that -

• The vehicle is in level ground.
• It is unladen.
• The tyre pressure is as per the recommendations and also no variation between left and
right tyres.
• The bump stop is not in deteriorated or damaged condition.
• The bump clearance is 85±10 mm and the variation between Left and right is allowed to be
7 mm

Re-cambering of the spring is not recommended. (Please note that the spring is of progressive type
– any re-cambering will result in the ride becoming linear as well as stiff.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 319
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications

Suspension :
Type and description (Leaf / Coil / Air / Semi-pneumatic / Torsion bar)
Front Rigid Suspension - Leaf Spring
Opt: - 2WD- Coil Spring (For Independent Front Susp.)
Rear Rigid Suspension - Leaf Spring
Make
Front For Leaf Spring - M/s Vikrant; Opt.Jamuna , TOYO
For Coil Spring - M/s Coventry,Opt. M/s.TC Springs
Rear M/s Vikrant Opt. Jamuna Opt. TOYO Opt. MAC
Type of spring Front. - Leaf Spring; Opt. Front - Coil Single Stage
Rear - Leaf Semi Eliptical Two Stage
Bolero; Bolero DI/DX BOLERO XL/XLS
If leaf spring Frt. Leaf Spring Rr. Leaf Spring Rr. Leaf Spring
Main spring
Stack height, at center 28.5 51 57
Width at the center point / stack point 63.5 63.5 63.5
Flat length 921 1219 1219

125 130 150

Free camber
No. of leaves
No. of leaves 6 6 7
No. of spacers 0 4 6
Suspension- Shock absorber :
Type and Number
Front/ Rear Hydraulic Double Acting, Telescopic , 2
Suspension- Stabilizer :
Front Torsion Type
Rear Torsion Type ( For Bolero XL/XLS Only )

• Torque Chart

Description Torque Values

Bolt – Leaf spring pivot 89 ± 6 Nm (66 ± 4 lbf-ft)
Bolt - Shackle 89 ± 6 Nm (66 ± 4 lbf- ft)
U Bolt 65 ± 5 Nm (48 ± 4 lbf-ft)
Shock absorber top 35 ± 5 Nm (26 ± 4 lbf-ft)
Shock absorber bottom 35 ± 5 Nm (26 ± 4 lbf-ft)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 320
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

BRAKES

Contents…

• Description………………………………………………………………….
• Trouble Shooting…………………………………………………………..
• Care of the Axle………..……..……………………………………………
• In Car Repairs………………………………………………………………
• Working Principles of various systems………………………………..
• Specification……………………………………………………………….

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 321
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description

The purpose of the brake system is to allow the driver to reduce the vehicle speed or stop the vehicle
in a stable & safe manner. The function of the brake system is to convert kinetic energy of the vehicle
into heat energy through the application of friction.

A vehicle is also equipped with a parking brake mechanism to be used in parking conditions of vehicle
or in case of hydraulic brake failure, usually through the application of a hand operated lever.

Generally the braking power is three to five times more than the engine power. Brake systems use
friction to slow down, stop and hold the wheels of a vehicle. Brake systems apply friction by the use of
brake shoes or brake pads. Although friction is being applied to the brakes it is actually the friction
between the tires and road surface that stops the vehicle.

A disc brake uses brake pads to carry the friction material. The brake pad friction material is bonded to
a steel pad (back plate). Most brake pad manufacturers use a combination of metallic fibers in a resin
material to create the friction material.

A drum brake uses a brake shoe to carry the friction material. The friction material may be riveted or
bonded on to a steel shoe (web). Kevlar or a steel and mineral fiber mix is a common friction lining for
the brake shoe. Brake friction materials must be able to withstand temperatures up to 700 degrees
Celsius for short periods.

New Bolero Brake System - Schematic

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 322
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

The brake system in New BOLERO Zlx/ Slx/ Sle - m2DICR is vacuum assisted ‘H’ split type. The front
brakes are single pot callipers with ventilated rotor (with angular vanes, hence the LHS and RHS are
different). The rear brakes are drum type with self-adjusting mechanism. The parking brakes are
actuated in the rear through cable. Both the front disc pads and the rear brake liners are non asbestos.

The braking system includes a Load sensing Proportioning Valve. It controls the brake fluid pressure
going to the rear depending on the load on the vehicle. Normally when the vehicle is loaded and
brakes applied; due to the weight transfer the load on the rear wheels become very less. In vehicles
without the LSPV; the full pressure of brake fluid going to the rear wheels tends to lock them. In
vehicles fitted with LSPV, the LSPV reduces the brake fluid going to the rear circuit depending on the
load hence avoids the rear wheel locking. Since the rear wheel locking is avoided it results in reducing
the braking distance (distance covered before the vehicle comes to a standstill)

The brake circuit is having an inbuilt bypass valve in the LSPV. In an unlikely situation of the front
brake circuit failure; the LSPV valve is bypassed and the full pressure of brake fluid goes to the rear.
This ensures that braking is achieved. The complete details about the LSPV valve & its functioning and
setting are mentioned later.

SUPER VAC SERVO / BOOSTER (MECHANICAL)

The super vac is a vacuum assisted mechanical servo unit. The above servo is designed to provide
controlled power assistance to the effort applied by the driver’s foot to the brake pedal. Power
supplied by the unit is obtained from the vacuum created by the pump fitted behind alternator. The
vacuum is applied on the both sides of the diaphragm and by admitting atmospheric pressure to one
side of the diaphragm the power is obtained. The unit is mounted of the brake pedal and the master
cylinder. The servo input push rod is connected to the brake pedal, while the output pushrod operates
the master cylinder. Should a vacuum failure occur, the two pushrod acts as a single pushrod and
brakes will work in a conventional manner, but more pedal effort will be required and fatigue of the
driver will increase.

LSPV

When there is a large difference in vehicle weight between laden &

empty conditions; during dynamic braking, the weight on the rear axle
tends to shift towards the frontal direction of vehicle (known as Load /
Weight Transfer) resulting into less vertical load on rear axle which
results into rear wheel locking. LSPV regulates the pressure in the rear
brakes in proportion to the load in vehicle. Hence it is called as Load
Sensing Proportioning Valve.

Refer illustration shown.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 323
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting

Preliminary checks involve inspecting fluid level, parking brake action, and wheel and tyre conditions,
checking for obvious or external leaks or component damage and pedal response. A road test will
confirm or deny the existence of the problem.

While road testing if the complaint involved low brake pedal, make several low speed stops and note if
pedal comes back to normal height. Check the pedal response with gear in neutral and engine
running. The pedal should remain firm under steady pressure. During road test make normal and firm
brake stops in speeds of 40 to 60 Km/h. Note faulty brake operation such as pull, grab, drag, noise, low
pedal, hard pedal, fade, pedal pulsation, etc.

Diagnosis –

Pedal falls away / Pedal sinking

A brake pedal that falls away under steady foot pressure is generally the result of system leak. The
leak point could be at a brake line, fitting hose, wheel cylinder or Master Cylinder Internal leakage’s
caused by worn or damaged piston, seals may also be the problem cause.

If leakage is severe fluid will be evident at or around the leaking component.

Low pedal

If a low pedal is experienced, pump the pedal several times. If the pedal comes back up, worn lining
and worn rotors or drums are the most likely cause. However, if the pedal remains low and / or the
warning light illuminates then the problem is in the master cylinder, wheel cylinder, or callipers.

A decrease in master cylinder fluid may only be the result of normal lining wear. Fluid level will
decrease in proportion to the lining wear. It is a result of the outward movement of caliper and wheel
cylinder pistons to compensate for normal wear. Top up reservoir fluid and check brake operation to
verify the complaint.

Spongy pedal

A spongy pedal is most often caused by air in the system. However thin drums or substandard brake
lining and hoses will also cause a condition similar to spongy pedal. The proper course of action is
bleed the system or replace thin drums and suspect quality brake lining and hoses. In case the system
has not been maintained as per recommendations and the brake hoses have not been replaced then
due to swelling of the hoses during braking – it also causes spongy braking. In such a condition it is
advisable to replace the hoses and replace all the seals and change the brake fluid.

Hard pedal or high pedal effort

A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed or
badly worn. Defective vacuum assistance will also cause hard operation. The vacuum booster or check
valve (NRV) could also be faulty. Test the booster function. As detailed below —

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 324
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

1. Start engine & check booster hose connections as well as the EGR valve connections. Correct any
vacuum leak before proceeding further.

2. Stop the engine and put in neutral.

3. Pump the brake pedal until all the vacuum in the reservoir is exhausted (normally after 6 to 8 pedal
applications the brake pedal will become hard)

4. Press and hold brake pedal under light foot pressure

a. If the pedal hold firm then proceed to step 5.
b. If the pedal does not hold firm then and falls away then the master cylinder is defective.

5. Start the engine and note pedal action.

a. If the pedal falls away slightly under light pedal action and then hold firm then proceed to
step 6
b. If no pedal action is discernable then vacuum pump or vacuum check valve is defective.

6. Rebuild the vacuum reserve as follows. Release brake pedal. Increase engine speed to 1500 rpm
and then bring it to idle and shut off engine.

7. Wait for about 90 seconds and try brake action again. Booster should provide two or more vacuum
assisted pedal applications. If vacuum assist is not performed then perform check for the check
valve and booster.

Find the enclosed Brake booster basic test flow chart –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 325
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

TROUBLE SHOOTING OF VACUUM BOOSTER ASSEMBLY

BASIC TEST

ENGINE ‘OFF’. Depress & release brake pedal several times to remove vacuum from Booster
Assembly. After this the pedal application will feel hard to press.

Depress the brake pedal & hold with light pressure of @ 10kgs. & start the ENGINE

If the booster is functioning satisfactory, the pedal will fall slightly & then hold. Here less pressure
will be needed to hold the pedal dawn.

IF THE BOOSTER IS NOT OPERATING If the BOOSTER is

Disconnect the vacuum hose from the NRV. Then with OPERATING pl. turns over & do
ENGINE RUNNING, Check vacuum supply with a the VACUUM LEAK
vacuum gauge. There should be at least 600 mm of Hg TEST.
vacuum for Diesel vehicle.

If VACUUM SUPPLY IS BELOW 600 mm of Hg for If VACUUM SUPPLY IS

diesel vehicle replace or repair vacuum hose & 600 mm of Hg for or more for diesel
vacuum source. vehicle, then the booster is faulty & should
be replaced.

When adequate vacuum supply is

obtained, repeat basic test.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 326
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

VACUUM LEAK TEST

Run engine to medium speed. Release accelerator

& turn Engine OFF. This builds up vacuum.

Wait for 90 sec. & apply brakes. Two or more

applications should be vacuum assisted.

IF APPLICATIONS ARE NOT VACUUM IF APPLICATIONS ARE

ASSISTED disconnect vacuum hose from VACUUM ASSISTED there is no
vacuum source or NRV whichever is vacuum leak.
easier. If disconnected from NRV, attach DO THE HYDRAULIC LEAK
short length of hose to valve. TEST

Blow into hose attached to NRV. If air passes

through, valve is defective.

IF NRV or CHECK VALVE IS IF NRV OR CHECK VALVE

DEFECTIVE install new NRV IS OK, vacuum booster is
& repeat VACUUM LEAK TEST. leaking & should be replaced.

Depress & release brake pedal several

times. Then hold pedal depressed with
medium pressure.

IF PEDAL FALLS AWAY hydraulic system is IF PEDAL DOES NOT FALLS

leaking. Check for external leakage at wheel AWAY hydraulic system is not
cylinders, callipers, brake pipes, hoses & leaking.
joints.
If there is no external leak, there may be an
internal leak (master cylinder seals).
Repair or replace parts needed to correct leak.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 327
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

CHECK VALVE/ NRV -- NON RETURN VALVE, MOUNTED ON VACUUM BOOSTER FRONT FACE.

Brake drag

Brake drag occurs when the lining is in constant contact with the rotor or drum. Drag can occur at one
wheel, all wheels, front only or rear only. It is caused by incomplete shoe release. Drag can be minor
or severe enough to overheat the lining, rotor and drum.

Brake drag has a direct effect on fuel economy. Undetected minor drag can be misdiagnosed as an
engine complaint. In case of severe drag it can also cause clutch slip.

Minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in the
rotor or the brake drum from the overheating/ cooling process. In most cases the rotors, drums,
wheels, and tyres are quite warm to touch after the vehicle is stopped.

Severe drag can char the brake lining all the way through. It can also cause distort and score rotors
and drums to the point of replacement. The wheels, tyre and brake components will be extremely hot.
In severe cases the lining may generate smoke as it chars from overheating.

Some common causes of brake drag are:

• Loose or damaged wheel bearing

• Seized or sticky caliper or wheel cylinder piston.
• Loose caliper-mounting bracket.
• Loose mounting bolts of the rotor.
• Bent sliding pins in the calliper.
• Distorted brake drum or shoes.
• Rear brake shoes binding on worn/ damaged support plates
• Misassembled components
• Incomplete release of parking brake
• No free play
• Clogged master cylinder return port
• Broken master cylinder return spring
• Early lock of rear wheel due to change in setting distance of LSPV .

If the brake drag occurs at all the wheels, the problem may be related to a blocked master cylinder
compensation port or faulty vacuum booster (binds does not release).

An improperly mounted brake light switch can also be a cause of drag. An improper mounting may
prevent the brake pedal to return completely. This will cause the master cylinder feed port to be
blocked. The brakes would be partially applied causing the drag.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 328
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Brake Fade

Brake fade is a product of overheating caused by brake drag. However overheating and subsequent
brake fade can also be caused by riding the brake pedal, making repeated high deceleration stops in a
short time span,

Constant braking on steep roads also cause brake fade. If the brake lining is contaminated with oil or
glazed then also the brake fading will take place.

Pedal Pulsation

Pedal pulsation is caused by components that are loose or beyond tolerance limits.

Disc brake rotors with excessive lateral run out or disc thickness variation, or out of round drums are
the primary cause of pulsation. Other causes are loose wheel bearings or calipers and worn, damaged
tyre

Brake Pull

A front pull condition would be the result of:

• Contaminated lining in one caliper.

• Seized caliper piston
• Binding caliper.
• Loose caliper.
• Loose or corroded slide pin.
• Improper brake shoes
• Inadequate contact of pad.
• Damaged rotor
• Incorrect tyre inflation (High variations between two wheel)
• Shoe return spring weak or broken

A worn, damaged wheel bearing or suspension components are further cause. A damaged front tyre
(bruised, ply separation) can also cause pull.

A common and frequently misdiagnosed pull condition is where the direction of pull changes after a
few stops. The cause is a combination of brake drag followed by brake fade at the dragging brake unit.
As the dragging brake overheats, efficiency is so reduced as the fade occurs. If the opposite braking
unit is still functioning then its braking effect is magnified. These causes pull to switch direction in
favour of the brake unit that is functioning normally.

While diagnosing a pull in change in pull condition, remember that pull will return to the original
direction if the dragging brake unit is allowed to cool down (and is not seriously damaged)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 329
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Rear Brake Grab

Contaminated lining, bent, or binding shoes and support plate usually causes rear grab (or pull). This is
particularly true when one wheel is involved. However when both rear wheels are affected the master
cylinder or the proportionate valve could be at fault.

Brakes do not Hold after Driving through Deep Water Puddle

This condition is generally caused by water soaked lining. If the lining is only wet it can be dried by
driving with the brakes lightly applied for 2 to 4 kms. However if the lining is both wet and dirty then it
will be necessary to dismantle, clean and reassemble.

Brake Fluid Contamination

There are two causes of brake fluid contamination. The first involves allowing dirt, debris, or other
liquid material to enter cylinder reservoir when the cover is off. The second involves adding to, or
filling the cylinder with a non- – recommended fluid. Brake fluid contaminated with only dirt, or debris
usually retains a normal appearance. In some cases the foreign material will remain suspended in the
fluid and be visible. The fluid and foreign material can be removed from the reservoir with a suction
gun but only if the brakes have not been applied. If the brakes are applied after contamination, system
flushing will be required. The master cylinder may have to be disassembled, cleaned and the piston
seals replaced. Foreign material lodged in the reservoir compensator/ports can cause brake drag by
restricting the fluid return after application.

Brake fluid contaminated by a non recommended fluid will usually be discoloured, milky, oily looking
or foamy. In some cases it may even appear as if the fluid contains sludge. However remember that
the brake fluid will darken in time and occasionally are cloudy in appearance. These are normal
conditions and should not be mistaken for contamination.

If some type of oil has been added to the system then the fluid can separate into distinct layers. This
can be verified by draining off a sample with a clean suction gun. Then pour the sample into a glass
container and observe fluid action. If the fluid separates into distinct layers, it is definitely
contaminated.

The only real correction for contamination by non-recommended fluids is to flush the entire
hydraulic system and replace all the seals and the brake hose.

Brake Noise

Squeak/Squeal

Brake squeak or squeal may be due to lining that are wet or contaminated with brake fluid, grease or
oil. Glazed linings and rotor/drums with hard spots can also cause squealing. Dirt and foreign material
embedded in the system will also cause squeak/squeal. Worn retaining pins can also cause disc pad to
squeak/ rattle.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 330
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

A very loud squeak or squeal is frequently a sign of severely worn brake lining (or the drum or the
rotor). If the lining has worn to the rivets then metal to metal contact takes place. If the condition is
allowed to persist then rotors/drums can become so scored that replacement is necessary.

Thump/clunk

Thumping or clunking noise during braking are not caused by the brake components. In many cases
such noises are caused by loose or damaged steering, suspension or engine components. However
calipers that bind on the slide surface can generate thump or clunk noise. In addition, worn out
improperly adjusted, or improperly assembled rear brake shoes can also produce a thumping noise.

Chatter

Loose or worn components or glazed/burnt lining usually causes brake chatter. Rotors with hard spots
can also contribute to chatter. Additional causes of chatter are out of tolerance rotors, brake ling not
secured properly to shoes, loose wheel bearings and contaminated brake lining.

Brake lining contamination

Brake lining contamination is usually a product of leaking calipers or wheel cylinders, driving through
deep puddles, or lining that has become covered with grease and gravel during repair.

Wheel & Tyre Problems

Some conditions attributed to brake components may actually be caused by a wheel or tyre problem.
 A damage wheel can cause shudder, vibration and pull. A worn or damaged tyre can also
cause pull.
 Severely worn tyres with very little tread depth can produce a condition similar to grab as the
tyre loses and recover traction.
 Flat spotted tyres can cause vibration and wheel tramp and generate wheel shudder during
brake operation.
 A tyre with internal damage such as bruise or ply separation can cause pull and vibration

Defective Parking Brake

This can be caused by excessive hand brake lever play. Sticky parking cable, grease or oil on shoe,
excess shoe clearance (normally caused by malfunction of automatic adjusting mechanism)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 331
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the system

The brake fluid should conform to DOT 4 specifications.

The brake fluid should be replaced twice a year or every 40,000 Kms. whichever is earlier. This is
because brake fluid is hygroscopic in nature hence it absorbs moisture. The normal braking operation
also results in brake fluid getting heated. The process of heating and cooling also results in moisture.

The brake fluid boiling point keeps coming down due to the presence of moisture hence if not
changed it can cause higher corrosion of the wheel cylinders/ master cylinders/ brake tubes as well as
spongy or poor braking.

Do not mixes brake fluid of different brands. Do not use any brake fluid, which is kept in an open
container. Always use brake fluid from a sealed container.

The brake fluid should not be contaminated with any mineral oil. Do not use reuse brake fluid that has
just been bled. The list of the recommended lubricants is enclosed at the end of the chapter.

This section consists of following Maintenance activities –

• Front brake disc/ brake pad check

• Rear brake – check

• Parking brake – check

• Brake booster – check

• LSPV – setting

• Brake fluid level & leak – check

• Brake fluid replacement & System Bleeding

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 332
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• FRONT BRAKE (PAD/ CALLIPERS) – CHECK

Front Brake – Check Refer illustration shown.

 Park the vehicle on levelled ground. Jack the vehicle up & remove the wheel.
1. Check the disc for wear (Minimum usable thickness of the disc is 19mm).
2. Loosen & remove the bottom side sliding pin bolt. Swing up the calliper.
3. Remove the pads & check the pad thickness. The minimum usable pad thickness is 8.5 mm. If
observed less; replace the pads. (The groove at the centre 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)
• Check for the oil leakage from Callipers.

 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.
 Check brake pads at every 10000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 333
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• REAR BRAKE (DRUMS/ LINERS) – CHECK

1 2

Brake Drum/ Liners – Check

Refer illustration shown.
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 3.0 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.

 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.
 Check brake liners for wear at every 20000 kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 334
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• PARKING BRAKE OPERATION – CHECK & ADJUST

Schematic - Parking Brake Hand Brake Lever

Lock Nuts

Parking Brake Cable - Front

Parking brake cable-

Front
Lock Nuts
Turn
buckle
assembly

Rr. RH & LH side

Parking brake cable

PARKING BRAKE – CHECK. Refer illustration shown.

1. 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.
• Loosen or tighten the adjuster nut to achieve the correct setting*.
2. Check the parking cables (especially rear) for correct routing / fouling.
*Setting Procedure – Do the Parking Break cable setting as follows:
• Before starting the Parking Break Setting, ensure all the parts are assembled properly.
• Parking Brake setting can be done through Turn Buckle Assembly located on bracket welded
chassis long member, near Rear Left side.(Refer Photograph no.1)
1. Lift the Rear Wheels by using four post / Jack.
 Before doing the setting, check the freeness of wheels by rotating the wheels.
2. The setting near Hand Brake lever to be kept around open thread length 20 mm. Tighten the
Nut and Lock nut by applying max 5N-m torque.
 Note: Ensure that cable is not getting twisted during tightening.
3. Rotate the Turn buckle (Refer Photograph) till the stud end reaches into the hole of the C-
Bracket.
4. Lift the Rear wheels and apply 2 notches of Park lever and see the rotation of both wheels. If
wheels are Jam, tighten the Lock nut (Torque 5 N-m).
5. If both wheels are still rotating, rotate the turnbuckle again to increase the setting. Check the
wheel jam and tighten the Lock nut.
6. Apply the Hand Brake lever and check for notches. Normally in 4 to 6 notch reading, Parking
Brake Setting can be completed.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 335
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 BRAKE BOOSTER – CHECK

Brake Booster Operation Check -

• Step 1
- Switch off the engine and pump the brake pedal till it becomes hard.
- Press and hold the pedal, start the engine.
- If the pedal moves down slightly, immediately after the engine starts, the Booster unit is
operating.
• Step 2
- Start the engine.
- Turn the engine off after 1 or 2 minutes.
- Depress the pedal with usual force.
- If the first pedal stroke is long and becomes shorter with subsequent strokes, the Booster
unit is operating.

Brake Booster Functional Test

Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and
their connections should be correctly secured in. Check the hoses for breakage, holes and
collapsed areas. Inspect the check valve on the brake booster for damage.
• Connect the vacuum gauge to the booster check valve with short length hose.
• Start and run the engine at idle speed for one minute.
• Observe the vacuum supply. If the vacuum supply is not adequate, repair the vacuum
supply.
• Shut the clamp hose between the vacuum source and the check valve.
• Switch off the engine and observe the vacuum gauge.
• If vacuum drops more than one inch Hg (33millibars) within 15 seconds, booster
diaphragm or check valve is faulty.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 336
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Booster Non-return valve Test

Brake

• Disconnect the vacuum hose from the check valve.

• Remove the check valve and the valve seal from the booster.
• Use a hand operated vacuum pump for test.
• Apply 15-20 inches vacuum at large end of check valve
• Vacuum should hold steady. If the gauge on pump indicates vacuum loss, then the check
valve is faulty and should be replaced.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 337
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 LSPV – SETTING

LSPV is mounted on 2 bolts on bracket fitted on chassis. It has got three brake fluid connections. One
is LSPV inlet from TMC, 2nd is LSPV outlet towards Rear wheel, 3rd is LSPV bypass connected to front
four ways TEE. The LSPV spring other end is mounted on the bracket on differential.

LSPV Setting - The LSPV setting is must in first service.

(This is necessary as the suspension gets settled and setting may change)
NOTE:
 The LSPV setting length is 112.25mm.
 The gauge used for LSPV setting is MST 0602BAA0001ST.
 Before start of LSPV setting, ensure the vehicle is Unladen.

Procedure for fitting and setting the LSPV Valve –

• Mount the LSPV valve on the bracket in the chassis. Fit all the hydraulic connections before
fitting / setting the LSPV valve ensure that the
• Vehicle unladen condition (Kerb weight) means No driver and no additional load.
• Fuel tank is assumed to be ¾ full.
• Before doing the fitment/setting run the vehicle through rough road /normal road for 5 to
10 kms. This is essential for the spring/ bush to settle.

1. Remove the clip. Remove the Washer. Refer illustration shown.

2. Slide the control spring out from the bolt. Put the projecting pin of the tool in the eye of the
spring & allow the tool to hang freely..
3. Loosen the nut the M8 Hex Nut (Use 12 Ring Spanner) during removal hold the other end with
14 Spanner & move the bolt in such a way that the bolt is aligned & enters in the slot on the
tool. Refer illustration shown.
4. Retighten the nut in such a way that the bolt is in the correct position as indicated by the tool.
5. Remove the tool.
6. Pull down the spring and locate the eye in the bolt. Ensure that the spring is sitting properly
in its position. Fit the washer & the ‘e’ clip.

1 3

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 338
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• BRAKE FLUID – LEVEL & LEAK - INSPECT

Brake Fluid – SAE J1703 FMVSS No.116 DOT 3 or IS 8654 Type-2 specification.
BRAKE FLUID – LEVEL & LEAK – INSPECT
(Refer illustrations) –
1. Check for Brake Fluid Level up ‘Max’ mark on the
brake fluid reservoir.
MAX 2. Check for Brake Fluid leakage and correct fitment at
all joints –
MIN • Brake Master Cylinder outlets.
• Brake tube to flexible hose joint.
• Brake bundy tube at all ‘Tee’ joints.
• Flexible hose joints at frt. callipers.
• Brake hose/ pipe connections on each wheel end.
• Brake Pipe connections at inlet & outlet on G-valve.
• Wheel cylinder inlets & bleed screws.

Brake System -

 Use recommended fluid & do not mix different brand fluids.

 In case brake fluid reservoir replaced, brake system needs to bleed.
 Brake fluid level & leak check to be done first at 5000kms then at every 10000 kms.
 Use the same brand fluid for top up; do not top up with used and unsealed brake fluid
container.
 The Brake fluid reservoir cap/ container should not be opened with dirty hands.
 Avoid direct water spray on reservoir while washing engine compartment.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 339
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• BRAKE FLUID – REPLACE

Brake Fluid – SAE J1703 FMVSS No.116 DOT 3 or IS 8654 Type-2 specification.

5 2

Brake Fluid Reservoir 1

4

Brake System bleeding Sequence 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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 340
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

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.

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.)

 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 to be replaced first at 35000 kms & then at every 40000 kms; or in a year, whichever
is earlier.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 341
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car repairs -

Following are the activities carried out in car without removing main aggregates –

• Front brake calliper – R & R

• Rear brake shoe – R & R

• Rear brake wheel cylinder – R & R

• Rear back plate – R & R

• Brake pedal – R & R

• Brake pedal – check

• Brake master cylinder – R & R r

• Brake booster – R & R

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 342
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

FRONT BRAKE CALLIPER – R&R

 Apply hand brakes. Place wheel chocks on rear wheel
 Jack up the front of the vehicle and remove the front wheels by loosening / removing the wheel
nuts.
 Disconnect the hose from the calliper by removing the banjo bolt

1. Loosen and remove the bottom retaining

bolt of the guide pin.

2. Remove the calliper sub assembly after removing the top retaining bolt.
(There is no need to remove the Carrier Assembly with pads from the rotor or stub axle.) Clean the
calliper sub assembly externally with alcohol or fresh brake fluid.
3. Remove the calliper pistons from the bore by blowing dry compressed air through the inlet port
of the calliper. Care must be taken to remove both the pistons at a time. Also to avoid the
damage to the pistons, place a wooden block in front of the pistons. (approx. 30 mm thick )
4. Remove the boot.
5. Remove the seal- Pistons from the groove by using a blunt edged connector or feeler gauge. Take
care during seal removal the bore is not damaged.
6. Remove the bleed screw from the calliper body.
Cleaning & Inspection –
All the removed parts should be cleaned properly using fresh brake fluid or alcohol and kept in a
clean tray.

 NEVER USE ANY MINERAL OIL BASE FLUIDS LIKE KEROSENE, DIESEL and PETROL etc. FOR
CLEANING OF REMOVED PARTS.
 DO NOT CLEAN THE BORE OF THE CALLIPER WITH WATER OR STEAM.

The Piston seals are to be lubricated with fresh brake fluid and assembled in to the seal grooves in
the calliper bores. Make sure the seating of this is properly done. Then lubricate the outer surface
of the pistons with fresh brake fluid.
Refer below illustration for orientation of the rubber boot -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 343
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Remove the boot - piston with the help of a screwdriver. Care must be taken not to damage the seat
of the boot in calliper body.

The piston boots are to be lubricated internally with the special grease supplied in Calliper Repair Kits
before it is assembled on the pistons.
Locate the boots on to the calliper pistons. Insert the calliper pistons into the bore & push it gently
into the bore.

Once the piston is home, ensure the fitment of the boot on to the boot groove on the piston.

The piston should be inserted into the bore in a straight position only. If it gets tilted while pushing,
there is a chance that the piston will get jam half way & also can damage the seal.
Once the piston is inserted inside the bore, put a wooden block on the piston & with the help of a ‘C’
Clamp push it inside the bore. Face to face fitment of the boot to be insured. Repeat the procedure
for the other piston.

The wooden block should have the corners rounded to ensure the proper fitment of boot into the
grooves. Otherwise the wooden block can foul against the radius on calliper body.
Replacement of Sliding pin Kit –
1. Loosen and remove the bottom retaining bolt of the guide pin.

2. Remove the top retaining bolt of the locking pin.

3. Remove the guide pin.

4. Remove the locking pin with bush from the carrier.

5. Remove the boot – Pin from the carrier.

Smear the pins and the pin bores with the special grease supplied in Sliding Pin Kit. Apply light grease
on locking pin. Fit the pin boots on to the pins and assemble it on to the carrier bore. Ensure proper
location of the boot lip on to the carrier. Move the pins in and out 3 to 5 times in order to allow for
the trapped air inside the bore to escape.
 Repeat the above procedure for the other side calliper assembly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 344
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

REAR BRAKE SHOE – R&R

Jack up the vehicle.
Remove the wheels.
Slacken the adjuster to keep the shoes in a completely retracted position.

Remove the brake drum. (Refer to the

instructions for removal of drum).

Pull out the hub along with the bearings.

Push the hand brake lever away from the shoe

rim and remove the cable from the operating
lever hook.

Using a ‘spring pliers’ remove the shoe return spring at the wheel cylinder end.
Remove the shoe hold down pins from both the shoes using B.I. Shoe hold down spring tool No.
64927118.
Remove both the shoes from back plate along with the abutment end spring.
Slip an elastic band over the wheel cylinder to retain pistons within the cylinder.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 345
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Assembly precautions –
 Place one shoe on back plate & assemble pin shoe hold down cup. Fit one end of the shoe return
spring - lower in the slot provided on brake shoe. Assemble the other end of the shoe return
spring – lower in the second shoe. Tilt & place the shoe on the back plate & fit the shoe hold
down pin & cup. While fitting the lower return spring take care that end with the fewer turns is
facing the trailing shoe (towards the rear of the vehicle.)

 Place the auto adjuster assembly between the shoe web slot & hand brake lever slot.
 Assemble shoe return spring –Upper return spring on adjuster lever. Place a screw driver inside
the small hook of the spring & by pulling fit the spring in the shoe slot. Ensure no damage to the
Auto Adjuster Lever.

 Ensure that the auto adjuster lever edge is properly located on tooth of auto adjuster wheel.

 Connect the Parking brake cable in reverse order of dismantling.

 Before refitting the brake drum check that the drum thickness has not gone below 1 mm.
A thin brake drum will flex during braking reducing the braking efficiency and also it will cause
improper functioning of the parking brakes.( Useful brake drum Ø is 284 mm)

 Apply brakes few times to adjust the brake shoes.

RELINING THE SHOES -

 Inspect the linings.
 Lining should not be allowed to wear down to the rivet heads.
 If the linings are worn down to rivets, they must be replaced.
 De rivets them carefully.
 Before de riveting, detach the hand brake lever cable from the trailing shoe this may be done as
follows:
 Remove the retaining plate from the pin groove by sliding with a screwdriver.
 Remove spring plate; Lightly tap the pin to remove the Hand brake lever from the shoe.
 If excessive wear on this pin is noticed, it should be replaced.

WHILE DE RIVETING, ENSURE THAT THE HOLES IN THE SHOE RIM ARE NOT ENLARGED.

Clean the shoe rim to ensure a smooth even surface for the lining.

ALWAYS USE GENUINE APPROVED GRADE OF SERVICE REPLACEMENT LININS DURING RELINING,
INCLUDING THE RIVETS SUPPLIED ALONG WITH THE RELINING KIT.

Clamp the lining evenly to the shoe rim and start riveting at the centre and progress outwards to the
ends of the shoe. A flat ended anvil of the correct diameter should be used against the rivet head and
the tubular shank of rivet should be properly clinched.

CARE SHOULD BE TAKEN, SINCE OVER RIVETTING MAY CRACK THE LINING. ENSURE THAT NO
CLEARANCE EXISTS BETWEEN THE LINING AND SHOE RIM.

Fit the hand brake lever to the trailing shoe in the reverse order of removal.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 346
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Ensure that the spring plate convex side is towards the retaining plate.

MAKE SURE THAT HAND BRAKE LEVER IS FREE TO OPERATE. DO NOT CONTAMINATE THE LINING
SURFACE WITH OIL OR GREASE.

Refit the shoes in accordance with following instructions:

FITTING SHOES -

 Clean the backplate.

 Check the backplate pads for grooving or other damages.
 The pads must be smooth and not corroded.
 If necessary, smoothen the pads with file or emery cloth, but do not remove any more material
than is absolutely necessary and note that each set of these pads should be reduced equally.
Clean off the metal fillings.

NEW SHOE RETRACTING SPRING SHOULD ALWAYS BE FITTED DURING MAJOR OVERHAUL.

 Remove the elastic band over the wheel cylinder.

Check the wheel cylinders for leaks by lifting the dust cover. Check the piston for freedom of
movement. If a leak is suspected from the wheel cylinder or if the piston movement is unsatisfactory
the unit must be overhauled. Refer to “WHEEL CYLINDER SERVICING”. Inspect the wheel cylinder dust
covers for cuts, hardening or other signs of deterioration. If in doubt, the dust cover should be
replaced.

Lightly smear high melting point graphite grease to the back plate shoe pads and abutment.
Position the leading shoe (the shoe with the longer lining) on the back plate and fit shoe hold down
pin. Spring cup washer as shown in figure. Ensure that the convex face of each washer is towards the
spring.

THE LEADING SHOE (THE SHOE WITH THE LONGER LINING) SHOULD BE FITTED TOWARDS THE FROTN
OF THE VEHICLE. HOOK THE SMALLER SPRING AT THE ABUTMENT END (BOTTOM) OF THE SHOE AND
THE LONGER SPRING TOWARDS THE WHEEL CYLINDER END.

 Position the trailing shoe (the shoe with the shorter lining and hand brake lever) on to the back
plate and hook the smaller spring at the abutment end. Move the hand brake lever and fit the
shoe hold down pin spring and washers.

If the rubber sleeve on the strut is removed or if you are fitting a new rubber sleeve, ensure that the
rubber sleeve is fitted in such a way that the flat portion of the sleeve is towards the straight edge of
the strut. Position the strut between the leading and trailing shoe webs.

Two slots are milled on either end of strut. One of them is wider that the other. The narrow slot
should be on the leading side. Using spring pliers, hook the longer spring on to the trailing shoe.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 347
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

WHILE USING THE SPRING PLIERS EXTREME CARE MUST BE TAKEN AS OTHERWISE THE LINING MAY
BE DAMAGED.

 Connect the hand brake cable to the hand brake lever in the reverse order of removal.

DO NOT HANDLE THE LINING NORE THAN IS NECESSARY AND BE SURE THAT THEY ARE COMPLETELY
FREE FROM GREASE.

Centralize the brake shoes relative to the backplate, before fitting the drum by lightly tapping in the
required direction.

 Refit the drum and wheel.

 Adjust the brakes as explained under “Brake Adjustment”.
 Check the hand brake cable adjustment in accordance to the vehicle manufacturer’s instructions
and road test.

REAR BRAKE WHEEL CYLINDER – R&R

When removing or servicing wheel cylinders, it is

necessary to draw fluid from the system and
remove the brake shoes.

Attach a bleed tube to the bleed screw having

first removed its rubber dust cap. Unscrew the
bleed screw ½ to ¾ turn and pump out the fluid
into a suitable container by operating the brake
pedal. Remove the bleed tube. Remove the brake
shoes as explained under “Removal of shoes”.

Disconnect the bundy pipe from wheel cylinder. Remove the bleed screw. Remove the wheel cylinder
mounting set screws and takeout the wheel cylinder from the backplate.

DISMANTLING OF WHEEL CYLINDER -

Clean the wheel cylinder externally. Remove the

dust covers fitted on wheel cylinder assembly.
Push out the piston seals, air excluders and
spring. Discard all rubber parts. Clean the parts
thoroughly in fresh brake fluid or alcohol and
place them on a clean sheet of paper.

NEVER CLEAN THE WHEEL CYLINDER OR

INTERNAL PARTS WITH KEROSENE, PETROL OR
DIESEL.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 348
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

EXAMINATION OF WHEEL CYLINDER -

Examine the cylinder bore and pistons. If they are not scored, corroded or ridged and are smooth to
the touch, new seals can be fitted. If there is any doubt about the condition of bore, a new wheel
cylinder assembly must be installed.

If the system has been contaminated with mineral fluid of any type, the system should be flushed out
with fresh brake fluid or alcohol and all rubber parts including hoses should be replaced. For example,
a contaminated seal be identified by comparing it with the new seal (but do not let them touch). If
the old one is appreciably larger, seal are serviced, replacement of seals and dust covers from an
appropriate TVS-Girling wheel cylinder kit is strongly recommended.

ASSEMBLING OF WHEEL CYLINDER -

ABSOLUTE CLEANLINESS HAS TO BE MAINTAINED AND CLEAN BRAKE FLUID MUST BE USED. NEVER
USE BRAKE FLUID BLED FROM THE SYSTEM.

 Lubricate the wheel cylinder bore liberally with the fresh brake fluid. Dup new seals, air
excluders, spring and pistons in fresh brake fluid.
 Insert one of the cup seals in the bore, the flat face of the seals towards the open end of the
wheel cylinder.
 Push the seal partly down the bore by inserting the piston behind the seal.
 Reverse the dust cover. Fit the smaller dia. of the dust cover on the neck of the piston.
 Insert the spring assembly in the bore.
 Insert other cap seal (flat face of the seal towards open end of the bore) followed by the second
piston and fit dust cover.
 Fit a rubber band around the pistons to retain them within bore.

REFITTING OF WHEEL CYLINDERS -

Install the wheel cylinder assembly to the backplate and secure with bolts and washers. Tighten the
wheel cylinder mounting bolts to a torque of 6.0 Nm. Fit adapters with a new gasket on to feed port
and tighten to a torque of 27 Nm. Fit the bleed screw (17) and tighten to a torque of 6.0 Nm.
Remove the rubber band from the wheel cylinder. Refit brake shoes as described under “FITTING
SHOES” Connect the bundy pipe to the adaptor port.

 Refit the drum and wheel.

 Bleed the system.
 Adjust the brakes as explained under “BRAKE ADJUSTMENT” and road test.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 349
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

BRAKE PEDAL – CHECK

The push rod serves as the brake pedal stopper

when the pedal is fully released.

Brake pedal height adjustment should be

performed as follows –

Measure the brake pedal height after making

sure the pedal is fully returned by the pedal
return spring.

Pedal height (L2) must be measured after starting

the engine and increasing the revolution several
 Pedal free play (L1): 7-11 mm. times by stepping on the accelerator pedal.
 Height (L2) : 164-174 mm.

 Pedal free play must be measured after turning off the engine and stepping on the brake pedal
firmly five times or more.

 If the measured value deviates from the above range, adjust the brake pedal as follows:
- Disconnect the stop lamp switch.
- Loosen the lock nut on the push rod.
- Adjust the brake pedal to the specified height by rotating the push rod in the appropriate
direction.

Clearance -

Between the Switch Housing and the Brake Pedal

(A).

A = 0.5 to 1.00 mm.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 350
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

BRAKE MASTER CYLINDER – R&R

REMOVING THE MASTER CYLINDER -

Connect a bleed tube to one of the rear wheel cylinders bleed screws and drain the fluid into the
container by pumping the pedal from secondary circuit. Repeat the same by connecting the bleed
tube to one of the caliper bleed screws and collect the fluid from the primary circuit. Disconnect all
outlet pipes from the master cylinder. Loosen master cylinder mounting nuts and remove the same.
Now the master cylinder can be separated from servo.

OVERHAULING OF MASTER CYLINDER -

Master Cylinder should be overhauled once in 12 months or 30,000KMs which occurs earlier. During
the first overhaul all rubber parts should be discarded and replaced with genuine Brakes India Seals
provided in the kit. During second overhaul, all internal guts including plungers and springs should be
replaced. Subsequently, if the condition of the bore is satisfactory, further overhauling should be
undertaken, or else, the whole cylinder should be discarded and fitted with a new assembly.

DISMANTLING OF THE MASTER CYLINDER -

Hold the fluid reservoir and rocking it on either side lift the seal fluid tank in the master cylinder.
Remove the seal fluid tank from the master cylinder body using a connector screw driver with blunt
edge. Slightly push the primary plunger and remove stop pin with gasket.

Without removing the stop pin, if any attempt is made to dismantle the master cylinder, the
secondary plunger cannot be removed. By slightly depressing the primary plunger, remove the cir clip
and retainer washer. Tap the cylinder on a wooden block and remove the primary and secondary
plungers along with the seals, springs etc. By slightly compressing the spring retainer unscrew the
connecting screw from primary plunger. Remove recuperating seal and seal shim from front end of
primary plunger. Remove back seal from the primary plunger using a connector screw driver. Remove
secondary spring seal retainer recuperating seal shim from the front end of the secondary plunger.
Remove gland seal from the secondary plunger using connector screw driver. Discard all the rubber
parts. Clean all the parts in fresh brake fluid or isopropyl alcohol and place them on a clean sheet of
paper. Never clean the master cylinder or internal parts with mineral oil like kerosene, petrol, diesel
etc. Be sure that the four holes in the cylinder body (two recuperating holes and two feed holes
visible through the primary and secondary inlet ports) are clear. This should be determined by
blowing dry compressed air only. Do not poke the holes with sharp instrument.

EXAMINATION OF MASTER CYLINDER AND PARTS -

Examination of master cylinder. If it is not scored, ridged or corroded and is smooth to the touch the
master cylinder can be rebuilt using appropriate parts from the Brakes India repair kit. If there is
slightest doubt about the condition of the bore like having deep groove or pit marks there is no other
way than to fit a new master cylinder. Examine both the plungers for rust, burrs or ridges. Ensure that
both primary and secondary plungers are in satisfactory conditions. Remove the adapter with gasket

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 351
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

along with the valve seal and valve spring from the secondary outlet port. Remove the valve seal
separately.

If contamination has been observed in the removed seals (normally they would have swollen and can
be compared with new seals from kit which will tell clearly that the size is enlarged) the entire
system. i.e. caliper rubber parts and rear wheel cylinder rubber parts including both front and rear
hoses must be discarded and the entire system should be flushed.

ASSEMBLING THE MASTER CYLINDER -

Dip, plungers and all seals in fresh brake fluid. Fit back seal on to primary plunger groove such that
lips are towards the flange on the plunger which has holes. Fit seal shim and recuperating seal on to
the primary plunger, making sure that the lip of the seal is towards the primary spring. Assemble
spring retainer into primary spring through the larger dia. of the coil in such a way that the small
petals are towards the seal and the big petals are towards the spring. Fix the primary spring small end
of the coil on the primary plunger. Insert the retaining screw through the spring retainer hole. By
slightly compressing the retainer against the primary spring, screw in the retaining screw until the
shoulder of the screw touches the plunger and release the spring retainer. Assemble gland seal in
secondary plunger groove such that the seal lip faces towards the primary spring. Fit seal shim and
recuperating seal on the stem side of the secondary plunger in such a way that the lip of the seal
faces towards the secondary spring. Fit seal retainer.

Fit secondary spring small end of the coil on the stem of the secondary plunger. Lubricate the bore of
the master cylinder liberally with fresh brake fluid. Insert the secondary plunger assembly into the
bore leading the spring end, taking care to guide the seals into the bore without allowing them to get
trapped. Now insert primary plunger assembly in the same manner into bore. Depress the primary
plunger and fit retaining washer and circlip. Make sure that the retainer sits squarely into the master
cylinder groove. Depress the primary plunger with the help of a hylem rod down the bore fully and fit
stop pin with new gasket and tighten it to 6 Nm. Release the hylem rod and watch for quick return of
both the plungers. Actuate a couple of times. Fit valve seal spring small dia into the valve seal and fit
the valve seal into the adapter. Now fit the adaptor with new gasket to the outlet port and tighten
them to the torque of 18.0/15.0 Nm Fit seal fluid tank to both inlet ports by liberally lubricating the
same with fresh brake fluid. Position the reservoir into seal fluid tank and slightly rocking them on to
either side, press it home.

It is essential that the reservoir filler cap must be removed. The baffle plate taken out from its place
and the breather hold in the cap is cleared and the baffle plate refitted before fitting the filler cap on
the tank.. It is advisable to replace the gasket in the filler cap during very overhaul.

Now the master cylinder is ready for fitment on to the servo. The master cylinder is to be fitted back
onto the servo in the reverse order of removal. Reconnect the outlet pipes.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 352
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

BRAKE BOOSTER – R&R

The parts available to service the unit are – filters, a non-return valve kit and a service kit. Servicing of
the internal parts is not recommended and if a major fault is apparent, a new complete guaranteed
unit should be fitted. The air filter should be changed every 40,000 KMs or two years when the
hydraulic cylinders or hoses are replaced. If dusty conditions prevail, the rod is retained internally and
cannot be extracted. If the rod or the domed screw on the rod end is damaged the super-vac unit
must be replaced completely.

NO ATTEMPT SHOULD BE MADE TO ADJUST THE DOMED SCREW. THIS IS CORRECTLY SET AT THE
FACTORY AND SHOULD NEVER BE DISTURBED.

REPLACING THE FILTER –

Pull back the dust cover and filter retainer. Hook out the filters and cut to remove from the input rod.
Cut the new filters, press into the neck of the valve body as shown and refit the filter retainer and
dust cover. If the dust cover is damaged fit a new from Brakes India Service Kit.

REPLACING THE NON RETURN VALVE –

Before removing the non return valve note the angle of the same in relation to the front shell so that
the new valve can be fitted in the same position.

 The non return valve fitted is push-in type valve.

 To remove this valve inserts a flat bladed screw driver between rubber grommet and valve
cotter. Leave the valve from the grommet.
 Then remove the grommet from the front shell and make sure that even by mistake you do not
drop the same into the vacuum chamber.
 Fit the new grommet.
 Lubricate the ribs of the new non-return valve with Castor oil and push fully into grommet.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 353
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Following are the important alerts on the braking system –

Brake fluid contains poly glycol ethers and poly glycols. Avoid contact with the eyes. Wash hands
thoroughly after handling. If the brake fluid comes in contact with the eyes, flush the eyes for 15
minutes with cold running water. Get medical attention if irritation persists. If taken internally,
drink water and induce vomiting. Get medical attention immediately. Failure to follow these
instructions will result in personal injury or prove fatal.

• If brake fluid is spilt on the paint work, the affected area must be immediately washed with cold
water.

• The brake fluid reservoir must remain full with new & clean brake fluid at all times during
bleeding.

• Make sure that the pressure bleeding equipment is filled with new brake fluid to the correct
specification.

• To prevent corrosion of the bleed nipple make sure that the bleed nipple cap is installed after
bleeding the brake lines. Failure to follow this instruction may result in seizing of the bleed
nipple.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 354
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• WORKING PRINCIPLE OF BRAKE BOOSTER -

SUPER VAC SERVO / BOOSTER (MECHANICAL)

The brake booster converts mechanical force applied by driver/customer into hydraulic force through
master cylinder. The booster is installed on the firewall/dash panel with brake pedal. It consists of
servo (tandem diaphragm), master cylinder, brake fluid reservoir & low brake fluid warning sensor
(FLWI).

The servo consists of Single Diaphragm in tandem with push rod connected to brake pedal. The output
rod connects the booster to the tandem master cylinder (TMC).

Servo is connected through vacuum hose to exhaust cam shaft driven vacuum pump.

TMC is designed to operate dual line (front & rear) hydraulic braking system. Brake Fluid is filled in
brake fluid reservoir consisting of two independent chambers working in tandem for brake system and
third independent chamber fro clutch system.

Even if leakage/damage occurs in one chamber or circuit the other remains operative. FLWI is a
contactless sensor connected to instrument cluster to warn the driver if the brake fluid level is closer
to minimum level marked on reservoir.

When the push rod is pressed by brake pedal, air enters through filter in vacuum servo. Power assist is
generated by utilizing the pressure differential between atmospheric pressure and vacuum. The force
gets multiplied based on boost ratio & applied to the output rod going inside master cylinder. The
output road strokes the master cylinder pistons & it generates hydraulic pressure in hydraulic brake
lines going to front & rear braking system independently. The super vac is a vacuum assisted
mechanical servo unit with 5.5: 1 boost ratio.

The Booster is a non- serviceable Unit & it should never be tampered with.

Ensure booster output rod is correctly aligned to the primary piston bore during the coupling of TMC
to the booster. The Scorpio vehicle is equipped with a Tandem type vacuum booster to assist driver’s
effort. This is achieved by using vacuum from the vacuum pump provided on alternator in case of
diesel engines & from inlet manifold in case of petrol engines.

A single diaphragm is provided between the two shells of the booster & difference of pressure on two
sides of diaphragms (one side vacuum & other side atmospheric pressure) gives mechanical
advantage. This amplifies the driver’s pedal effort while braking. The booster assembly & TMC
assembly are coupled with the help of two nuts & washer. The meeting dimensions of booster & TMC
are factory set. Hence –

Do not alter the height of the output rod of the Vacuum Booster unit at any stage and ensure
Booster output rod is correctly aligned to the primary piston bore during the coupling of TMC to the
booster.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 355
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• WORKING PRINCIPLE OF LSPV

Description –

When there is a large difference in vehicle weight between laden &

empty conditions; during dynamic braking, the weight on the rear
axle tends to shift towards the frontal direction of vehicle ( known
as Load / Weight Transfer ) resulting into less vertical load on rear
axle which results into rear wheel locking. LSPV regulates the
pressure in the rear brakes in proportion to the load in vehicle.
Hence it is called as Load Sensing Proportioning Valve.

Installation & Working Principle –

This valve is mounted on vehicle chassis with the help of two bolts
near the rear axle. It is provided with a control spring which is
attached to the rear axle by a special bolt passing through a bush.
The control spring is in pre elongated condition. This spring senses
the deflection of rear axle under different loads & thereby automatically adjusts the operating
characteristics (Knee point Pressure) of the valve. Inlet port of the valve is connected to the delivery
port of secondary circuit of TMC & outlet port of the valve is connected to rear brakes through piping.
The front inlet (bypass) port of valve is connected to the front (secondary) circuit of the TMC to sense
the front circuit failure.

Working of LSPV/ Valve – Refer illustration.

Area ‘A’

Area ‘P’

Spring Force ‘F1’

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 356
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Initially the main spring force keeps the piston pressed in upward direction keeping outlet port
connected to rear circuit open at seal, till knee point i.e. inlet pressure is transmitted to the rear circuit
through outlet port without any pressure regulation.
Further pressing of brake pedal increases the inlet pressure to LSPV & in turn increases the downward
force acting on the piston. (The downward force is created by hydraulic pressure available in front
circuit acting on area ‘A’.)

The downward movement of the piston closes the entry of oil from rear inlet port to outlet port at
sealing point ‘P’.

At this point there are three forces acting on the piston –

1. Upward force ‘F1’ of main spring.

2. Hydraulic force acting on area ‘P’.
3. Hydraulic force acting downwards on area ‘A’.

Since the resultant force is positive, the piston lifts upwards & the Oil entered from Inlet port is fed to
outlet Port & the pressure to outlet increases. Further increase in inlet pressure (due to pressing of
brake pedal) again results into downward movement of piston, thereby closing the outlet at point ‘P’
& results into drop in outlet pressure. The process continues & follows a fixed pattern.

LSPV Performance in Front Fail Condition (Bypass Function) –

In case of leakages – Internal or External, in the front circuit there is a failure of front circuit & front
callipers become ineffective. Under this emergency condition the bypass valve operates automatically.
This is achieved by following mechanism. In front fail condition the force acting on piston will only be –

1. Control Spring Load ‘F1’ acting upwards

2. Hydraulic force acting on area ‘P’
3. Upward force at ‘O’ ring in front circuit

This keeps the sealing point ‘P’ always open. (Due to the front circuit failure the hydraulic force acting
on area ‘A’ is zero.) So input pressure becomes equal to output pressure. This is called bypass function
& transmits the whole pressure developed in rear circuit of TMC to rear brakes without any pressure
reduction.

Maintenance Precautions –

LSPV is a non-serviceable unit & should be replaced if any problem arises.

During vehicle servicing control spring setting should be checked & corrected if required with the help
of an ‘Installation gauge ‘provided for the purpose. The stretched length of the control spring should
be set at 92.5 mm with the help of Installation gauge.

The correct setting of Control Spring ensures adequate oil pressure to rear circuit & thereby ensures
no skidding of rear wheels. The LSPV setting needs to be carried out if:

1. The axle has been removed.

2. LSPV Valve replaced.
3. Any change in rear suspension carried.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 357
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specification –

Illustration Description Value

Disc pad Usable 10.35 mm
thickness
Replace disc pad if 1.5 mm
worn out thickness
less than
Disc pad Material R804/APC 522/12/FER 3443
Rotor thickness 21 mm

Minimum disc thickness 19 mm

Run out of rotor face- 0.12 mm
permissible limit
Disc thickness variation allowed ± 0.012 mm
Rear Drum thickness 8.20 – 8.35 mm
Minimum thickness of brake 8.20 mm
drum
Maximum taper/ bell mouthing 0.05 mm
of brake drum
Rear brake lining Usable 5.65 mm
thickness

Replace when lining thickness 1.5 mm

falls below Minimum Usable
thickness of
Brake shoe Lining Material SA 91 /APC 108
Master cylinder I.D 25.4 mm

Wheel Cylinder I.D 25.4 mm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 358
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Brake disc O.D 272.8 mm

Rear Drum I.D 282 mm

Boost ratio 5 :1
Booster size 9”
Clearance Adjustment -
Front Automatic
Rear Automatic
Free Play of the Brake Pedal 3 mm

• Torque Values –

Description Torque Value

Front Brake Caliper Mounting Bolts 75 ± 7 Nm (55 ± 5 lbf-ft)
Sliding Pin Bolts 27 ± 5 Nm (20 ± 4 lbf-ft)
Banjo Bolt - Caliper 35 ± 5 Nm (26 ± 4 lbf-ft)
Brake pipe connectors – Master Cylinder 14.5 ± 2.5 Nm (11 ± 2 lbf-ft)
Vacuum Booster – Mounting Nuts 21 ± 7 Nm (15 ± 5 lbf-ft)
Master cylinder Mtg. nuts on vacuum booster 13 ± 3 Nm (10 ± 2 lbf-ft)
Brake Pipe connectors – Wheel Cylinder 6.5 ± 1.5 Nm (5 ± 1 lbf-ft)
Brake pipe connectors at ‘G’ valve inlet & outlet ports 6.5 ± 1.5 Nm (5 ± 1 lbf-ft)

• Recommended Lubricants –

Specification: DOT 3/ DOT 4

Hindustan Petroleum: HP Super Duty Brake Fluid

Castrol: Brake Fluid
Indian Oil: Servo Brake fluid Super HD

Sealant: METALOCK 343 or ANR124 from FEVICOL

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 359
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

WHEELS AND TYRES

Contents…

• Description……………………………………………………………………………..
• Trouble Shooting………………………………………………...............................
• Care of the System…………………………………………………………………..
• In Car Repairs…………………………………………………………………………
• Specification…………………………………………………………………………..
• Tightening Torques………………………………………………………………….

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 360
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description –

The tyres fitted in New Bolero are radial tyres and with a suitable wheel disc.

In the tyre P 215/75 R 15 - The 215 is the width of the tyre in mm at the designated air pressure and
load. The / 75 is the aspect ratio of the tyre. (Ratio between the height and width here the height is
0.75 times the Width.

The tyres play a very important and vital role in the vehicle handling and ride characteristic. Hence it is
advised that any change not as per the specification have to be done with caution.

The air pressure maintained has a direct influence on the tyre life, fuel average obtained, braking and
also on ride characteristic. Hence it is imperative that the tyre pressure be maintained as per
specification.

Wheel Replacement –

Wheels to be replaced if they found bend, have excessive lateral/ radial run-out, have elongated bolt
holes or if they are heavily rusted.

When replacing the wheels ensure that it must be equivalent to the original equipment wheels in load
capacity, diameter, and rim. A wheel of improper size or type may affect wheel and bearing life, brake
cooling, vehicle ground clearance and tyre clearance to body and chassis.

Tyre Replacement -

When replacing the tyres ensure that original equipment type tyres should be used. Refer to the tyre
Placard. Replacement tyres should be of the same size. Use of any other size or type tyre may affect
ride characteristic, vehicle handling, speedometer/odometer calibration, vehicle ground clearance and
tyre or snow chain clearance to the body and chassis.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 361
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

Symptom Causes Remedial action

 Maintain the correct tyre

pressure.

 Do the tyre rotation.

Under Inflation
Lack of rotation
Rapid wear at Shoulder Excessive cornering.

 Maintain the correct tyre

pressure.

Rapid wear at centre Over inflation

 Maintain the correct tyre

pressure.

Cracked Treads
Under Inflation

 Check and adjust:

 Hub end play
 Camber to be checked and
adjusted.

One Edge Wear

Excessive camber
Excessive cornering

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 362
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Check & correct Toe In

 Check the chassis bend

 If tyre rotation not carried out as

per schedule. Do the tyre
rotation.
Feathered Edge Wear
Incorrect Toe In
No tyre rotation

 Balance the tyres.

 Check the brake drum

roundness.
Bald Spots
Unbalanced tyre  Check jammed wheel cylinder/
calipers.
• Out of round brake
drums in rear.  Check the wheel bearings.

• Faulty wheel bearings.  Avoid driving with sudden brake

locking.
• Sudden braking.
Lack of rotation or Worn or  Tyre rotation.
Out of Alignment Suspension  Check & replace the suspension
components.

Wavy / Scalloped wear

Side Wall crack- radial/
diagonal Kerb damage/ Stone hit

Side wall crack

circumferential / tyre Run Flat (It is more obvious
bulging from inside)

• Higher than recommended pressure can cause: Hard steering, tyre damage and rapid
tread wear at centre of tyre.
• Unequal pressure on same axle can cause: Uneven braking, Steering pulling. Valve caps to
be used to avoid dust and water entry.
• Lower than recommended pressure can cause: Tyre shriek on turn, Hard Steering, Rapid
and uneven wear on the edges of the tread, Tyre cord breakage, High tyre temperature.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 363
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the Wheels & Tyres –

The tyre is one of the most abused components hence maintaining the tyre is of utmost importance.
The tyre pressure should be checked once in a fortnight. (Once in a week during summer) The tyre
pressures should always be checked & corrected in cold condition. The valve should be always covered
with the valve cover. An opened valve can have the valve needle stuck in a partial position causing the
tyre to bleed during operation.

The tyre pressure specified can cater to continuous high-speed performance. Hence it is not advisable
to increase the tyre pressure before going on a high speed run.

The practice of keeping the tyre pressure lower in summer is actually detrimental to the tyre. To
understand that let us examine what happens – if lower pressure is kept. Then the sidewall flexing is
going to be more hence the heat generation will also be higher which will result in a faster increase in
tyre pressure. So the wear rate is going to be higher.
Similarly the practice of bleeding the tyre pressure to reduce the pressure after a long run can cause
the sidewall to crack and in a worst scenario sidewall bulging.

Before going on a long drive it is a good practice to remove the stones/pebbles trapped in the treads.
The probability of a puncture due to stone trapped and digging through the crown once it gets heated
up is reduced.

It should also be kept in mind that a radial tyre with higher pressure is more prone to burst under
impact from stone at high speed or kerb impact. Lower air pressure results in higher sidewall flexing
and drastically increases the chance of sidewall damage / cut in bad roads.

Wheel balancing should be done at least every 20,000 KMs. It is compulsory to do a balancing of the
wheel after any puncture.

The tyre rotation should be carried out every 10,000 KMs.

Wheel alignment is recommended. If the wheel disc is having any deformation particularly in the bead
seating area then do not wait until the mileage has covered- get it balanced.) In case of abnormal tyre
wear refer to the Trouble shooting section and take the corrective action suggested.

The grooves in the tyre are used to pump out the water between the road and the tyre. In case the
water is not pumped out the tyre will ride on water. Since the coefficient of friction of water is very
low that will result a sliding action. Obviously the amount of water which the tyre can pump out
between the ground and the tyre will depend on the depth of the groove which is acting as a channel.
The tyre manufacturers recommend that a minimum tread depth of 1.6 mm should be present.

Once the tread depth is less than 1.6 mm it is recommended to replace the tyres. It is not advisable to
retread the tyre. Any kind of lubricant on the tyre is detrimental as it promotes degradation of rubber
and also increases the chance of hardening. Normally this happens when a mechanics rubs the spare
oil or grease on to the sidewall of the tyre.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 364
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tyre Rotation – refer below illustrations for tyre rotation.

Tyre Rotation Schematic – New Bolero

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 values: Refer below chart, air pressure values given for both types in Bolero tyres-

COLD TYRE INFLATION PRESSURE

215 / 75 R15 185 / 85 R16
TYRE SIZE/
Laden Unladen Laden Unladen
Location
Kg/cm2 (bar) Kg/cm2 (bar) Kg/cm2 (bar) Kg/cm2 (bar)
FRONT 1.6 (23) 1.6 (23) 2.6 (37) 2.6 (37)
REAR 2.4 (34) 1.8 (26) 2.8 (40) 2.6 (37)

 Tyre rotation to be done first at 5000kms; then at every 10000kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 365
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

In case the vehicle reports for wheel wobbling then the sequence of balancing &

rotation should be as follows:
IMPORTANT: Before going ahead with the procedure; do road tests and at that time:-
Remember that the road shocks can come to the steering wheel while going over rough or uneven
patch. The important point is that after the road shock is over then it should not continue to
vibrate.

Preliminary Stage:

• Mark each tyre assembly position with respect to the hub/ axle shaft.
• Balance all the tyre and place it back it each wheel in the same position.
• Ensure correct Tyre pressure for all wheel- Refer recommendations.

Now follow the sequence of Stage A, Stage B, Stage C. Road test after each stage:

If the stages of A, B, & C are done together then improvement may not be noticed. In worst case
scenario the problem may get aggravated.

Before dismounting the wheel Mark the position of the wheel & tyre assembly with
respect to the hub (uses any wheel mounting bolt as a reference and applies a paint
mark to hub with respect to disc + tyre.

Check the wheel

balancing.
( )

If the imbalance amount C After B - If after If the imbalance

road test no change
is less than 40 gm. is > 40 gm
in wobbling; then
Rotate the assembly
by 180 degree in
clockwise direction

Rotate the wheel assembly & check the

imbalance

Imbalance location should not change

more than 80 mm in circumference.
The max imbalance can be 40 gms

While mounting the wheel assembly, rotate the wheel assembly by 180 degrees.
Now the matching marks will be opposite

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 366
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Flow chart to attend Vibration Concern

Vibration observation at certain speed

Loosen & re-torque all Suspension

Joints, Body Mounts, Engine Mounts,
Seat Mountings & Transmission
mounts as specified in manual.

Not Resolved Resolved

Stop

Check Shock Absorber for dampening value

(by hand feel), Suspension Ball Joints &
Steering Intermediate Shaft for play

Replace the part (s), All parts are OK,

if required Not Resolved

Resolved Loosen & re-torque

Propeller Shaft
mountings
Stop

Not Resolved Resolved

Rotate the tyre Stop

one by one from
Front to Rear

Resolved Not Resolved

Stop Swap the tyre(s)

one by one with
good vehicle tyre(s)

Resolved, Change Not Resolved, Call

the Particular tyre Technical Support Cell

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 367
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car Repairs –

 The tyres should be removed and then only be attended for puncture or damage. In situ repairs
are not recommended.

 For removal of the tyre from the vehicle the correct jacking points to be used.

 Never go under the vehicle when it is jacked up. This jack is meant for only raising the wheel. For
any under body work/inspection support the vehicle on vehicle stands
 The vehicle is fitted with Rod guard run flat system.
 The vehicle can be driven at speed of 37 Km/ hr with flat tyre.

Removal & Refitting of the tyre -

• Tyre puncture

 Recommended air pressure in cold should be maintained in all the tyres –

FRONT-2.46 Kg/cm2 (For highway)

Laden Tyre pressure (front & rear) (kg/cm2)
1.76 Kg/cm2 (For Loose sand)
 In case of a run flat due to puncture the tyre should be immediately removed.
 The Km runs of the removed tyre to be recorded in the run flat record card. (Encl.)
 The spare tyre to be fitted on the vehicle.
 The punctured tyre not be dismantled from the rim.
 The punctured tyre to be repaired only by Tiptop “Super Radial Anchor Seal Kit” as per prescribed
procedure.
 Repaired tyre to be inflated to the recommended air pressure.
 The repaired tyre to be kept as a spare wheel or fitted back to the vehicle.

INSTRUCTIONS FOR INSTALLING AND REMOVING RODGARD RUNFLAT SYSTEM

INSTALLING THE SYSTEM -

1. Separate the two Roller Segment by removing the cross bolts of each section.
2. Do not remove the factory installed grease. It is special, high temperature lubricant that will not
harm the tyre or the wheel. If reinstalling the Run flat apply grease to the top surface of the “C”
shaped runner and the channel of the roller half interface.
3. Fit on the tubeless Metal Valve of the correct type on the valve seating of the rim.
4. Install your tyre on your rim and inflate enough to seat beads.
5. Deflate the tyre and break the outboard bead. Raise the bead with the help of a tyre spreader and
place two wooden blocks adjacement to the each other to hold the raised beads. Insert the “C”
shaped runner outboard side up. Runner ends should straddle the tyre valve and snap into place
in the wheel drop center.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 368
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

6. Insert the two roller halves into the tyre outboard side up. Seat them around the roller and
engage the bolts of both ends. Ensure that the bolts are tightened at approximately 90 degrees
from the “C” shaped runner ends.
7. Tighten both ends equally until rollers stop revolving on the runner. Usually the gap at each end
will be approximately 3/8 inch but may vary because of slight wheel diameter differences.
8. Apply loctite to the thumb screw and thread into the spanner nut, use hand plier to tighten until
snug.
9. Rotate the spanner toward the outside of the tyre until contact is made.
10. Remove all wooden blocks and tools from the inside of the tire.
11. Reinstall the outboard bead and inflate the tyre.

REMOVING THE WHEEL -

1. Deflate the tyre.

2. Break the outboard bead. With the help of the tyre spreader raise the bead and put the wooden
blocks to hold the bead at two points adjacent to each other.
3. Remove the thumb screw.
4. Loosen both the ends of the roller half interface.
5. Remove both the roller halves.
6. Remove the “C” shaped runner from the rim.

IMPORTANT INSTRUCTIONS -

1. Always apply a good bead lubricant to the tyre beads while installing or removing the Run flat
system, this will ensure that the beads will not be damaged.
2. The installation and removing should be done on a good tyre changing machine.
3. Each Rod guard Run flat System should be fully assembled and completely covered when not in
use. This is necessary to prevent contamination of grease, rusting of metal parts, and other
changes caused by temperature, sunlight and moisture.

THE RUNFLAT SYSTEM IS MAINTENCE FREE. HOWEVER, WHEN A RUNFLAT INCIDENCE OCCURS A
PHYSICAL CHECK IS REQUIRED AND IF NEED BE THE RUNFLAT SYSTEM SHOULD BE REGREASED.

FAILURE TO FOLLOW THESE INSTRUCTIONS COMPLETELY MAY RESULT IN A COMPONENT FAILURE.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 369
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specification –

Tyres :
Make and country of origin (if imported). 215/75R15 -Bridgestone, Goodyear, JK, Ceat, Apollo, MRF
Opt. 185/85R16 - JK, Apollo,
Optional:- 215/75R15 ( Tubeless ) - Apollo & MRF, Maxxis
No. and arrangement of wheels 4 & 1 Spare Wheel
Front & Rear 2/2
Type: - Radial, With tube
Optional: - Radial, Tubeless
Tyre type (Radial/cross ply) (with Tube / (For 215/75R15 Size Apollo, MRF & Maxxis makes only)
Tubeless), size designation including ply Size: - 215/75R15 Optional. - 185/85 R16
rating, Speed rating, Load rating or Load
TYRE 215/75 R15 185/85 R16
index.
LOAD INDEX 100 , 102 (For Maxxis) 105
SPEED RATING S Q
Front wheel P215/75R15 Opt. 185/85R16
Dynamic rolling radius, mm, as per P215/75R15 -340 : 185/85R16 - 349
AIS:044
Inflation pressure – Unladen in kg/cm2
Front 2.1( with P215/75R15 Tyres) & 2.6 (with 185/85R16
Tyres)
Rear 2.1 ( with P215/75R15 Tyres) & 2.6 (with 185/85R16
Tyres)
Inflation pressure – Laden in kg/cm2
Front 2.1 ( with P215/75R15 Tyres) & 2.6 (with 185/85R16
Tyres)
Rear 2.1 ( with P215/75R15 Tyres)
For Bolero DX / DI , Bolero - 2.8 (with 185/85R16 Tyres)
For Bolero XL/XLS - 3.5 (with 185/85R16Tyres)
• Tightening Torque’s –

Description Torque in Nm
Wheel Nut (Normal) 60 to 75 Nm
Body Mounts 55 ± 5 Nm

• Specification & Wear Data –

Description Value
Run out of the tyre- radial 1.5 mm
Run out of the tyre- lateral 1.5 mm
Unbalanced allowed- tyre Max. 1.8 Kg-f
Minimum tread depth 1.6 mm

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 370
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

CHASSIS

Contents…

• Description………………………………………………………………………….….
• Frame measurement……………………………………………………….………..
• Tightening Torques………………………………………………………………….

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 371
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• General description

The chassis has C in C pressed and welded section. The cross members connect the side members to
each other.

Frame Alignment –

Normally frame misalignment is happens only due to:

 Collision
 Excessive overloading.

An improper frame alignment will affect axles alignments thus influencing the tyre wear. It will also
affect the door closure & window operation. In severely misaligned frame it will affect the vehicle
handling.

• Frame Inspection & Measurement

Inspection –

 Before proceeding with measurements, inspect all components for visible damage and other
damage.
 All damaged areas must be repaired or replaced.

Measurements –

 Measure the frame for misaligned with body attached to the frame. The inspection sketch
attached gives the alignment reference dimensions.
 However before proceeding with any measurements, the following precautions have to be
taken.

• Park the vehicle on level ground.

• The vehicle should be in unloaded condition with fuel tank full.
• If any extra fittings have been fitted; Please remove them. (E.g. winch etc.)
• Measure the tyre inflation pressure. Keep it as per recommendation

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 372
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Diagonal frame measurements –

• Select reference points along one frame long member. It is suggested that the body mounting
points be used.

• Transfer these points to the surface floor with a plumb bob. (Attaching paper sheets below on the
ground will improve the measurements accuracy)

• Locate the reference point on the other long member.

• Measure the frame outer distance in front and the frame outer distance in rear.

• Move the vehicle away.

• Measure the distance between all the reference points diagonally. The measurement should not
vary more than 10 mm.

• Divide the distance between the front outer points and the rear frame outer points. This gives the
centre of the frame.

• Join the centre of the frame width at front and the centre of the frame width at rear. Place a chalk
line between these two points.

• This gives the centre line of the chassis.

• Determine how close to centre line is to diagonals intersection point.

• The reference mark on the floor will provide an illustrated indication of the degree of
misalignment.

• A reference point transferred from one side’s long member may be 5 mm ahead or behind the
reference point from the opposite long member.

• Frame bow to the side should not exceed 5 mm per 2540 mm in length.

Inspection points –Measurement of Independent Front suspensions points –

 Take the measurement of the IFS points as shown in the sketch & using the same procedure of
marking.
 The dimension for the LCA bracket front & rear is the same.

Frame Repair –
It is not recommended to repair the chassis frame. In case of any bend / twist due to accident
collision: if the bend is beyond the specified limits then it has to be replaced.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 373
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Tightening Torque’s –

 BODY MOUNTING BOLTS - TIGHTEN

Nut/ Bolt description Spanner Size Quantity Nos. Torque Value – Nm.
• Body mtg. bolts 13 mm. 10 nos. 55 ± 05 Nm.
Refer below sketch for Chassis frame and body mounts locations –

Bolero – Body Mounts Locations

Bolero – Body Mounts

 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.

 Check and adjust all the body mounts at every service interval.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 374
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

ELECTRICALS

Contents…

• General Description………………………………………………………………..
• Care of the System………………………………………………………………….
• General Specification………………………………………………………………
• Vehicle Security System………………………………………………………….

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 375
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• General Description –

The body electrical components of these vehicles are designed to operate on 12 volts power supplied
by the battery. The electrical system utilizes negative grounded polarity.

All body low voltage wires are insulated. The insulation is color coded for identification of individual
body circuit.

Refer New Bolero Electrical Wiring Manual for more details on Electrical System.

• Care of the System –

 Inspection of Fluid level and specific gravity –

New Bolero – Battery Electrolyte Level & Specific Gravity Check

• 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.
 Check specific gravity first at 5000 kms then at every 10000 kms.

• Check the connections at –

 Battery Terminals for correctness & Tightness.
 Battery Earth for correctness & Tightness.
 Check the battery connections at every 5000 kms and correct it if required.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 376
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Instruments, Lights, Horn, Wiper, Washer & Accessories - Check

A. Battery Charging Warning Lamp H. OBD Check Lamp

B. Low Engine Oil Pressure Warning Lamp I. Low Fuel Warning lamp
C. Parking Brake ON/ low brake Fluid J. Water in Fuel Filter Warning lamp
Warning Lamp K. Parking Lamp
D. High Coolant Temp Warning lamp L. Headlamp High Beam Indicator
E. Seat Belt Warning lamp M. Left Turn Indicator
F. Immobilizer Lamp/ Ignition ON –or- N. Right Turn Indicator
Immobilizer Lamp/ Ignition OFF O. Micro Hybrid Stop-Start Lamp.
G. Check Engine lamp

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 377
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

LIGHTS/ HORN/ WIPER/ WASHER – CHECK

Refer illustrations shown for Instrument Cluster, Combination Switch & Hazard Switch –

 Check all instruments & gauges in instrument cluster for proper operation.
 Check combination switch for all the functions & operation of respective applications.
 Turn signal & Hazard.
 Wipe & Wash – All Modes.
 Head light aiming switch.
 Horn operation.
 Above checks to be carried out at every service interval for all New Bolero models.

 If the turn signal lamps on the instrument panel flash faster than normal, there may be a
possibility that one or more of the turn signal lamp bulbs have blown. Replace the blown bulb
immediately.
 The tail lamp, license plate lamp, side marker lamps, instrument panel illumination lamps and
all interior switches are also activated when the Parking lamp is switched ‘ON’.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 378
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Head Lamp Operations -

Head Lamp High Beam

With the head lamp low beam ON, push the

lighting control stalk down (away) from
steering wheel to switch on the head lamp
high beam. The head lamp high beam telltale
lamp in the instrument cluster illuminates
indicating high beam option selected.

Head Lamp Low Beam

With the head lamp high beam ON, pull the

lighting control stalk up towards the steering
wheel to switch ON the head lamp low beam.

Head Lamp Flash

Pull the lighting control stalk (from the head

lamp low beam position) towards the steering
wheel to instantaneously flash the head lamp
high beam. The head lamp flash works even
when the head lamp is OFF.

A: FLIP WIPE (MIST) C: INTERMITTENT (INT) E: HIGH SPEED (HI)

B: OFF D: LOW SPEED (LO)

 Press the pad on the steering wheel to blow/sound the horn. The horn functions even when the
ignition has been switched off.
 The wipe/wash function can be activated only when the ignition is in “ACC” or “ON”
position.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 379
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 Wiper Off – It is off when the wipe control stalk is in neutral position (B).
 Flick-Wipe (Mist) - Push the wipe control stalk to position A for a flick-wipe, hold to operate
the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate
the wash). The stalk automatically comes back to position B when released.
 Intermittent (INT) Mode - Intermittent (INT) wiping is selected when the wipe control stalk is
pushed down to position C. In the INT mode, the wiper operates on preset intervals.

 Low Speed Wiping - Push the wipe control

stalk down to the position D to operate the
wiper at a fixed low speed.
 High Speed Wiping - Push the wiper control
stalk down to position E to operate the
wiper at a fixed high speed.
 Rear Wiper (if equipped) - Rotate the outer
rotary switch on the wiper control stalk to
align the “dot” on the switch to the “1st
detente” position on the wiper stalk to
Rear Wipe operate the rear wiper

NOTE: To operate the rear wash, the rear wiper needs to be switched ON; pull/lift the wiper
control stalk towards the steering wheel. Hold the stalk for continuous spray of washer fluid from
the rear.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 380
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• HEADLAMP AIMING/ ALIGNMENT

Headlamp alignment can be done by two methods -

(1) HEADLAMP ALIGNMENT USING THE AIMING INSTRUMENT:

(Follow instructions of the equipment supplier, if any)

 Vehicle & black screen/ board both are placed on the same Level surface.
 Check and ensure all four tyre pressures as per specification.
 Headlamp levelling switch position is on zero (0).

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. -

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 381
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

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 in New BOLERO to be checked actual.

Head Lamp Leveling System -

Bolero Instrument Panel - Schematic

When the vehicle is either fully or partially loaded, it may have an upward inclination disturbing the
head lamp aiming. A correct head lamp setting provides good visibility to the driver with minimum
inconvenience to other road users. To properly aim the head lamp beam, use the head lamp leveling
switch. This switch is located on the right side of the steering column shroud in the instrument panel.
This switch has four positions marked as 0, 1, 2 & 3.

The head lamp leveling should be done when the head lamp low beam is ‘ON’.

Select the suitable switch position depending on the pay load as advised in the table.

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.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 382
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

(2) HEADLAMP ALIGNMENT IN THE DARK ROOM:

 Vehicle & black screen/ board both are placed on the same Level surface.
 Check and ensure all four tyre pressures as per specification.
 Headlamp levelling switch position is on zero (0).

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 to be measured actual in vehicle.
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
All seats occupied with luggage or Driver with luggage at extreme
3
rear side.

1. If Head lamp centre height in BOLERO assumed is X mm. So here h(mm) is the height
(X-130mm) below the HL-centre height. i.e. –1.3% setting of cut-off pattern.
2. Distance of vehicle from black board is 10 meters.
3. Do check and adjust Head Lamp aiming at 5000kms.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 383
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Bulb Specification – New BOLERO Zlx/ Slx/ Sle

Lamp Bulb Wattage CAP Type No. of Bulbs

per Vehicle
Head Lamps 12V 60/55W H4-P43T 2
Front Turn Signal Lamp 12V 21W Amber BAU15D 2
Front Parking Lamps 12V 5W W5W 2
Side Turn Signal Lamps (Fender) 12V 5W W5W 2
High Mount Stop Lamp (Tail Door Type 1) 12V 21W BAS15D 1
Brake Lamp/Tail Lamp 12V 21W/5W BAY15D 2
Rear Turn Signal Lamp 12V 21W BAS15D 2
Reversing Lamp 12V 21W BAS15D 2
Rear License Plate Lamp 12V 5W W5W 2
Interior Courtesy Lamp 12V 10W C10W 1

• General Electrical System Specification – New BOLERO Zlx/ Slx/ Sle

Description Specification
AMARON Sp. Gravity of fully charged Battery 1.280 to 1.270
EXIDE Sp. Gravity of fully charged Battery 1.240 to 1.230
75Ah--> N70Z/MF 70Z/EF-70Z/75D31L OPT
Type & number
65 Ah -> MFS70 / 65D-26R; 1
Voltage & Capacity (Ah) 12 V, 75 Ah OPT 65 Ah
Wind Screen Wiper
Type (Manual/power) Electrical operated
No. of wipers 2
Wiper motor
Type RACK & PINION TYPE OPT LINK TYPE
Rated voltage 12 V
Number of sweep Frequencies 2
Highest sweep frequency (Cycles/min) 68
Lowest sweep frequency (Cycles/min) 45
Wiper arm
Length 352 mm (DRIVER & CO-DRIVER)
Wiper blade
Length 255
Washer tank
Type Electrical operated
Capacity 1.5 Lit.
Horn
Type CLEAR TONE ( Type 2B)
Operating voltage 12 V DC
Number 1 (LOW TONE)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 384
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Fuse and Relay Identification – Engine & passenger Compartment

• ECU Fuse/ Relay Identification – Passenger Compartment

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 385
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Passenger Compartment – ECU Fuse/ Relay Identification

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 386
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• VEHICLE SECURITY SYSTEM –

A vehicle security system is an Engine Immobilizer system that prevents the vehicle being operated by
an unauthorized person. The Engine Immobilizer prevents the engine from being started unless it
recognizes signals from the correct coded key.

The system is automatically activated when the key is removed from the ignition.

Features:

1. This prevents the vehicle being driven by anyone not in a possession of correct vehicle key.
2. The vehicle is automatically protected within a few seconds after the key is removed from
ignition. At every IGN ON if the vehicle does not recognizes the correct key code engine check
lamp will be ON/blink and the engine cannot be started.
3. The vehicle will not be protected until the key has been taken out of the ignition.

After ignition has been switched ON If engine check lamp continues to flash or remains continuously
ON then there is a system operating fault. Contact Mahindra authorized dealer for any repair or
service required in immobilizer system.

Engine Immobilizer warning lamp illuminates when the ignition is switched ON, and goes OFF
immediately confirming its normal function.

In an unlikely event of vehicle not starting even with the correct key, switch OFF the ignition for a
minimum of 1 minute then give a starting attempt and an IGN toggle and start the vehicle again.

1. Any unauthorized work carried out on the engine immobilizer could be dangerous and work must
be carried out by Mahindra authorized dealer.
2. In case of any key lost the same to be reported at service station immediately.
3. In an unlikely event of vehicle not starting even with right key. It is recommended to give a crank
attempt before trying to start the engine.
4. Do not modify, remove or disassemble the engine immobilizer system. Any unauthorized changes
or modifications can affect proper operation of the system and will void your warranty.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 387
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• DRIVER INFORMATION SYSTEM (DIS) –

Driver Information system (where fitted) -

The Driver Information System (DIS) is above the

central AC vents. The DIS screen displays five
categories of information when the ignition is
switched ON apart from the Mode (I) and Set (H)
buttons.

Refer below callouts -

Callout Description
A Date
B Day
C Time
D Door Ajar
E DIS Error Symbol
F AFE/DTE/DT
G Gear Position
H Set knob/button
I Mode knob/button

When the ignition is Switched ON, DIS initializes to the screen in which DIS was before ignition OFF.
Press the “MODE” button (I) for 1 second and release to scroll/cycle through the below information-
• AFE- Average Fuel Economy
• DTE- Distance to Empty
• DT- Driving Time

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 388
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Display Parameter Information

Introduction:
Date, Day and Time (A, B and C)
The date, day and time will be shown on this area of the
DIS. The time is in 12 hr format only showing hours and
minutes and the range is 01:00 to 12:59 along with
am/pm.

The Date and Time will retain the values on every

ignition cycle except when battery has been
disconnected and reconnected

The day will be selected automatically based on the set

date.

Setting of Date and Time:

The date and time can be set in ignition ON condition using the below procedure

• During Ignition ON condition, Press “MODE” (I) and “SET” (H) button together for > 2sec, on
release the DIS will enter into clock and date setting mode
• Hours will start blinking
• Press “SET” (H) continuously or step by step to increment the Hours and other parameters
• If the ”SET” (H) switch is held for longer than 1 second, the digits increment at faster rate until
released
• AM/PM will toggle automatically while changing Hour
• Press “MODE” (I), to confirm the Hours and move to next setting parameter, the parameters
will cycle in the following order for setting on pressing of “MODE” (I) button-

Exiting Setting mode:

• If no knob is pressed for 10 seconds, the Clock setting mode will be exited
• Press “MODE” (I) Button for > 2sec to exit from Clock/Date setting mode

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 389
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Door Ajar (C) Introduction:

The door ajar information is available for the following

three doors only-
• Bonnet (A)
• Co-Driver Door (B)
• Driver Door (C)

The Car symbol will appear only when any of the door’s
(mentioned above) is open and the respective door(s)
will be shown as open in the DIS.

Contact an authorized Mahindra dealer if Door Ajar is

not indicating.

Average Fuel Economy (E) Introduction:

The Average Fuel economy or efficiency or mileage is the

last 30km average mileage that the vehicle is giving
based on the driving pattern or the way the vehicle is
being driven.

• This Average Fuel economy might not match with any other method of determining the fuel
mileage. The reason being that the value shown is average of last 30kms, which may not be
exactly calculated in any other method if used.

Re-setting AFE:

• While on the AFE screen, press “MODE” (I) button for > 2 second and release to reset AFE
• AFE will show “---” for the first 1km after AFE is Reset or Battery disconnect and reconnect
• After 1km, the real time AFE calculation will be displayed on the screen

 The AFE reset can be done only when vehicle is in stationary condition
 Contact an authorized Mahindra dealer if AFE is not updating.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 390
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Distance to Empty (E) Introduction:

The distance to empty is the information in km for the

driver to be aware of number of km the vehicle can be
driven with the available fuel and the Fuel economy that
the vehicle is giving at that instance.

The DTE update will be faster if the refueling quantity is

greater than 6 liters else will be slow and happen while
driving.

DTE will show “---” for the first 1km after the Battery is
disconnected and reconnected. After 1km, the real time
DTE calculation will be displayed on the screen.

• DTE feature should never be used to calculate the fuel remaining/refilled in the vehicle.
• For maintaining good health of the Engine, the vehicle should never be driven after the DTE
shows “---“.
• During air lock, there are chances that the DTE will be showing some value but the engine will
stop and will not be able to crank.
• In case if the refuel quantity is less than 6 liters than the update of the DTE will not happen
quickly, but still if user wants to update the DTE, than the following procedure should be
followed-
- While on the DTE screen, press “MODE” (I) button for > 2 second and release to reset AFE.
This manual update of the DTE can be done only when the vehicle is in stationary condition.

 Contact an authorized Mahindra dealer if DTE is not updating.

Driving Time (E) Introduction:

– This feature enables user to know the actual time

taken to cover a trip excluding non-driving times
(engine off time)

– When Engine is ON, DIS will calculate the driving

time.
– The time will be calculated across the ignition
cycles from the time the reset was done or
Battery disconnected and reconnected

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 391
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Re-setting DT: While on the DT screen, press “MODE” (I) button for > 2 second and release to reset DT

 Contact an authorized Mahindra dealer if DT is not updating.

Current Gear Position (F) Introduction:

• It shows the current gear engaged information

to the user on the DIS screen.

• The gear position will be shown only in Engine

ON condition, and will be shown only and only
when clutch is completely released.
• If the gear is in neutral gear and vehicle is
moving, the gear position will be shown wrongly
on the screen, not neutral.
• There is chance that if the clutch is pressed for a
longer time while driving, than wrong gear
would be displayed on the DIS screen.

Warning Symbol (D) Introduction:

• Warning symbol will appear only and only if

there is an error in the DIS or any feature is not
working
• If the warning symbol appears, or appears and
disappears, please contact an authorized
Mahindra dealer.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 392
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

AIR CONDITIONING

Contents...

• Description…………………………………………………………………………………

• Trouble Shooting………………………………………………………………………….

• Care of the system…………………………………………………………….…………

• In Car repairs…………………………………………………………………….………..

• Control panel………………………………………………………………….….……….

• Specifications…………………………………………………………………………….

• Recommended Lubricants……………………………………………..………………

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 393
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Description -

AC system provided in vehicle enable occupants to manually adjust air flow distribution, air flow rate
and air temperature inside passenger compartment. The air flow speed and air temperature can be
adjusted by operating buttons/knobs provided AC control panel.

To achieve desired cooling/heating effect, there are basically three sub-systems which need to work in
coherence. These are Air Conditioning sub-system and Heating sub-system. User interface to select
the desired effect is the AC control panel.

Air Circulation sub-system Air Circulation sub-system mainly consist of –

• AC air filter
• Blower Motor Assembly
• Blower resistor
• Air ducts and vents/louvers

Before air gets sucked inside the system, it is filtered first by AC filter located just above blower.

Filtered air is then forced circulated towards the main distribution hosing where multiple flaps are
provided. Air flow is distributed among different vents present inside passenger compartment.

Air flow speed is controlled via a blower resistor and can be adjusted by adjusting blower speed knob
on AC control panel. Flow direction of air flow coming out of vents can be controlled by manually
adjusting the louvers. Depending upon selected temperature knob position on AC control panel,
amount of air passing through evaporator and heater is controlled. Finally both cold and hot air
streams are mixed together and are distributed further.

Air Conditioning sub-system

• The Air conditioning sub-system uses closed circuit configuration based on Vapor Compression
Refrigeration Cycle. The system uses R134a as refrigerant and suitable lubricating oil.
Refrigerant gets circulated through a closed loop as long as air conditioner is in operation.

Heater system

The heater system is controlled water flow system. An electric water valve controls the quantity of
water entering the heater core.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 394
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Air conditioning System

• The system uses non-CFC refrigerant R134A.
New Bolero – AC System Schematic

The refrigerant at low pressure and temperature enters the compressor where it is compressed and
its pressure and temperature increase. The refrigerant after leaving compressor enters condenser and
here it is condensed into high-pressure liquid and is collected in receiver drier. From the receiver drier
it passes through expansion valve where it is throttled down to a low temperature and pressure. After
finding its way through expansion valve it finally passes into evaporator coil where it extracts heat
from surrounding. The refrigerant, which was in low-pressure liquid state, converts to low-pressure
vapour. The low-pressure vapour then again enters the compressor. The air then gets cooled and
dehumidified by the evaporator. The evaporator is in operation all the times unless the AC switch is
kept in off condition. To maintain minimum evaporator temperature a fixed thermostat-setting switch
controls the compressor clutch. This switch which is called Anti freeze switch has a probe so that it
touches the coldest part of the evaporator is used to avoid formation of ice. (If ice formation is
allowed then the ice formed prevents exchange of heat thus reducing the cooling and forcing the
compressor to work continuously/ longer period leading to low cooling as well as system failure.)

The evaporator always cools the air to an amount set by the fixed thermostat value. The cooled air
later goes through the heater coil. When the heater button is pressed the electrically operated water
valve opens & the hot water enters in the heater coil.

Binary Pressure switch: It is mounted on Receiver drier & the cut in & cutout values are 2 ± 0.2 bar &
32 ±2 bar. High-Low Pressure operation: If the system pressure becomes low then it switches off the
compressor. Thus in the case of refrigerant loss due to any system leak the compressor failure is
avoided. Once the pressure increases above 32 bar then the compressor is shut off to avoid any
system failure. If the system pressure falls due to any leaks then the compressor is switched off.

Medium pressure operation: When the pressure in the system goes above 17 bars then it switches on
the condenser fan. As the pressure reduces below 14 bar the condenser fan is switched off.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 395
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Trouble Shooting –

Symptom Causes Remedial action

Low pressure side Evaporator flooding due to  Remove refrigerant
pressure high Block valve stuck/ open.  Evacuate/dehydrate
Ps>2.5to 2.9 1. Dirt in Block valve.  Change expansion
And 2. Moisture in the valve
High pressure side pressure gauge refrigerant circuit  Change filter/drier.
high.  Charge correct amount of
Pd>19.5 to 25 bar oil & refrigerant.
Discharge air warm  Check performance.

Low side –High Non condensable  Remove refrigerant

High Side- High (excessive air)  Evacuate/dehydrate
Ps>2.5-3.0 bar 1. Large amount of air  Change filter/drier.
Pd> 19.5-25 bar caused by insufficient  Charge correct amount of
Suction side piping is hot to touch. evacuation after repair or oil &
servicing of system refrigerant.
2. Leak in system allowing  Check performance
air and moisture to enter.
Low side –High 1. Expansion valve stuck  Change the expansion
High Side- High open. valve.
Ps>2.5-3.0 bar
Pd> 19.5-25 bar
Frosting on suction side piping
Low side –High 1. Excessive refrigerant  Check refrigerant
High Side- High condition
Ps>2.5-3.0 bar 2. Poor condenser cooling  Check & repair condenser
Pd> 19.5-25 bar 3. Engine or condenser fan.
Discharge air- Warm fan not working  Check condenser.
High side tubes-Very hot 4. Fan direction reverse.  Check pressure cap,
Compressor clutch- Could 5. Condenser fan clogged clearance between fan
continuously cycle on the high with debris/ sand. and radiator.
pressure switch Pressure does not 6. Radiator Coolant  Check coolant and any
come to normal when condenser overheating. other radiator problem.
cooled by water
Low side- Low or 1. Expansion valve- Stuck  Remove refrigerant
vacuum closed and or insufficient  Evacuate/dehydrate
High side- High refrigerant flow to suction  Change filter/drier.
Ps> 1.5 bar to vacuum side of the compressor.  Charge correct amount of
Pd> 19 to 22 bar 2. Foreign material or oil & refrigerant.
Discharge air- slightly cool moisture entry causing rust  Check performance.
formation.

Low side _ low or vacuum Clogging on high side  Remove refrigerant.

High side- High 1. Clogging between  Clean & flush system.
Ps> 1.5 bar to vacuum compressor outlet  Change filter drier.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 396
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Pd> 5 to 7 bar and evaporator inlet  Charge correct amount of

Discharge air-slightly cool ( High side) oil & refrigerant.
High side tubes- Cool and showing 2. Very little or no  Check performance
signs of sweating or moisture build refrigerant flow to
up at the position after the point suction ( low) side of
of restriction. the compressor
Temperature difference found on
both the sides of the clogged
component.
Low side Gauge- 1. Excessive moisture in  Remove refrigerant
Normal to Vacuum system  Evacuate/dehydrate
Gradual reduction) 2. Moisture can freeze  Change expansion
High side- Normal within the expansion valve valve
Ps> 1.5 to vacuum and cause blockage through  Change filter/drier.
Pd> 14 to 16 bar rust formation.  Charge correct amount of
Discharge air becomes warmer as oil and refrigerant.
low side cycles to vacuum.  Check performance.

Low side- High 1. Compressor mal function.  Replace compressor.

High side- Low 2. Compressor faulty,  Remove refrigerant
Ps> 4 to 6 bar internal blockage in suction  Evacuate/Dehydrate
Pd> 7 to 10 bar Hose after low side filing  Change filter drier.
Compressor –Noisy. port.  Charge correct amount of
Discharge air- Warm oil & refrigerant
Discharge hose- Cool.  Check performance.

Abnormal noise 1. Belt slippage/damage.  Correct belt tension/

2. Idler pulley misalignments replace belt.
3. Compressor clutch pulley  Replace bearing in the
faulty. pulley.
4. Loose compressor  Check the compressor
mounting bolts mounting
5. Loose A/C plumbing  Check for loose parts and
touching firewall/ front correct.
panel/ fenders.  Fit rubber packing where
6. Compressor internal clearances low.
damage.  Replace compressor

High /Low pressure equalize soon 1. Faulty compressor  Replace compressor.

after compressor stops. discharge or inlet valve.
Compressor is not hot to touch. 2. Faulty compressor seal.

Compressor pressure drops rapidly 1. Non condensable in  Recover refrigerant/ check

after switching off and does not system for leaks and repair
stabilize to saturation pressure as
per ambient temperature.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 397
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Line to condenser is excessively Restricted flow of  Remove restriction

hot. refrigerant in system  Charge through the
charging unit.
Insufficient/ no air 1. Blower rotation direction  Correct the blower
flow wrong. fitment.
2. Sealing disconnected.  Renew sealing.
Insulation piece blocking air  Remove blockage.
passage.
3. Mode cable not adjusted  Adjust cable.
properly.
4. Voltage insufficient  Recharge battery.
< 12 Volts  Check the charging system.

5. Improper earthing.  Correct earthing.

6. Open circuit, wiring  Correct wiring.
harness.
7. Fuse blown  Replace fuse.
8. Filter clogged  Clean filter element by
tapping/ Replace filter
element if airflow is still
insufficient after cleaning.
Compressor clutch 1. Open circuit/ Fuse blown.  Replace fuse.
engagement not 2. Weak battery.  Charge battery.
satisfactory 3. Faulty clutch relay.  Change relay.
4. No refrigerant.  Check for leaks, charge
5. Shorted clutch coil. refrigerant & oil & check.
6. Oil/ dirt on clutch plate  Replace oil.
 Change clutch plates
Check condenser/ 1. Condenser fan pusher  Check and rectify.
radiator Fan- direction type Radiator fan puller.  Loose connection
of rotation If fan not operating:  Loose wiring harness.
 Motor burnout

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 398
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Care of the system –

The system should be checked for leakages at every 2 year of operation; and recharged if required.

The quantity of the gas which has to be filled is 550 ± 20 grams.

The refrigerant used is R134a (AC Gas).

Do not use / mix R12 & R134 A. the oils used for compressor is unique for R134. DO NOT MIX. IT WILL
CAUSE DAMAGE TO ‘O’ RINGS as well as the R/D.

Use only Sanden SP10 (Compressor Oil) Quantity 135 ml.

Though R134A is non-CFC, it is recommended that it should not be discharged to atmosphere.

We recommend the use of ROBINAIR equipment for evacuation, charging of the system.

Following are the activity to be covered during vehicle regular maintenance –

• AC SYSTEM – LEAK CHECK & RECHARGE

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 399
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 AC SYSTEM – LEAK CHECK & RECHARGE

Bolero Instrument Panel - Schematic

AC SYSTEM – EVACUATION, RECHARGE & LEAK CHECK.

A. The following procedure is recommended for evacuation.

1. Connect the hose of Recovery unit to the vehicle circuit.
- Red hose to the high pressure charging port.
- Blue hose the low pressure charging port.
2. Open the quick coupler valves on the hose after they are connected to the system.
3. Check the manifold gauges the units control pane. They should register above zero. If it is
indicating zero then either the hose is not connected properly/or/quick coupler valves are
not opened or the system is empty.
4. Make sure that the drain valve at the bottom is closed.
5. Open both the manifold valves on the control panel.
6. Open the Gas (vapour valve and liquid valve on the tank).
7. Switch on the power.
8. Choose Recover option from the panel.
9. To assure that the complete recovery of the refrigerant. Wait for 5 minutes and watch the
manifold gauges for a rise above zero. If a rise occurs, press HOLD/CONT. repeat until the
system pressure hold for at least 2 minutes.
10. The system displays the weight of the refrigerant recovered.
11. Confirm that the oil catch bottle is empty. Then slowly open the drain valve and allow the
oil to be drained into the bottle. When all the oil has been recovered, close the valve
immediately. New clean oil must be added to system before recharging with the refrigerant
12. The automatic recovery unit will operate until the air conditioning system has been emptied
of refrigerant down to atmospheric pressure. The cylinder can now be closed.

B. AC System Recharging – The procedure to be followed is –

Ensure recovery of refrigerant from the system by evacuation before Recharging.
1. Drain out the refrigerant oil.
2. Flush the remaining oil using R134a refrigerant.
3. Add 135 cc of new refrigerant oil to the compressor.
4. Install the compressor after replacing the Suction and discharge “O” rings.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 400
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

C. Preliminary charging & High Pressure leak test –

This ensures that the system does not leak under high pressure conditions.
• Confirm that the hoses are connected to the charging ports and valves on the hose, Tank &
manifold are open.
• Enter the refrigerant quantity by weight and press ENTER. (At least 200 grams of charge are
required to do the high-pressure leakage test)
• Press CHG to start charging. The unit displays the completed message after the charging is
completed.
• Use the electronic leak detector to probe the leakages. Leakage checking to be done at the
following points –

 Expansion valve joints

 All pipe joints.
 Suction & discharge ports.
 Both the charging ports

 Ensure that the ‘O” rings are not twisted and that both the seals and ‘O’ rings are clean and
then oil.

 Inspect for leaks by slowly moving the probe of the detector around all the hose connections
and points of possible leakages. The R134A is heavier than air; hence, any leakage will be
more apparent at the bottom of fitting.

 AC System should be recharged and leak test to be done once in 2 years.

Refrigerant used in the system is a hazardous liquefied gas and remains under high pressure. It is
colorless and has an ethereal or faint sweetish odor. Exposure of the refrigerant to skin or eyes
may cause irritation and frostbite. They can also cause suffocation, dizziness and loss of
concentration. When mixed with compressed air or certain other refrigerants, they may form a
flammable mixture.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 401
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• In Car repairs –

• Extreme care has to be taken to prevent any liquid refrigerant in coming in contact with skin.
Always wear safety goggles.

• Do not allow liquid refrigerant to touch bright metal. Refrigerant will tarnish bright metal and
chrome surface. Refrigerant in combination with moisture is very corrosive and can damage
to all metal surfaces.

• When charging, always keep the tank in upright position. If the tank is on its side or upside
down, liquid refrigerant will enter and affect the compressor.

• Always double check that the gas being used is a R134A.The refrigerant cylinder is color-coded
to avoid confusion. R134A is Blue.

• The compressor oil for R134A gas is different from R12A compressor oil. Do not mix. If the
R12A compatible compressor oil is used then it will damage the O rings as well as the receiver
Drier.

• The Robinair equipment AC 350 should be used with R134A gas only.

• Never discharge a system or do brazing/welding operation when the engine is ON.

• PAG oil is highly hygroscope. Open containers only when ready to use. Cap containers
immediately after use.

• Use only the specified oil for the AC system

• Do not allow PAG oil to contact bare skin.

• Do not allow PAG oil to contact paint work- wash immediately.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 402
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

The charging procedure comprises of the following distinct steps –

• Discharging the system

• Evacuation of the system and checking for low vacuum leak

• Purging – if required

• Preliminary charging & High Pressure leak test

• Charging the system

• Evaporator cleaning

• Performance test

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 403
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Discharging the system –

The following procedure is recommended for evacuation.

1. Connect the hose of Recovery unit to the vehicle circuit.

- Red hose to the high pressure charging port
- Blue hose the low pressure charging port
- Open the quick coupler valves on the hose after they are connected to the system.

2. Check the manifold gauges the units control pane. They should register above zero. If it is
indicating zero then either the hose is not connected properly/or/quick coupler valves are not
opened or the system is empty.

3. Make sure that the drain valve at the bottom is closed.

4. Open both the manifold valves on the control panel

5. Open the Gas (vapor valve and liquid valve on the tank).

6. Switch on the power

7. Choose Recover option from the panel

8. To assure that the complete recovery of the refrigerant. Wait for 5 minutes and watch the
manifold gauges for a rise above zero. If a rise occurs, press HOLD/CONT. repeat until the
system pressure hold for at least 2 minutes.
- The system displays the weight of the refrigerant recovered.

9. Confirm that the oil catch bottle is empty. Then slowly open the drain valve and allow the oil
to be drained into the bottle. When all the oil has been recovered, close the valve
immediately. New clean oil must be added to system before recharging with the refrigerant.

10. The automatic recovery unit will operate until the air conditioning system has been emptied
of refrigerant down to atmospheric pressure. The cylinder can now be closed.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 404
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Evacuation of the system –

The evacuation and leak test ensues that the system does not leak under low-pressure conditions.

Ensure that the hoses are connected to the charging ports and valves on the hoses. Tank & manifold
are open.

Choose vacuuming program (Shift/Reset option) from the control panel.

Set up the vacuuming time in minutes. Approximately 15 minutes of vacuuming time is recommended.

The unit displays the complete message after the vacuuming is over.

Check the moisture indicator. If it is green, it means that the system is ready for recharging. If it is not
green then manual recycling has to be done for one hour. In case the moisture indicator still does not
turn green, the reason could be saturated receiver drier. It should be replaced.

The charging station is equipped with recycling facility. During evacuation the refrigerant is
automatically recycled to assure recharging with the cleanest possible refrigerant. Recycling begins
automatically after 5 second of the vacuum pump starting. Non condensable gases (mostly air) are
automatically vented from the tank.

The system must hold the vacuum of –100 Kpa for a minimum of 15 minutes. If vacuum is held then
the system has no ands and should be evacuated for further 15 minutes

This completes the evacuation process.

• Purging – if required –

Where the system has been ruptured, contaminated, or a compressor has to be removed, reinstalled
or replaced, the system should be checked for contamination, and if so then the entire system must
be flushed.

The system can be flushed with Nitrogen.

Preliminary charging & High Pressure leak test –

This ensures that the system does not leak under high pressure conditions.

Confirm that the hoses are connected to the charging ports and valves on the hose, Tank & manifold
are open.

Enter the refrigerant quantity by weight and press ENTER. (At least 200 grams of charge are required
to do the high-pressure leakage test)

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 405
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

Press CHG to start charging. The unit displays the completed message after the charging is completed.
Use the electronic leak detector to probe the leakages. Leakage checking to be done at the following
points –

• Expansion valve joints

• All pipe joints.
• Suction & discharge ports.
• Both the charging ports

Inspect for leaks by slowly moving the probe of the detector around all the hose connections and
points of possible leakages. The R134A is heavier than air; hence, any leakage will be more apparent at
the bottom of fitting.

• Charging the system –

If no leaks are found then do an additional charging. The total system requirement is 550 ± 20 grams.

However in case of leakage, the system should be discharged. After that repeat, the steps from
evacuation onwards till the above steps. Then proceed.

In case the system was checked for High pressure leaks by using Nitrogen,

Evacuation should do first and then system should be directly charge with 550 ± 20 grams.

Close both the manifold valves and then start the vehicle.

Start the vehicle’s AC system and set it to maximum cooling. Check the pressure gauges and
temperatures in the vehicle.

Turn off the engine.

Disconnect the high side hose and start the vehicle. Open both the manifold valves to pull the
refrigerant from both the hoses into the system.

At the lowest operating pressure close the low side valve and switch off the vehicle. Disconnect the
low side hose and remove adapters if used.

Close the high side manifold valve. Both the valves should now be in closed position.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 406
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Do not start the engine when the valve on the manifold and tank are open.
• Ensure that the valves are closed before starting the engine.
• Never run the compressor without the refrigerant in the system as the lubricant relies on the
refrigerant flow

Accurate system refrigerant charge can only be determined by charging the correct amount of R134a.

If in doubt as to gas charge, e.g.

Suction pressure low

Or
Discharge pressure low
Or
Air outlet temperature at the face high.

Then: Evacuate the system and Charge with the 550 +/- 20 grams of R134 A;

Carry out cooling system pressure test and suction (low side) pressure reading comparison.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 407
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Evaporator Cleaning Procedure –

New Bolero – AC Evaporator

Cleaning Procedure Schematic

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.
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.

Special Instructions for Vehicle Users to avoid Wet Smell on the Evaporator:

Put OFF the AC & put Blower on 4th speed 5 minutes before stopping the Vehicle, this will keep
Evaporator DRY & NO WET SMELL will come from Evaporator.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 408
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• AC Performance Test -

This test has to done in shade and at an ambient temperature of 30 to 40 degrees maximum. If the
ambient temperature is more than that, then please take the vehicle to the coolest area available in
shade and then carry out the test.

AC Vent Grill - Middle

AC Vent LH & RH

Temperature
Gauge

a. Start the engine, switch on the AC and keep the Engine RPM at 1500.
b. Set the Blower to 3rd speed, the ventilation mode to be set to chest and recirculation mode.

The temperature control should be set to the coolest.

1. These tests have to be performed at ambient temperature ranging from 30°C – 40°C.
2. Vehicle must be in shed, bonnet closed & 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 12°C. (Open Door
Test - in 10 minutes open door test the drop in average grill temperature with respect to ambient
temperature should be 15°C).

In normal conditions:
• The low side pressure should be 1.5 to 2.5 bars.
• High-pressure side the pressure should be 15 to 17 bars.
• This is with reference ambient temperature of 30°C to 35°C
• If the ambient temperature is different from the range refer to the chart for getting the
range of suction and discharge pressures.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 409
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Checking system oil charge —

The compressor is charged at the factory with 135 cc of Sanden SP 10 refrigerant oil, which circulates
within the entire AC system. This brand of oil is only recommended (it is pale yellow in color) and must
be used when adding or changing oil. This oil is not compatible with any other PAG oil. It is not
necessary to regularly check the oil level in the system. It should be remembered that the oil gets
circulated within the whole system. Therefore, whenever an AC system component is replaced a
quantity of new refrigerant oil must be added to the system, where a major loss of system oil has
occurred. The loss normally takes place when: Hose failure or leak is present.

Refrigerant system component is damaged due to collision.

If oil is suspected to be in the system

The procedure to be followed is –

• Recover refrigerant from the system by evacuation.

• Drain out the refrigerant oil.
• Flush the remaining oil using R134a refrigerant.
• Add 135 cc of new refrigerant oil to the compressor.
• Install the compressor after replacing the Suction and discharge “O” rings.

NOTE: Ensure that the ‘O” rings are not twisted and that both the seals and ‘O’ rings are clean and
then oil.
• Follow the steps of charging procedure.

• Compressor Replacement –

Procedure for removal of the AC Compressor –

1. Discharge the refrigerant

2. Remove the suction and discharge pipes from the compressor, ensuring no foreign items get
clogged to the ports.
3. Loosen the tensioner bolt of the compressor.
4. Remove the fan belt
5. Loosen the compressor mounting bolts.
6. Remove the compressor.
7. Drain and measure the refrigerant oil from the original compressor by removing the drain plug.
8. The replacement compressor comes with 135 cc of compressor oil. So there is no need to add
any further quantity of Oil.

The refitting procedure is the reverse of assembly procedure.

Follow the steps of charging procedure.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 410
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• AC Control Panel –
In Bolero the AC control panel is mounted on
center bezel of IP. Refer illustration. The Blower
can be operated in 4 different speeds. Heater
operation can be performed by switching ‘ON’
press button ‘B’ shown in above illustration.

Temperature Control (if equipped)

By operating the temperature control knob,

temperature of air being discharged from various
vents can be adjusted to the desired level. Engine
coolant is utilized to heat whereas the air
conditioner is used to cool the air inside the AC
unit. Based upon selected position of the
temperature control knob, the desired discharged air temperature can be obtained.

By operating the temperature control knob, temperature of air being discharged from various vents
can be adjusted to the desired level. Engine coolant is utilized to heat whereas the air conditioner is
used to cool the air inside the AC unit. Based upon selected position of the temperature control knob,
the desired discharged air temperature can be obtained.

•The air conditioner might not actually be functioning even when LED on the AC switch remains
illuminated. This is to be considered as normal AC system operation.
• During extreme cold weather conditions, the air conditioner may not function until temperature of
the air near the evaporator rises above a predefined threshold.
• When air conditioner is ON, moisture is extracted from the air. The resulting condensate is drained
off from the vehicle. It is therefore normal, if you see a small pool of water under your vehicle.
• The air conditioner should be operated at least for ten minutes once every fortnight, even during
winter months. This allows AC system components to get lubricated periodically and ensures optimum
system performance.

Rapid Cabin Cooling

For rapid cooling of the cabin, the following AC settings are recommended:
1. Make sure that all the windows are fully closed
2. Set the blower to maximum speed
3. Fully open the vents and adjust louvers to direct air toward face
4. Turn the air conditioner ON
5. Set the temperature control knob to extreme right (coolest) position
Once the passenger compartment reaches a comfortable temperature, the blower speed and
temperature control knob can be readjusted as desired.
If vehicle was parked in the hot sun with all the windows closed, drive the vehicle with windows open
for the first few minutes. This will help inventing the hot interior air out and allow the air conditioner
to cool the cabin quickly.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 411
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

• Specifications –

Description Specification
Compressor Capacity 130 cc
Oil Specification Sanden SP 10
Oil Quantity 135 ml
AC Gas Specification R 134 a
Gas Quantity 550 ± 20 gms.

• Recommended Lubricants –

Refrigerant: R134a
Compressor oil: Sanden SP – 10 Quantity- 135 ml.

Oil quantity to be filled while replacing components –

• Condenser/evaporator: In addition to the drained quantity- 30 cc

• Receiver Drier: Add 20 cc of new oil
• If anyone pipe is replaced then 10cc. (If 2 pipes replaced then it should be 20 cc.)

Evaporator cleaning Agent -

"Coil Rinse" Packaged by Chemguard Laboratories; Kuala Lumpar.

In India Marketed by Astro Trading Company

Contact person Mr. Rakesh Bhai; Mobile no 9820141308

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 412
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

APPENDICES

Contents...

• Abbreviations and Measuring Units…………………………………………….

• Lubrication Chart……………………………………………………………………
• Greasing Points……………………………………………………………………..
• Do’s and Don’ts……………………………………………………………………..
• Vehicle Preservation……………………………………………………………….

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 413
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

APPENDEX – A

• Symbols and Abbreviations -

PDI : Pre Delivery Inspection

S.L. No. : Serial Number
CQAV : Central Quality Assurance - Vehicle
ACC : Accessories
2WD : 2 Wheel Drive
4WD : 4 Wheel Drive
2WDH : 2 Wheel Drive High
4WDH : 4 Wheel Drive High
4WDL : 4 Wheel Drive Low
N : Neutral
T/F Case : Transfer Case
FIP : Fuel Injection Pump
OEM : Original Equipment Manufacture
NOx : Nitrogen Oxides
O2 : Oxygen
SAE : Society of Automotive Engineers
CI : Compression Ignition

• Measuring Units –

KM : Kilo Meter
CC : Cubic Capacity
Mm : Millimeters
Kw : Kilo Watt
RPM : Revolutions per Minute
Kg : Kilogram
Nm : Newton Meter
Amps : Amperes
Km/h : Kilo Meters per Hour
M : Meter
L : Liters
C : Centigrade temperature scale

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 414
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

APPENDEX – B

• Lubrication Chart - Refer below chart for BOLERO m2DICR vehicle lubrication details.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from
which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 415
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

APPENDEX – C

• Greasing Points –

Refer bellow illustrations (A) & (B) for greasing points.

(A) Lubricate the Propeller Shaft at Universal Joints through the nipples.

(B) Lubricate the Front & Rear Suspension Pins.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 416
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

APPENDEX – D

DO’S

1. Use recommended lubricants only. Replace oil in engine, gear box & transfer case, front & rear
axles, steering box & Brake & Clutch master cylinder periodically as per schedule.
2. Use only genuine oil filter and fuel filter elements.
3. In order to obtain trouble free and enhanced engine life, clean air filter element regularly. Replace
filter element when service indicator shows red band even after cleaning the filter element.
4. Ensure periodic servicing as per maintenance schedule.
5. Insist on use of genuine MAHINDRA spare parts for all replacements.
6. Allow the starter pinion to come to rest before again attempting to start the engine in order to
avoid pinion and flywheel ring gear damage.
7. Replace thermostat in the event of failure and ensure fitment of pressurized radiator cap to get
better engine life.
8. Maintain correct tyre pressures as specified in chart. Before moving the vehicle releases the
parking brake.
9. Maintain electrolyte level in the battery (using distilled water). Keep battery terminals clean and
cable joints tight. Apply Vaseline/petroleum jelly on terminals.
10. Disconnect alternator/battery/electrical connection while carrying out welding work on the
vehicle. Observe correct polarity when connecting battery terminals.

DONT’S

1. Do not run the vehicle with leaky air pipes, fuel pipes and water hoses.
2. Do not run the vehicle without a battery in its electrical circuit as the life of alternator will be
reduced.
3. Do not run the engine without radiator cap. Use genuine cap only, to keep system pressurised.
4. Do not open radiator cap when engine is hot. Never add cold water when engine is hot as this may
lead to cylinder head/block crack.
5. Do not continue to run the engine when temperature gauge shows more than 1000 C.
6. Do not use clutch pedal as a foot rest. It will cause premature wear of clutch plate, release bearing
and clutch finger /diaphragm and also result in high fuel consumption.
7. Number of passengers carried should be within approved seating capacity.
8. Do not race or rev the engine especially when starting. This is destructive to engine.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 417
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

APPENDEX – E

• VEHICLE PRESERVATION – VEHICLE MAINTENANCE WHEN OUT OF USE

Long term storage of new vehicles requires special care to keep vehicles factory fresh and ready for
reuse. The following guidelines should be performed to minimise vehicle component/ part
degradation due to extended vehicle storage conditions.

STORAGE LOCATION & PARKING

• Vehicles should be stored in a Dry, Well Ventilated and Drained area with a Roof above.
• If an indoor storage area or other location with a roof overhead is not available, the following
conditions should be met:
- Location should be where damage to painting due to factory smoke, metallic powder, acid
rain, salty winds, bird droppings, tree sap etc. can be prevented.
- Floor of such a storage area should be paved and have good water drainage.
• Ensure to remove the Adhesive Film (if any) from Exterior Trim / Mouldings / Seats.
• Ensure that the Window Glasses are covered with cardboard or Cloth to prevent fading and
deformation of the Instrument Panel, Upholstery and Seats.
• Park vehicles with at least 3-feet gap in between them and enough space in the front and rear
to walk around.
• Park the vehicle in First / Reverse gear. DO NOT apply Parking Brake.
• Ensure that all windows / sun roofs are closed.
• Lift the Wiper Arm / Blade from the wind screen glass.

OTHER INFORMATION

If the vehicles in the storage area are exposed to salty environment, sea breeze, corrosion with rust
may appear in some of the ferrous parts. If rust is found, remove it and apply suitable rust inhibitor.

The disc brake rotors are made of cast iron and may show gradual build up of surface rust during long
storage, accelerated if the environment is salty. On a monthly basis, drive the vehicle to 50 Kmph and
brake normally to stop the vehicle to remove rust. Repeat this exercise at least 10 times.

Plastic materials used in the vehicle as well as insulation material of wires might attract small rodents
which nibble at these components. Inspect the vehicle for “Rat-bite” at the time of PDI/ reuse. Small
birds and rodents might find it interesting to build their nests inside air cleaners, exhaust system.
Inspect these areas thoroughly at the time of reuse.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 418
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Repair Manual MAN-00145
New BOLERO Zlx/ Slx/ Sle Sept 2011/Rev 1

 List of activities/checks to be done during vehicle long time storage condition -

 ELECTRICALS & BATTERY

• Ensure that all electrical accessories are turned OFF.
• Remove the memory fuse* (*if applicable).
• For Long Term Storage, it is recommended to remove the battery negative cable.
• Ensure to reset all memory related components before delivery to the customer.
• Test & charge battery, as per Battery service manual, before reinstalling.

 TYRE
• Inflate the road tyres to 20% - 30% higher than the recommended pressure. Ensure to reduce
the pressure at the time of reuse.
• Rotate each wheel by ¼ turn on a monthly basis. This is to prevent tyre flat spot from
developing.

 ENGINE
• Condensation may form within the engine, if vehicles are run for short intervals (5 minutes or
less) during storage.
• On a weekly basis, run the engine in idle for at least 10-minutes to avoid condensation
possibility. Also, gradually raise the engine speed to max RPM for 10-times to eliminate
moisture from the exhaust.
• Move the vehicle to approx. 30 to 40 feet to lubricate the Transmission / Differential
assembly.
• Drive the vehicle a little forward and backward once a fortnight.

 COOLING SYSTEM - Add anti-rust to the water. Add antifreeze during cold weather. Cover the
instruments.

 CLUTCH - Press the clutch pedal to the floor board and hold it in this position. Operate the
clutch pedal a few times once in a week, check and top-up clutch fluid in master cylinder
reservoir once in a month.

 BRAKES - Operate the brake pedal a few times once in a week, check and top-up brake fluid in
master cylinder reservoir once in a month.

 BODY - coat rust proof to all bright metal. Cover up with upholstery.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra Page 419
& Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.