Mahindra Bolero Single Cab Turbo Owner'S Manual Download Page 7

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Bolero Single Cab Turbo / Double Cab Turbo

Engine Specification

Cylinder block

Cast Iron

Cylinder Liner

Wet replaceable

Crank Shaft

Forged Steel, 5 Bearing journal

Connecting rods

Forged Steel

Main bearings

Aluminium tin Si

Pistons

Aluminium

Cylinder Head

Cast Iron

Camshaft

Chilled casting, 3 Bearing

Turbo Charger

Model K03-2070, Make: TEL

Valves

Overhead, Rocker Arm operated

Timing

Chain timing

Lubrication

Pressure lubrication

Cooling

By water

Bore

94 mm

Stroke

90 mm

Cubic capacity ( cc )

2498

Compression ratio

18.5:1

Operating cylcle

4stroke (order 1-3-4-2)

Cylinders

In line arrangement

Max Power

100 HP or 74 ± 2 KW @ 3800 RPM

Max Torque

235 N-m @ 1700 -1900 RPM

Weight of the engine

310 Kg with flywheel & Starter

NEF TCI 2.5L ENGINE

Summary of Contents for Bolero Single Cab Turbo

Page 1: ...Owner s Manual Mahindra Bolero Single Cab Turbo Double Cab Turbo LHD...

Page 2: ...ISSUED JANUARY 2006 MAHINDRA MAHINDRA LTD GATEWAY BUILDING APOLLO BUNDER MUMBAI 400039 INDIA...

Page 3: ...et is accurate up to date The procedures specifications dimensions referred to are subject to change in accordance with the Company s policy of constant product improvements Please contact nearest Aut...

Page 4: ...er this Warranty is dependent upon the strict observance by the Purchaser of the following provisions a The purchasershall take Pre Delivery Inspection b All the paid services are mandatory to be carr...

Page 5: ...thout delay after the defect has been ascertained Certain limitations wherein the Warranty does not apply are listed below a If repairs is required because of the following reasons i The Vehicle is no...

Page 6: ...covered by ordinary factory inspection g Repairs required due to following reasons i Due to unauthorised modification to the Vehicle which in any way affects the stability or reliability of the compon...

Page 7: ...on Camshaft Chilled casting 3 Bearing Turbo Charger Model K03 2070 Make TEL Valves Overhead Rocker Arm operated Timing Chain timing Lubrication Pressure lubrication Cooling By water Bore 94 mm Stroke...

Page 8: ...T G WB OL OF OH AA 35 6 WB OR DA 8 Bolero Single Cab Turbo Double Cab Turbo Vehicle Specification Bolero DC Turbo Dimensions...

Page 9: ...r OR 1320 51 9 Approach Angle AA 41 5 41 5 Departure Angle DA 150 Overall Width 1815 71 45 Weights ITEM 4WD 2WD Kerb weight Kg 1975 1875 GVW Kg 2800 2800 Front Axle Capacity Kg 1000 1000 Rear Axle cap...

Page 10: ...T WB OL OF AA 35 6 WB OR OH DA 10 Bolero Single Cab Turbo Double Cab Turbo Vehicle Specification Bolero Single Cab Turbo Dimensions...

Page 11: ...OR 1320 51 9 Approach Angle AA 4103 4103 Departure Angle DA 15 Overall Width 1875 71 45 Weights ITEM 4WD 2WD Kerb weight Kg 1875 1775 GVW Kg 2800 2800 Front Axle Capacity Kg 1000 1000 Rear Axle capac...

Page 12: ...N MAHINDRA BOLERO SINGLE CAB TURBO DOUBLE CAB TURBO ENGINE NEF TCI 2 5 Litres TRANSMISSION NGT 530 AXLE RATIO 4 55 1 STEERING POWER AIR CONDITIONING SYSTEM HEAT COOL CENTRAL LOCKING YES POWER WINDOW O...

Page 13: ...tion plate located on the right side of the engine compartment for LHD vehicle on left side of the engine compartment for RHD vehicle Vehicle Serial Number The vehicle serial number is stamped on the...

Page 14: ...t knob The tripmeter indicates the distance travelled during a particular trip or period Press the reset knob to return the tripmeter indication to zero 4 Fuel Gauge Indicates the approximate level of...

Page 15: ...vehicle has been driven The trip meter can be used to measure the distance travelled on short trips or between fuel stops When the ignition switch is turned to ON the display shows the odometer or tri...

Page 16: ...tor This red tell tale lamp is lit when the starter switch is first turned on It goes out after the engine is started If the light does not go out it indicates low oil pressure or Clogged Filter Cartr...

Page 17: ...g Indicator if applicable This when ON indicates that pre heating is on Do not crank the engine when glow plug is ON to avoid excessive load on battery ensure effective starting 10 Driver Seat Belt If...

Page 18: ...dow opens or closes while this switch is operated Driver front passenger can operate the windows from the switch panel switches Passenger s Control The middle seat passengers can operate their individ...

Page 19: ...rned clockwise the temperature is set to lower 2 Blower Switch Air flow can be controlled in three stages low medium high 4 Heater Switch The knob is turned clockwise the heater comes ON 5 Lock Unlock...

Page 20: ...t if required Opening and Closing the Bonnet 1 Ensure that the vehicle is in neutral gear and set the parking brake Pull the bonnet release lever to position B from A and release which is located unde...

Page 21: ...o Single Cab Turbo Double Cab Turbo Centre side vents The airflow volume can be adjusted with the rotary controls at the sides The air vanes can be adjusted horizontally vertically by swivelling the v...

Page 22: ...seconds will go off Then the 4WD indication will turn ON d Now for shifting from 4wd low to 4wd high position turn to the knob of the switch from 4L to 4H with clutch pedal in the depressed position...

Page 23: ...2 Intermittent pass 7 Lever turned left Left indicator 8 Lever turned right Right indicator Left lever wiper 1 Intermittent operation 2 Slow speed Low 3 High speed High 4 Windshield washer operation I...

Page 24: ...mirror can be used to adjust the mirror to reduce the glare from the headlight of vehicles behind you during night driving 2 Ash tray Ash trays are located one on each side of instrument panel 3 Glove...

Page 25: ...ng in the Vehicle Avoid smoking inside the vehicle Smoking in the vehicle spoils the ambience and the interiors of the vehicle Do not toss a cigarette out of the window It may land on somebody or may...

Page 26: ...ent potential failures From time to time keep an eye on the gauges If any abnormality is noticed stop the vehicle for safety check Frequent eye on the dash board is essential to monitor the functionin...

Page 27: ...dle the engine for a minute after starting and before stopping Not doing so may lead to premature failure of the turbo charger bearing Starting in Cold Weather or at High Altitudes To start the engine...

Page 28: ...engine do not rev it up Warm up gradually at idling speed Do not drive over 100 km hr Avoid sudden acceleration and full throttle Do not drive for a long time at a single speed Either increase or dec...

Page 29: ...e require separate lubrication for each unit as they have no cross over oil passage At each Transmission service check the filler plugs of transmission transfer case should be removed the lubricant re...

Page 30: ...ard with the starter When engine starts control the downward speed with the accelerator Down hill Shift to 4WD Low range first gear Do not use clutch brakes Now the vehicle can proceed safely down a g...

Page 31: ...in longer stopping about four times that of normal stopping distance So it make sense to keep a good distance from other vehicles people and objects on you path Maintain tyres Tyres do not provide ade...

Page 32: ...and cause a skid Driving in Low Visibility Being able to see clearly in all directions and being visible to other drivers is important in all weather conditions This is more difficult in bad weather c...

Page 33: ...m 4WD to 2WD Reverse the vehicle in a straight line for about a meter An audible click will indicate that the hubs have been released Manual Locking Hubs The free wheeling hubs disconnect the drive at...

Page 34: ...r than operating the vehicle exclusively with the hub in the Free position This keeps the operation of free wheeling mechanism always smooth and provides lubrication to the axle components Caution Whe...

Page 35: ...shoulder to the inboard hip where the buckle is located Push the tongue into the buckle slot until a firm click is heard Check the buckle for security by tugging sharply on the webbing To unbuckle sim...

Page 36: ...cle is emitting excess smoke Blue white black smoke get your vehicle checked at authorized service station Allow your engine to warm up after a cold start Drive the vehicle in correct gears Avoid sudd...

Page 37: ...the nearest outlet for a short time at low engine speed Caution Avoid use of high sulphur diesel Use only diesel with sulphur content below 500 ppm Avoid frequent cold starts Avoid starting the engin...

Page 38: ...le release the parking brake 9 Maintain electrolyte level in the battery using distilled water Keep battery terminals clean cable joints tight Apply Vaseline petrolium jelly on terminals 10 Disconnect...

Page 39: ...ect the tyre pressure before the vehicle stands on the wheel Body Coat rust proof to all bright metal Cover up with upholstery Engine Topping up the Engine Oil The engine oil level should be maintaine...

Page 40: ...filter element is choked up and needs servicing Clogged air filter leads to higher intake resistance and can reduce the driveability of the vehicle Servicing Instructions It is adviced to service air...

Page 41: ...ot recommended Use the anti freeze when the operating temperature falls below 0 C Caution Never remove the Degassing Tank cap when the engine is hot Degassing Tank Fuel Injection System Fuel Injection...

Page 42: ...eding screw is free from any air bubbles Tighten the bleeding screw Fuel Filter It is a dual 0 5 lit filter provided with hand primer Bleeding procedure is similar to FIP bleeding Note Fuel outlet ban...

Page 43: ...e OFF during prolonged waits at traffic signals railway crossings etc Avoid fast start and unnecessary stops Avoid sudden acceleration or deceleration Maintain a clear air cleaner Clogged air cleaner...

Page 44: ...steering system Power steering with universal joint reduces effort during steering vehicle The procedure for filling oil in reservoir is as follows Fill the reservoir nearly full Crank the engine for...

Page 45: ...nt Investigate correct any external leaks no matter how minor Do not attempt to weld any broken steering gear component Use genuine component of steering only Keep the tyres inflated to correct pressu...

Page 46: ...CLUTCH BRAKE FLUID DOT 3 BRAKE FLUID MEETING FMVSS NO 116 SAE J 1703 SPECIFICATIONS As Required ENGINE RADIATOR COOLANT BASF MAKE GLYSANTIN 48 24 or 45 23 for Diesel vehicle Note Mix coolant and clean...

Page 47: ...Bumper BA15S 10 2 Reverse indicator lights Tail Lamp BA15S 21 2 Illumination lamp Instrument Cluster Capless BA9S 3 4 2 Headlight Main beam Do Do 1 4 1 Turn indicators Do Do 1 4 2 Battery charging in...

Page 48: ...alve clearance 3 3 3 3 3 Check the drive belts for cracks fraying wear tension 3 3 3 3 3 3 3 3 3 3 3 3 Chanqe Enqine oil oil filter R R R R R R R R R R R Check Vacuum pipe oil hoses connection 3 3 3 3...

Page 49: ...stg Ball joint and dust covers 3 3 3 3 3 3 3 3 3 3 Check Steering wheel linkage gear box oil 3 3 3 3 3 3 Check Power steering reservoir fluid level and hose connections for leaks 3 3 3 3 3 3 3 3 3 3...

Page 50: ...ce if necessary 3 3 3 Check condition of rubber bushes in lower link of front suspension Replace if necessary 3 3 3 Check condition of pivot bushes in top wishbone Replace if necessary 3 3 3 Check and...

Page 51: ...VH covers door panels for fit and alignment 3 Check lubricate Latches Keys and locks for operation 3 3 3 3 3 3 3 3 3 3 3 3 Check apply grease Door lock striker Check arm Bonnet opening lever lock plat...

Page 52: ...Seat belts mat Side foot step Ski rack mud flaps Inspect for interior and exterior metal and paint damage Check for spare tire jack jack rod tools and literature Wash Clean interior and exterior befor...

Page 53: ...W L B B W B G B B R L B B R 85 86 86 30 51 30 51 87A 87 87A 87 W G I GN SW ACC W G M P W MOTOR COMB SW PARK SW O P UP DN W W W MAXI FUSE 60 A BATT B 53 Bolero Single Cab Turbo Double Cab Turbo Power...

Page 54: ...ER MASTER UNIT FRONT LH FOLLOWER REAR LH FOLLOWER L G CONTROL MODULE FROM VEHICLE CIRCUIT M L G M W B B Y W G R G Y 54 Bolero Single Cab Turbo Double Cab Turbo Central Locking Circuit Diagram for Bole...

Page 55: ...ors W W W G W I W Y W G W W fuse blower relay l l G G B G l G B B w w G R G w R R l w B R R B b y b y y b r w b b B w b b y y l w b y b r b r led indicator b yb y r b l w l y l b W G 20 A 25 A 55 Bole...

Page 56: ...R ST ON ACC OFF W W G W Y L W R B G L Y B L L W B 60AMPS MAXIFUSE IGNITIONSWITCH BATTERY 56 Bolero Single Cab Turbo Double Cab Turbo Circuit Diagram Heater for Bolero SC Turbo DC Turbo Sb sky blue P p...

Page 57: ...Single Cab Turbo Double Cab Turbo Record of Services Performed Recommended Services at KM Date Odometer Reading KM Repair Order No Servicing dealer s Signature with stamp PDI 5000 10000 20000 30000 40...

Page 58: ...58 Bolero Single Cab Turbo Double Cab Turbo Recommended Services at KM Date Odometer Reading KM Repair Order No Servicing dealer s Signature with stamp 60000 70000 80000 90000 100000...

Page 59: ...ER BRACKET LH SIDE MEMBER FRONT 59 Bolero Single Cab Turbo Double Cab Turbo Spare Wheel Mounting Spare wheel mounting Tighten the spare wheel hanger as shown in the figure To loosen rotate in the oppo...

Page 60: ...els is below rear axle Jack mounted below middle seats on the centre floor in the vehicle 60 Bolero Single Cab Turbo Double Cab Turbo Jack Position Jacking position for front wheels Jacking position f...

Page 61: ...A Tail gate closed position C Tail gate position for Arm lift off B Tail gate 90 position Assy check arm 61 Bolero Single Cab Turbo Double Cab Turbo Tail Gate Opening Procedure...

Page 62: ...m Use of Seat Belts In the interest of safety to the driver and passengers of all four wheelers wearing of seat belts at all times during the driving is essential Using a hand phone while driving cons...

Page 63: ...63 Bolero Single Cab Turbo Double Cab Turbo Notes...

Page 64: ...y faulty electrical systems irregular servicing failure to use distilled water negligent maintenance wilful abuse or destruction by fire collision theft or recharging 6 The warranty is NOT VALID if th...

Page 65: ...a Amaron Prestolite Battery Type __________________________________________ Battery Serial No ______________________________________ Vehicle Serial No ______________________________________ Battery Ma...

Page 66: ...ase 4 BATTERY TOP should be kept clean dry 5 CHECK that voltage regulator setting generator output are normal for the battery Indications as to this are that topping up intervals are regular not too f...

Page 67: ...Cell 3 Cell 4 Cell 5 Cell 6 KEY TO REMARKS A Electrolyte level low B Alternator needs attention C Electrical system needs attention D Vehicle not running sufficiently to maintain battery Bench charge...

Page 68: ...68 Bolero Single Cab Turbo Double Cab Turbo...

Page 69: ...er Date Serial Number At km Owner Chassis Number Registration Number Service Rendered Date Engine Number Model At Km Registration Number Dealers MASC Seal Signature Dealers MASC Seal Signature I am sa...

Page 70: ......

Page 71: ...er Date Serial Number At km Owner Chassis Number Registration Number Service Rendered Date Engine Number Model At Km Registration Number Dealers MASC Seal Signature Dealers MASC Seal Signature I am sa...

Page 72: ......

Page 73: ...urbo PAID SERVICE Model 5000 KM AT ODOMETER READING 5000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 74: ...5000 km paid service jobs to be done as per the maintenance schedule...

Page 75: ...rbo PAID SERVICE Model 10000 KM AT ODOMETER READING 10000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 76: ...10000 km paid service jobs to be done as per the maintenance schedule...

Page 77: ...rbo PAID SERVICE Model 20000 KM AT ODOMETER READING 20000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 78: ...20000 km paid service jobs to be done as per the maintenance schedule...

Page 79: ...rbo PAID SERVICE Model 30000 KM AT ODOMETER READING 30000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 80: ...30000 km paid service jobs to be done as per the maintenance schedule...

Page 81: ...rbo PAID SERVICE Model 40000 KM AT ODOMETER READING 40000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 82: ...40000 km paid service jobs to be done as per the maintenance schedule...

Page 83: ...rbo PAID SERVICE Model 50000 KM AT ODOMETER READING 50000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 84: ...50000 km paid service jobs to be done as per the maintenance schedule...

Page 85: ...rbo PAID SERVICE Model 60000 KM AT ODOMETER READING 60000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 86: ...60000 km paid service jobs to be done as per the maintenance schedule...

Page 87: ...rbo PAID SERVICE Model 70000 KM AT ODOMETER READING 70000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 88: ...70000 km paid service jobs to be done as per the maintenance schedule...

Page 89: ...rbo PAID SERVICE Model 80000 KM AT ODOMETER READING 80000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 90: ...80000 km paid service jobs to be done as per the maintenance schedule...

Page 91: ...rbo PAID SERVICE Model 90000 KM AT ODOMETER READING 90000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendered...

Page 92: ...90000 km paid service jobs to be done as per the maintenance schedule...

Page 93: ...bo PAID SERVICE Model 100000 KM AT ODOMETER READING 100000 KM AT ODOMETER READING Service rendered Date Invoice Number Date Serial Number At km Owner Chassis Number Registration Number Service Rendere...

Page 94: ...100000 km paid service jobs to be done as per the maintenance schedule...

Page 95: ...entioned in ensuing pages by the dealer s representative I We agree to abide by the terms conditions DATE OWNER S SIGNATURE DATE OF SALE DIRECT SALE DEALER SALE KILOMETER READING KEY NO REGISTRATION N...

Page 96: ......

Page 97: ...entioned in ensuing pages by the dealer s representative I We agree to abide by the terms conditions DATE OWNER S SIGNATURE DATE OF SALE DIRECT SALE DEALER SALE KILOMETER READING KEY NO REGISTRATION N...

Page 98: ......

Page 99: ...ranty terms conditions as mentioned in ensuing pages by the dealer s representative I We agree to abide by the terms conditions DATE OWNER S SIGNATURE DATE OF SALE DIRECT SALE DEALER SALE KILOMETER RE...

Page 100: ......

Page 101: ...ranty terms conditions as mentioned in ensuing pages by the dealer s representative I We agree to abide by the terms conditions DATE OWNER S SIGNATURE DATE OF SALE DIRECT SALE DEALER SALE KILOMETER RE...

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Page 103: ...ns Others Finance for vehicle Own Others If others from whom This vehicle is mainly for Personal Use Commercial Use Official Use First Impressions of the Vehicle On the following parameters I would ra...

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