Download as pdf or txt
Download as pdf or txt
You are on page 1of 111

Published : September 2003

Created By: Publication Cell, Launch Planning Technical, A.S.Kandivali


GENERAL INFORMATION

F THIS PARTS CATALOGUE COVERS SERVICEABLE COMPONENTS OF BOLERO


RANGE OF VEHICLES. IT SHOWS ALL 'BOLERO DI' VEHICLES FITTED WITH
'MDI TC 3200 GEAR DRIVE DIESEL ENGINE'.

F FOR CONVENIENCE, THIS PARTS CATALOGUE HAS BEEN SUB - DIVIDED INTO
SUB - SECTIONS CALLED GROUP. GROUPS LIST REPLACEMENT PARTS FOR
PARTICULAR AREAS OF THE VEHICLE. EXPLODED VIEWS ARE ILLUSTRATED
GROUPWISE FOR IDENTIFICATION OF PARTS AND THESE ARE FOLLOWED
BY PART NUMBERS AND DESCRIPTIONS. INDEX SHEETS ARE PROVIDED
FOR EASY AND QUICK REFERENCE.
PARTS CATALOGUE
F BEFORE ORDERING REPLACEMENT PARTS, PLEASE IDENTIFY THE VEHICLE
MODEL BY MODEL, VEHICLE SERIAL NUMBER AND ENGINE NUMBER. THE VEHICLE
SERIAL NUMBER IS THE LEGAL IDENTITY OF YOUR VEHICLE.

Di F THE VEHICLE SERIAL NUMBER AND ENGINE SERIAL NUMBER ARE LOCATED
ON THE MANUFACTURER'S PLATE
LOCATED ON RIGHT SIDE TOP
CORNER OF DASH CORNER OF
(2WD) DASH PANEL ABOVE THE BATTERY
WITH TRAY. ENGINE SERIAL NUMBER IS
MDI TC 3200 GEAR DRIVE DIESEL ENGINE ALSO PUNCHED ON CYLINDER
AND BLOCK ON FRONT PAD
NGT - 520 TRANSMISSION (NEAR WATER PUMP)

F THE VEHICLE CHASSIS NUMBER


IS STAMPED ON THE RIGHT SIDE
CHASSIS 'SIDE MEMBER' BELOW
THE FRONT FENDER.

F ADDITIONAL PART NUMBERS GIVEN IN THE BRACKETS ARE OPTIONAL ONCE


IT IS ADVISABLE TO MENTION THE OPTIONAL PART NUMBER ALSO WHILE
ORDERING THE SPARES.

FIRST EDITION : FEB 2005 - VERSION: 1 F THE ASSEMBLIES AND SUB ASSEMBLIES ARE SHOWN EXPLODED VIEW FOR
EASE OF UNDERSTANDING ONLY. THEREFORE ALL THE PARTS SHOWN IN THE
EXPLODED VIEW ARE NOT ESSENTIALLY SERVICEABLE.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
F WHEREVER KIT IS APPLICABLE PLEASE ORDER AS A KIT ONLY. ITEMS
MARKED 'NS' ARE NOT SEPARATELY SERVICEABLE.
MAHINDRA & MAHINDRA LTD.
MUMBAI - INDIA
INDEX SHEET
S. NO. GROUP DESCRIPTION PAGE NO.

MODEL CODES 1 GENINFO GENERAL INFORMATION 3


BM726MN7URT BOL MDI-TC 3200 NGT520 T/M 2WD 7STR BS2. 2 INDEX INDEX 4
BM726MN8URT BOL MDI-TC NGT520 NON AC 2WD 8STR BS2. 3 M11A01 ENGINE ASSEMBLY M11A01.1
4 M11A02 LUBRICANTS M11A02.1
5 M11B01 CYLINDER BLOCK M11B01.1
6 M11B02 CYLINDER HEAD M11B02.1
7 M11B03 CRANKSHAFT M11B03.1
8 M11B04 CRANKSHAFT BEARING M11B04.1
9 M11B05 CRANKSHAFT PULLEY M11B05.1
10 M11B06 CONNECTING ROD M11B06.1
11 M11B07 CONNECTING ROD BEARING M11B07.1
12 M11B09 OIL PAN M11B09.1
13 M11B11 FRONT CASE M11B11.1
14 M11B12 ROCKER COVER M11B12.1
15 M11B13 BREATHER M11B13.1
16 M11B14 CYLINDER HEAD GASKET M11B14.1
17 M11B15 PISTON M11B15.1
18 M11B16 FLYWHEEL M11B16.1
19 M11B19 CAMSHAFT M11B19.1
20 M11B20 IDLER GEAR M11B20.1
21 M11B21 VALVE GEAR TRAIN M11B21.1
22 M11B22 INLET MANIFOLD M11B22.1
23 M11B23 EXHAUST MANIFOLD M11B23.1
24 M11B25 OIL FILLER & OIL LEVEL GAUGE M11B25.1
25 M11B26 AC COMPRESSOR M11B26.1
26 M11C01 OIL PUMP AND GEAR TRAIN M11C01.1
27 M11C02 OIL FILTER M11C02.1
28 M11C04 OIL STRAINER AND PIPE M11C04.1
29 M11C05 WATER PUMP M11C05.1
30 M11C07 THERMOSTAT M11C07.1
31 M11C08 FAN AND PULLEY M11C08.1
32 M11C09 DRIVE BELT M11C09.1
33 M11C11 OIL PRESSURE SWITCH OR GAUGE M11C11.1
34 M11C12 OIL LINES - ENGINE M11C12.1
35 M11D01 FUEL INJECTION PUMP (ROTARY) M11D01.1
36 M11D02 FUEL INJECTION PIPE (ROTARY) M11D02.1
37 M11D04 FUEL INJECTION NOZZLE M11D04.1
38 M11F02 EMISSION CONTROL SYSTEM M11F02.1
39 M25A01 ENGINE MOUNTING M25A01.1
40 1101 CLUTCH 1101.1
41 1102 CLUTCH HOUSING NGT - 520 1102.1
42 1103A CLUTCH LINKAGE - 2WD 1103A.1
43 1104 CLUTCH CYLINDER 1104.1
44 1201 FUEL TANK GAUGES AND LINES 1201.1
45 1202 AIR CLEANER BS II / EGR PARTS 1202.1
46 1203 ACCELERATOR LINKAGE 1203.1

3
INDEX SHEET INDEX SHEET
S. NO. GROUP DESCRIPTION PAGE NO. S. NO. GROUP DESCRIPTION PAGE NO.

47 1301 RADIATOR AND HOSES 1301.1 93 2602B FENDER LEFT 2602B.1


48 1401 EXHAUST SYSTEM 1401.1 94 2603 RADIATOR GUARD AND GRILL 2603.1
49 1501 ALTERNATOR 1501.1 95 2604 FOOT STEPS SIDE AND REAR 2604.1
50 1501B ALTERNATOR (MICO) 1501B.1 96 2605 BODY MOUNTINGS (NGT - 520) 2605.1
51 1502 STARTER MOTOR 1502.1 97 2606 ASSEMBLY INSTRUMENT PANEL 2606.1
52 1502A STARTER MOTOR (LUCAS MAKE) 1502A.1 98 2607 BODY SHELL ASSEMBLY 2607.1
53 1502B STARTER MOTOR (MICO MAKE) 1502B.1 99 2608 DOORS AND FITTINGS (FRONT) 2608.1
54 1503 HEAD LIGHT 1503.1 100 2609 DOORS AND FITTINGS (REAR) 2609.1
55 1504A INDICATING LAMP 1504A.1 101 2610 BACK DOOR AND FITTINGS 2610.1
56 1504B HIGH MOUNTED STOP LAMP 1504B.1 102 2611 BODY TRIMMING 2611.1
57 1505 TAIL, STOP, TURN SIGNAL AND REVERSE LIGHT 1505.1 103 2612 PLATES AND COVERS (2WD) 2612.1
58 1507 BATTERY HOLD DOWN & CABLE 1507.1 104 2613 DRIVER SEAT 2613.1
59 1508 HORN 1508.1 105 2614 FRONT PASSENGER SEAT 2614.1
60 1509 WINDSHIELD WIPER MOTOR 1509.1 106 2615 MIDDLE PASSENGER SEAT 2615.1
61 1509A WIPER MOTOR SERVICEABLE COMPONENTS 1509A.1 107 2616 SIDE PASSENGER SEAT 2616.1
62 1510 WIRING HARNESS 1510.1 108 2617A FRONT BUMPER 2617A.1
63 1601 INSTRUMENTS 1601.1 109 2617B REAR BUMPER 2617B.1
64 1602 WINDSHIELD WASHER 1602.1 110 2618A FENDER EXTENSION 2618A.1
65 1700 TRANSMISSION ASSEMBLY 1700.1 111 2618B REAR WHEEL ARCH AND MUD FLAP 2618B.1
66 1701A TRANSMISSION HOUSING AND ATTACHING 1701A.1 112 2618C ORNAMENTS 2618C.1
67 1702 SELECTION BIASING 1702.1 113 2619 TOOLS 2619.1
68 1703 SHAFT RAIL AND FORKS 1703.1 114 2620 FLOOR TRIMMING 2620.1
69 1704 DRIVE SHAFT 1704.1 115 2621A SEAT BELT DRIVER & CO-DRIVER 2621A.1
70 1705 MAIN SHAFT DRIVE GEAR & SYNCHRONIZER 1705.1 116 2621C SEAT BELT MIDDLE 2621C.1
71 1706 COUNTERLAY SHAFT DRIVE GEAR & SYNCHRONIZER 1706.1
72 1707 TRANSMISSION SHIFT LEVER 1707.1
73 1901 PROPELLER SHAFT 1901.1
74 2001A FRONT AXLE (2WD) 2001A.1
75 2002 REAR AXLE 2002.1
76 2101 STEERING GEAR & MOUNTINGS 2101.1
77 2101A SERVICEABLE COMPONENTS OF STEERING GEAR 2101A.1
78 2101D SERVICEABLE COMPONENTS OF RESERVOIR 2101D.1
79 2103 STEERING TIE ROD 2103.1
80 2104 STABILIZER BAR 2104.1
81 2201 HAND BRAKE (PARKING BRAKES ON REAR WHEELS) 2201.1
82 2202 FRONT DRUM BRAKE 2202.1
83 2202B WHEEL BRAKE REAR 2202B.1
84 2204 BRAKE MASTER CYLINDER & RESERVOIR 2204.1
85 2205 BRAKE PEDAL 2205.1
86 2206A BRAKE TUBES 2206A.1
87 2301A WHEEL AND ATTACHING PARTS 2301A.1
88 2401 FRAME 2WD (NGT - 520) 2401.1
89 2502A FRONT SPRING AND SHOCK ABSORBER 2502A.1
90 2502B REAR SPRING AND SHOCK ABSORBER 2502B.1
91 2601 HOOD 2601.1
92 2602A FENDER RIGHT 2602A.1

4 5
GROUP M11A01 - ENGINE ASSEMBLY GROUP M11A02 - LUBRICANTS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
0301BB0410N ENG ASSY MDI3200TC BS2 (G D) 1 1 022678 MAHINDRA MAXIMILE 10 K OIL - 7.5 LIT NS

M11A01.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11A02.1
#
GROUP M11B01 - CYLINDER BLOCK GROUP M11B01 - CYLINDER BLOCK

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0302AB0310N CRANKCASE ASSEMBLY - BS2 1
CONSIST OF :
1 0302AB0300N 1 - CRANKCASE - BS2
2 050930 4 - CAP CRANKSHAFT BRG FRONT NS
3 024607 1 - CAP CRANKSHAFT BRG REAR NS
4 0302AB0220N 10 - BOLT CRANKSHAFT MAIN BRG CAP NS
5 051322 1 - BEARING FRONT CAM SHAFT NS
6 051323 1 - BEARING CENTER CAM SHAFT NS
7 050028 1 - BEARING REAR CAMSHAFT NS
8 024721 CYLINDER LINER 4
9 084054 'O' RING 8
10 0302AB0210N BRIDGE LADDER FRAME 2
11 024503 FLANGED BOLT M8 x 1.25 - 30 4
12 9420000232 WATER DRAIN PLUG M12 x 1.5 1
13 7903062026 COPPER WASHER 2
14 7903067028 SPRING PIN 20 x 20 N/S 1
15 075221 PLUG EXPANSION 1
16 7932561906 PLUG M13 x 1.5 3
17 024739 TAPER PLUG M10 x 1 3
18 0303EC0310N STUD 1
19 G141287 PIN DOWEL, CYLINDER BLOCK REAR 1

M11B01.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B01.2
#
GROUP M11B02 - CYLINDER HEAD GROUP M11B02 - CYLINDER HEAD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0302BB0070N CYLINDER HEAD ASSEMBLY 1
CONSIST OF :
1 0302BB0080N 01 - CYLINDER HEAD 17mm NS
2 075222 06 - PLUG EXPANSION 31.75mm (1 - 1/4")
3 075221 01 - PLUG EXPANSION
4 051342 08 - GUIDE VALVE STEM
5 091016 04 - VALVE SEAT INTAKE
5 0310BB0010N 04 - VALVE SEAT INTAKE (OPT)
6 091017 04 - VALVE SEAT EXHAUST
6 0310BB0020N 04 - VALVE SEAT EXHAUST (OPT)
7 051349 04 - PLUG WATER JET
8 024609 BOLT CYLINDER HEAD SHORT 16
9 051611 TEMPERATURE SENSOR UNIT (I.I.L.) 1
10 071566 COPPER WASHER 14 x 20 1
11 091043 STUD ROCKER ARM BRACKET 4
12 G141244 PIN DOWEL, CYL BLOCK FRONT 2
13 094040 ENGINE LIFTING HOOK - MDI 1
14 0302FB0010N BRAKET, ENGINE LIFTING FRONT 1
15 024501 FLANGE BOLT M8 x 1.25 - 15 4

M11B02.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B02.2
GROUP M11B03 - CRANK SHAFT GROUP M11B04 - CRANKSHAFT BEARING

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 051967 CRANKSHAFT 1 1 7932580560 THRUST WASHER (UPPER) 2
2 0306HB0100N WOODRUFF KEY 2 2 7932580561 THRUST WASHER (LOWER) 2
3 0310BB0350N PINION CRANKSHAFT 1 3 051412 BEARING FRT & CNTR - BYMETAL 5
3 051432 BEARING FRT & CNTR - GABRIEL 5
3 084091 BEARING FRT & CNTR - KIRLOSKAR * 5
(* OPTIONAL)
3 051413 BRG FRT & CNTR LWR - BYMETAL 5
3 051433 BRG FRT & CNTR LWR - GABRIEL 5
3 084092 BRG FRT & CNTR LWR - KIRLOSKAR * 5
(* OPTIONAL)

M11B03.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B04.1
GROUP M11B05 - CRANKSHAFT PULLEY GROUP M11B06 - CONNECTING ROD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0306HB0130N FAN DRIVE PULLEY - GEAR DRIVE - 1 GR 1 1 091002 CONNECTING ROD ASSEMBLY 4
1 0306HB0070N FAN DRIVE PULLEY - GEAR DRIVE - 3 GR 1 CONSIST OF:
(FOR A/C) 1 2 051976 04 - CONNECTING ROD NS
2 084136 SPACER DAMPER PULLEY 1 3 051977 04 - CAP CONNECTING ROD NS
3 9350208280 SCREW M14 x 1.50 - 45 N/S 1 4 0312BB0410N 04 - BUSH, CON ROD (SMALL END)
5 084440 08 - SCREW, CONNECTING ROD
6 0312BB0150N 08 - NUT, CONNECTING ROD

M11B05.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B06.1
GROUP M11B07 - CONNECTING ROD BEARING GROUP M11B09 - OIL PAN

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 051979 CONNECTING ROD BEARING - HALF 8 1 0303CB0100N OIL PAN ASSY - NVH - BS2 1
1 084256 CONNECTING ROD BEARING - HALF 8 2 0311AB0090N GASKET OIL PAN 1
1 084268 CONNECTING ROD BEARING - HALF * 8 3 024501 BOLT FLANGED M8 x 1.25 - 15 14
1 084291 CONNECTING ROD BEARING - HALF 8 4 7903062003 SEAL 16 1
(* OPTIONAL) 5 0303CB0050N MAGNETIC DRAIN PLUG ASSEMBLY 1

M11B07.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B09.1
GROUP M11B11 - FRONT CASE GROUP M11B12 - ROCKER COVER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0311DB0050N COVER ENGINE FRONT NS 1 0310BB0270N ROCKER ARM COVER - BS 2 1
2 0305BB0820N TIMING INDICATOR 1 2 0310BB0190N GASKET ROCKER ARM COVER 1
3 0311AB0070N GASKET, FRONT COVER 1 3 5308202 NYLOC NUT M8 x 1.25 4
4 0311DB0010N OIL SEAL ENGINE FRONT COVER 1 4 091041 WASHER SEAL ROCKER COVER 4
5 024628 FLANGE BOLT M8 x 1.25 - 50 10
6 024626 BOLT FLANGED M8 x 1.25 - 20 3
7 024614 FLANGE BOLT M8 x 1.25 - 28 9
8 024717 INJECTION PUMP GEAR COVER 1
9 084142 'O' RING, INJECTION PUMP GEAR COVER 1
10 024615 FLANGE BOLT M6 x 1.0 - 12 2
11 024623 RETAINER, CRANKSHAFT REAR OIL SEAL 1
12 0311AB0040N GASKET, C/CASE REAR OIL SEAL 1
13 094080 CRANKSHAFT REAR SEAL 1

M11B11.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B12.1
GROUP M11B13 - BREATHER GROUP M11B14 - CYLINDER HEAD GASKET

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
0303BB0070N OIL FILLER ASSEMBLY 1 1 051335 GASKET, CYLINDER HEAD 1
CONSIST OF :
1 9420000345 01 - OIL FILLER CAP 11 DEG OUTLET T
2 9420000104 02 - SEAL - OIL FILLER CAP
3 0303BB0080N 01 - OIL ENAMATION TUBE
4 03110B0010N CLIP CLOSED 1

M11B13.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B14.1
GROUP M11B15 - PISTON GROUP M11B16 - FLYWHEEL

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
0312BB0060N KIT - PISTON, PIN, RING, CIRCLIP 4 1 024687 FLYWHEEL ASSEMBLY (KMT90) 1
CONSIST OF : 1 0312CB0120N FLYWHEEL ASSEMBLY (LCT) 1
1 0312BB0010N 04 - PISTON (IPL) 2 050116 GEAR FLYWHEEL RING 1
2 051666 04 - PISTON PIN 3 050112 FLYWHEEL DOWEL PIN 2
3 051463 08 - CIRCLIP, PISTON PIN 4 050231 BOLT FLY WHEEL (KMT 90) 6
4 0312BB0040N 04 - KIT, PISTON RINGS IPL 4 0312CB00110N BOLT FLY WHEEL (LCT) 6
CONSIST OF: 5 SF0400005 WASHER SPECIAL PLAIN M12 6
024736 04 - COMPRESSION RING TOP (IPL) NS 6 9420000007 FLYWHEEL BUSHING 1
0312BB0020N 04 - RING, PISTON, COMPRE MIDDLE NS 7 9420000528 CYLINDRICAL COTTER PIN 3
0312BB0030N 04 - RING, PISTON, OIL CONTROL (IPL) NS

M11B15.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B16.1
GROUP M11B19 - CAMSHAFT GROUP M11B20 - IDLER GEAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 091072 CAMSHAFT 1 1 0310BB0430N IDLER GEAR ASSEMBLY 1
2 G218217 WOODRUFF KEY - 1 CONSIST OF :-
4.76mm x 15.88mm ( 3/16" x 5/8" ) 0310BB0330N 1 - GEAR IDLER NS
3 024605 THRUST PLATE, CAMSHAFT 1 2 0310BB0401N 1 - BUSH, IDLER GEAR 1
4 084144 FLANGED SCREW M10 x 1.5 - 25 2 3 0310BB0370N THRUST PLATE 1
4 024630 FLANGED BOLTM10 x 1.5 - 25 (OPTIONAL) 2 4 7932560855 PLUG M9 x 1.0 1
5 0310BB0320N GEAR CAMSHAFT 1 5 0310BB0360N SHAFT IDLER GEAR 1
6 0310BB0410N GROOVED PIN 1
7 7932564136 SPACER WASHER 1
8 SF0601040 EXTERNAL RETAINING RING 28 1
9 024501 FLANGE BOLT M8 x 1.25 - 15 3

M11B19.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B20.1
GROUP M11B21 - VALVE GEAR TRAIN

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0310BB0080N VALVE TAPPET 8
2 051503 VALVE PUSH ROD 8
3 091048 VALVE INTAKE 4
091058 VALVE INTAKE (SRIRAM) OPT 4
4 091049 VALVE EXHAUST 4
091059 VALVE EXHAUST (SRIRAM) OPT 4
3 0310DB0040N VALVE INTAKE (PATTERN HARD) 4
4 0310DB0030N VALVE EXHAUST(PATTERN HARD) 4
5 051345 VALVE STEM SEAL 8
6 0310BB0310N RETAINER VALVE SPRING LOWER 8
7 03100B0010N VALVE SPRING 8
8 03100B0020N RETAINER VALVE SPRING UPPER 8
GROUP M11B21 - VALVE GEAR TRAIN

9 0310DB0010N CONE HALF, VALVE LOCK 16


10 091027 ROCKER ARM SHAFT ASSY COMPLETE 1
CONSIST OF :
11 091029 01 - ROCKER ARM SHAFT
12 G117918 02 - PLUG EXPANSION 14.29mm (9/16")
13 091031 01 - OILER BRACKET
14 072048 01 - PLUG CORE 8 DIA
15 7910016442 01 - GASKET INTERNAL BEARING N/S
16 7903057013 01 - ELASTIC WASHER M6
17 091033 01 - POSITIONING SCR, VALVE ROCKER
18 051332 04 - BRKT VALVE LEVER SH FRT & RR
19 0084156 08 - ROCKER ARM ASSY
20 050226 08 - SCREW, VALVE LEVER ADJ
21 050227 08 - NUT, VALVE LEVER ADJ SCREW
22 051327 02 - SPRING, VALVE, LEVER SHAFT
23 051325 06 - WASHER, ROCKER ARM SHAFT
24 051326 02 - RET RING, VALVE LEVER SHAFT
25 9420000177 01 - PLAIN WASHER M8
26 6110214 04 - WASHER M10
27 7903032023 04 - NUT M10
091028 SHAFT VALVE LEVER WITH PLUG 1
CONSIST OF :
11 091029 01 - ROCKER ARM SHAFT NS
12 G117918 02 - PLUG EXPANSION 14.29mm (9/16")
091030 ASSEMBLY OILER BRACKET 1
CONSIST OF :
13 091031 01 - OILER BRACKET NS
14 072048 01 - PLUG CORE 8 DIA

M11B21.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B21.2
GROUP M11B22 - INLET MANIFOLD GROUP M11B23 - EXHAUST MANIFOLD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 024756 AIR INTAKE MANIFOLD 1 1 0302DB0030N EXHAUST MANIFOLD 1
2 0302CB0020N GASKET, AIR INTAKE MANIFOLD 1 2 0302BB0010N STUD, EXHAUST MANIFOLD 4
3 084143 FLANGE BOLT M8 x 1.25 - 40 11 3 0302DB0130N GASKET EXHAUST MANIFOLD (MLS) 2
4 SF0400002 WASHER PLAIN SS M10 x 2 - 21 4
5 SF0300001 NUT, SPECIAL CLINCH M10 x 1.5 4
6 024014 EXHAUST MANIFOLD STUD 31 x 8 5
7 024018 GASKET, EXHAUST FLANGE 1
8 0305GB0021N TURBOCHARGER ASSY K03 - 1875ECA4.82 1
9 024033 STUD-PIPE TURBOCHARGER OUTLET 2
10 03010G0010N STUD, PIPE TURBO OUTLET - SHORT 3
11 0302DB0070N GASKET, TURBO OUTLET FLANGE 1
12 0302DB0060N PIPE, TURBO CHARGER OUTLET 1
12 0305GB0050N PIPE TURBOCHARGER OUTLET 1
(CL \ CDR \ LCV APPLICATION)
13 57080A0050N FLANGED CLINCH NUT M8 x 1.25 8
14 091083 STUD M8 x 1.25 3

M11B22.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B23.1
GROUP M11B25 - OIL FILLER & OIL LEVEL GAUGE GROUP M11B26 - AC COMPRESSOR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0303BB0110N ASSEMBLY DIPSTICK GUIDE 1 1 0306AB0020N BRACKET, COMPRESSOR MTG 1
2 0303BB0190N OIL LEVEL DIPSTICK ASSEMBLY 1 2 0306AB0061N ASSY A/C COMPRESSOR - SANDEN 1
3 0303BB0210N BRACKET, DIPSTICK ASSEMBLY 1 3 0306AB0030N BOLT, COMPRESSOR MTG 1
4 024617 ADAPTOR DIPSTICK 1 4 085181 TRIANGULAR WASHER 2
5 024743 COPPER WASHER M10 1 5 0306AB0010N BRACE, COMPRESSOR 1
6 024501 BOLT FLANGE M8 x 1.25 - 15 1 6 6110214 PLAIN WASHER M10 3
7 6510214 LOCK WASHER SPRING 3
8 085179 NUT M10 x 1.25 2
9 084144 FLANGE SCREW M10 x 1.5 2
10 0306GB0010N BELT, COMPRESSOR AV x 13 - 912 1
11 085178 BOLT M10 x 1.25 - 35 2

M11B25.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11B26.1
GROUP M11C01 - OIL PUMP & GEAR TRAIN GROUP M11C02 - OIL FILTER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 050770 OIL PUMP ASSEMBLY 1 1 9420000073 OIL FILTER CARTRIDGE (OE) 1
2 024630 BOLT FLANGED M10 x 1.5 - 25 1 2 09040A0120N HEAT SHIELD, OIL COOLER 1
3 024615 FLANGE BOLT M6 x 1.0 - 12 2

M11C01.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11C02.1
GROUP M11C04 - OIL STRAINER & PIPE GROUP M11C05 - WATER PUMP

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0303AB0010N STRAINER ASSEMBLY 5 LTR 1 1 0304EB0250N WATER PUMP ASSEMBLY 1
2 3106226 SCREW HEX HD M6 x 1 - 16 2 2 0304EB0190N GASKET WATER PUMP 1
3 6506208 SPRING LOCK WASHER M6 2 3 024521 FLANGED BOLT M10 x 1.5 - 45 4

M11C04.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11C05.1
GROUP M11C07 - THERMOSTAT GROUP M11C08 - FAN & PULLEY

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0304EB0130N HOUSING THERMOSTAT - BS2 1 1 7910007436 COOLING FAN ASSEMBLY (8 BLADES) 1
2 0311AB0050N GASKET, THERMOSTAT HSG 1 2 024517 FLANGED BOLT M6 x 1 - 20 3
3 0024805 THERMOSTAT - 82 DEG 1
4 0304EB0210N CAP, THERMOSTATE HSG 1
5 0311AB0080N GASKET, WATER OUTLET FITTING 1
6 024502 BOLT FLANGED M8 x 1.25 - 25 6
7 9420001104 TEMP SENSOR 1
8 024743 COPPER WASHER M10 1

M11C07.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11C08.1
GROUP M11C09 - DRIVE BELT GROUP M11C11 - OIL PRESSURE SWITCH OR GAUGE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0306GB0020N BELT ALTERNATOR AVX 13 - 1060 1 1 0303EB0270N ADAPTOR, OIL PRESSURE SWITCH 1
2 0303EB0260N ADAPTOR OIL LINE 1

M11C09.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11C11.1
GROUP M11C12 - OIL LINES - ENGINE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 03030B0040N PIPE OIL VACUUM PUMP INLET - MICO 1
2 0303EB0180N OIL LINE TURBO INLET 1
3 0303EB0250N BANJO BOLT SPECIAL M12 x 1.5 2
4 9420000194 COPPER WASHER 4
5 0303EB0060N ASSEMBLY PIPE, TURBO OIL RETURN 1
CONSISTS OF: 1
0303EB0070N 01 - PIPE, TURBO OIL RETURN
0303EB0080N 01 - HOSE, TURBO OIL RETURN
6 0023825 GASKET, TURBO OIL DRAIN PIPE 1
7 0024517 FLANGE BOLT M6 x 1.00 - 20 2
8 062147 CLAMP, HOSE 2
9 SF0705022 CLIP, SPRING BAND 19 x 12 x 0.90 2
10 03130C0020N NIPPLE, TURBOCHARGER RETURN 1
GROUP M11C12 - OIL LINES - ENGINE

11 7903062003 COPPER WASHER 16 N/S, OIL SUMP 1


12 024743 COPPER WASHER M10 5
13 056882 BANJO BOLT M10 (VACUUM PUMP END) 1
14 050336 BANJO BOLT 1
15 0303EB0170N OIL DRAIN HOSE, ALT VACUUM PUMP 1
16 0303EB0090N ADAPTER, OIL RETURN 1

M11C12.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11C12.2
GROUP M11D01 - FUEL INJECTION PUMP (ROTARY) GROUP M11D02 - FUEL INJECTION PIPE (ROTARY)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0305BB0671N ASSY FUEL INJ PUMP, MDI TC - GD - BS2 1 1 0305BB0230N SET, ASSY HIGH PRESSURE PIPE - BS II 1
1 0305BB0721N ASSY FUEL INJ PUMP, MDI TC - LCV - BS2 1 CONSISTS OF :
2 0091061 GASKET, VE PUMP 1 0305BB0240N 1 - ASSY HIGH PRESSURE PIPE 1 & 2 NS
3 0310BB0340N GEAR, INJECTION PUMP (FORGE) 1 0305BB0250N 1 - ASSY HIGH PRESSURE PIPE 3 & 4 NS
4 0305BB0740N BRACKET, FIP 1 2 0305DB0030N LEAK OFF PIPE ASSY - MICO 1
5 7932566524 PLATE 3
6 7903055003 LOCK WASHER SPRING M8 4
7 7903232005 NUT HEX M8 x 1.25 4
8 024626 FLANGE BOLT M8 x 1.25 - 20 1
9 9420000193 BOLT BANJO M12 x 1.5 1
10 9420000194 WASHER COPPER M12 2
11 091083 STUD, INJECTION PUMP 3
12 024501 BOLT FLANGE M8 x 1.25 - 15 1

M11D01.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11D02.1
GROUP M11D04 - FUEL INJECTION NOZZLE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0305BB0781N INJECTOR ASSEMBLY 4

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11D04.1
#
GROUP M11F02 - EMISSION CONTROL SYSTEM GROUP M11F02 - EMISSION CONTROL SYSTEM

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0309DB0020N EGR PIPE ASSEMBLY 1
2 022672 GASKET, EGR PIPE FLANGE 2
3 0309DB0121N EGR VALVE DIA 13.5/ 90 - PADMINI (A) 1
(4 SPEED GEAR BOX)
3 0309DB0121N EGR VALVE DIA 12.8/ 90 - PADMINI (B) 1
(5 SPEED GEAR BOX)
4 57080A0050N FLANGE CLINCH NUT M8 x 1.25 2
5 022673 GASKET, EGR VALVE 1
6 7903009053 SCREW CHS M8 x 1.25 - 25 4
7 062138 CLAMP, HOSE 55-75 NO 75A 1
8 0313AB0170N PIPE, AIR INTAKE ASSEMBLY - BS2 1
9 0313AB0150N HOSE, AIR TURBOCHARGER SIDE 1
10 0313AB0160N HOSE, AIR MANIFOLD SIDE - BS2 1
11 062139 CLAMP HOSE 45-60 NO.2X 3
12 0313AB1140N BRACKET AIR INTAKE UPPER 1
13 0313AB1150N BRACKET AIR INTAKE LOWER 1
14 024501 BOLT FLANGED M8 x 1.25 - 15 3
15 091041 WASHER SEAL ROCKER COVER 2
16 0309DA0050N VACUUM RESERVOIR 1
17 18050A0010N VACUUM MODULATOR 1
18 3106226 SCREW HEX M6 x 1 - 16 4
19 6506208 WASHER SPRING M6 4
20 6106206 PLAIN WASHER M6 4
0309DA0040N KIT VACUUM TUBES 1
CONSISTS OF :
21 16000A0070N 1 - HOSE VACUUM MODLTR /AIR CLEAN
22 0309DA0010N 1 - TUBE VACUUM
23 0309DA0020N 1 - TUBE VACUUM
24 0309DA0060N 1 - TUBE VACUUM

M11F02.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 M11F02.2
GROUP M25A01 - ENGINE MOUNTING GROUP 1101 - CLUTCH

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 099828 INSULATOR, FRONT 2 1 0801BA0281N CLUTCH DRIVEN PLATE ASSY 1
2 G120396 PLAIN WASHER 2 1 0801BA0282N CLUTCH DRIVEN PLATE ASSY * 1
3 5312204 NYLOC NUT M12 - 1.25 2 (* FOR NGT-520 T/M)
4 099105 SPECIAL BOLT HEX HD M10 x 1.5 - 25 4 2 0801CA0030N CLUTCH COVER ASSY NEF TC 1
5 7903055007 SPRING LOCKWASHER M10 10 3 3108224 SCR HEX HD M8 x 1.25 - 20 6
6 804373 WASHER SPECIAL 6 4 6508212 LOCK WASHER SPRING M8 6
7 0302AB0360N BRKT, ENGINE FRONT SUPPORT - RH 1
8 094025 BRKT, ENGINE FRONT SUPPORT - LH 1
9 024720 SPECIAL BOLT M12 x 1.25 7
10 052385 LOCKWASHER SPRING M12 7
11 069895 INSULATOR, ENGINE RR SUPPORT 1
12 052064 BOLT M10 x 1.25 - 17mm 4
13 6110214 PLAIN WASHER M10 2
14 5110206 NUT HEX M10 x 1.25 2

M25A01.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1101.1
GROUP 1102 - CLUTCH HOUSING NGT - 520

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0801AA0280N CLUTCH HOUSING 1
2 024632 BOLT CL HOUSING M12 x 1.5 - 35 2
3 6512216 LOCKWASHER SPRING M12 5
4 024635 BOLT CL HOUSING M12 x 1.5 - 80 1
5 024633 BOLT SPECIAL 1
6 0802CA0020N CLUTCH RELEASE THRUST BRG. 1
7 0802CA0050N CLUTCH RELEASE FORK 1
8 0802CA0030N PROP SPRING CLUTCH RELEASE 1
9 0802CA0710N CLIP CLUTCH RELEASE FORK 2
10 0801AA0240N GROMMET CLUTCH RELEASE FORK 1
11 0802CA0890N BALL STUD 1
12 0801AA0300N VENTILATION CAP 1
13 57100A0040N FLANGE NUT M10 x 1.5 (A/C - 16) 2
14 024601 COVER PLATE CLUTCH HSG BOTTOM 1
15 024603 COVER PLATE TOP BELL HOUSING 1
16 024615 FLANGE BOLT M6 x 1.0 - 12 3
17 0110FG0090N COMBI BOLT M10 x 1.5 6

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1102.1
GROUP 1103A - CLUTCH LINKAGE - 2WD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0802CA1410N SUSPENDED PEDAL ASSY COMP 1
1 0802CA1420N BRKT ASSY PEDAL SUPPORT 1
2 0802CA1400N PEDAL ASSY CLUTCH 1
3 036422 BUSH 2
4 099269 PEDAL SHAFT 1
5 G131016 PLAIN WASHER ID G16.67mm ( 21/32" ) 1
6 7032208 PIN COTTER 3.2 x 25 1
7 062452 SPRING RETRACTING 1
8 3108208 SCREW HEX HD M8 x 1.25 - 25 9
9 5108206 NUT HEX M8 x 1.25 6
10 01050N0030N STAY TUBE SUSP PEDAL HORZ 1
11 081805 PEDAL PAD COVER 1
GROUP 1103A - CLUTCH LINKAGE - 2WD

12 0101CK0930N PLATE REINF OUTER ASSY 1


13 01050N0020N STAY TUBE SUSP PEDAL VERTICAL 1
14 6108212 WASHER PLAIN M8 8
15 6508212 LOCK WASHER SPRING M8 8
16 3106208 SCREW HEX HD M6 x 1 - 20 6
17 6106208 PLAIN WASHER M6 6
18 6506208 SPRING LOCK WASHER M6 6
19 5106206 NUT HEX M6 x 1 6

1103A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1103A.2
#
GROUP 1104 - CLUTCH CYLINDER GROUP 1104 - CLUTCH CYLINDER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0802CA0751N ASSY CLUTCH MASTER CYLINDER 1
2 0802CA1210N CLUTCH TUBE 1
3 0802CA0861N CLUTCH SLAVE CYLINDER 1
4 0802CA0830N CLUTCH TUBE SLAVE CYLINDER 1
5 08010A0030N ALLEN BOLT SLAVE CYLINDER MOUNTING 2
6 7903055007 SPRING LOCKWASHER M10 2
7 2108232 BOLT HEX HD M8 x 1.25 - 35 2
8 6508212 LOCK WASHER SPRING M8 2
9 6108212 WASHER PLAIN M8 4
10 5108206 NUT HEX M8 x 1.25 2
11 06000A0130N CLIP, BRAKE BUNDY TUBE 3
0802CA0861N ASSEMBLY CLUTCH SLAVE CYLINDER 1
0802CA0371N KIT CLUTCH MASTER CYLINDER MAJOR 1
CONSIST OF :
0802CA0501N 1 - DUST COVER NS
0802CA0481N 1 - PLUNGER ASSY (WITH SPRING ETC) NS
0802CA0491N 1 - CIRCLIP NS
0802CA0511N 1 - CRIMPING SLEEVE NS
0802CA0381N KIT CLUTCH MASTER CYLINDER MINOR 1
CONSIST OF :
0802CA0501N 1 - DUST COVER NS
0802CA0511N 1 - CRIMPING SLEEVE NS
0802CA0521N 1 - SEAL NS
0802CA0531N 1 - VALVE SEAL NS
0802CA0541N 1 - SPRING NS
0802CA0551N 1 - WASHER NS
0802CA0491N 1 - CIRCLIP NS
0802CA0391N KIT CLUTCH SLAVE CYLINDER 1
CONSIST OF :
0802CA0561N 1 - SEAL (PRESSURE) NS
0802CA0571N 1 - SEAL (BACK) NS
0802CA0581N 1 - CIRCLIP NS
0802CA0591N 1 - DUST COVER NS
0802CA1471N KIT CLUTCH SLAVE CYLINDER (MAJOR) 1
0802CA1481N 1 - PLUNGER NS
0802CA1491N 1 - SEAL NS
0802CA1501N 1 - DUST COVER NS
0802CA1511N 1 - CLIP NS
0802CA1521N 1 - SPRING NS
0802CA1441N KIT CLUTCH SLAVE CYLINDER (MINOR) 1
0802CA1451N 1 - SEAL NS
0802CA1461N 1 - DUST COVER NS

1104.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1104.2
GROUP 1201 - FUEL TANK GAUGES AND LINES

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 10010A0090N FUEL TANK ASSEMBLY 1
2 1001BA0050N SKID PLATE FUEL TANK 1
3 1001BA0060N ASSY BRKT FRT SUPPORT FUEL TANK 2
4 3108228 SCREW HEX HD M8 x 1.25 - 30 5
5 G120393 PLAIN WASHER G7.94mm (5/16") 14
6 010218 RUBBER PACKING 8
7 6508212 LOCK WASHER SPRING M8 8
8 5108206 NUT HEX M8 x 1.25 6
9 029791 REST BUTTON FUEL TANK 2
10 088391 PLUG DRAIN 1
GROUP 1201 - FUEL TANK GAUGES AND LINES

11 088392 WASHER DRAIN PLUG FUEL TANK 1


12 G120392 SCREW HEX HD M8 x 1.25 - 30 3
13 1001BA0070N BRACKET REAR SUPPORT FUEL TANK 2
14 067148 BANJO BOLT 16mm 1
15 067147 COPPER WASHER 16mm 2
16 050331 BANJO BOLT 3
17 050332 COPPER WASHER 14mm 6
18 098509 ASSEMBLY TANK UNIT 1
19 011594 GASKET FUEL TANK GAUGE 1
20 3304206 SCREW PAN HD M4 x 0.7 - 12mm 6
21 6204204 EXT TOOTHED LOCK WASHER M4 6
22 078298 HOSE FUEL TANK TO FILLER NECK 1
23 062140 CLIP WORM TYPE NO - 2 (42 - 55) 2
24 081504 HOSE VENTILATOR FUEL TANK 1
25 1001DA0200N FUEL FILLER NECK ASSEMBLY 1
26 1001DA0260N CAP FUEL FILLER NECK 1
27 099460 RUBBER FUEL TANK LID ASSEMBLY 1
28 099461 FUEL LID ASSEMBLY 1
29 3106206 SCREW HEX HD M6 x 1 - 16 3
30 5106206 NUT HEX M6 x 1 2
31 9420000319 FUEL FILTER ASSEMBLY MICO 1
31 9420000388 FUEL FILTER ASSEMBLY LUCAS 1
31 051512 TWIN FUEL FILTER ASSEMBLY 1
32 1001CA2470N FUEL LINE TANK TO FILTER 1
33 1001CA2690N FUEL LINE FILTER TO FIP 1
34 099981 RETURN FUEL LINE 1
35 097888 CLIP FUEL LINE 6
36 10000A0330N BRACKET ASSEMBLY FUEL FILTER 1
37 10000A0320N BRACKET EXTN FUEL FILTER 1
38 3108226 SCREW HEX HD M8 x 1.25 - 25 8
10000A0370N KIT FUEL FILTER 1
CONSIST OF:
050423 2 - MICRO PAPER FILTER INSERT COIL NS
050506 2 - FILTER INSERT (STAR) (OPTIONAL) NS
035786 2 - WASHER - FILTER COVER NS

1201.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1201.2
#
GROUP 1202 - AIR CLEANER - BS II / EGR PARTS GROUP 1202 - AIR CLEANER - BS II / EGR PARTS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0313AB0311N AIR FILTER ASSY 1
2 0313AC1710N HOSE ASSY AIR CLEANER 1
CONSISTS OF :-
0313AB0420N 1 - CONNECTOR HOSE AIR CLEANER
0313AC1720N 1 - HOSE AIR CLEANER UPPER
0313AC1730N 1 - HOSE AIR CLEANER LOWER
3 0313AC1900N 2 - CLAMP HOSE (WIRE TYPE)
4 0313AB0940N AIR INTAKE PIPE ASSY CONSISTS OF :- 1
0313AB0330N 1 - ELBOW AIR INTAKE PIPE
0313AB0910N 1 - PIPE AIR INTAKE REAR
0313AB0920N 1 - PIPE AIR INTAKE FRONT
0313AB0930N 1 - MESH AIR INTAKE
5 0313AC0820N WIRE CLAMP - AIR CLEANER END 1
6 0313AC0840N WIRE CLAMP - TC END 1
7 062136 CLIP WORM TYPE 70 - 90 NO 4 1
8 01010N0080N CLAMP AIR CLEANER 1
9 01010N0070N CLAMP AIR CLEANER SUPPORT 1
10 010218 RUBBER PACKING 1
11 2108232 BOLT HEX HD M8 x 1.25 - 35 1
12 3106226 SCREW HEX M6 x 1 - 16 1
13 6506208 WASHER SPRING L M6 x 1.6 - 11.6 1
14 6106208 PLAIN WASHER M6 1
15 0313AG0230N SERVICE INDICATOR 1
16 0313AC0280N AIR ELEMENT 1
17 0102DN1630N EDGING STRIP PANEL AIR DEFLECTOR 2

1202.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1202.2
GROUP 1203 - ACCELERATOR LINKAGE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 10020A0790N ACCELERATOR PEDAL ASSY COMP 1
2 10020A0150N BRKT ASSY ACCELERATOR PEDAL 1
3 6506208 SPRING LOCK WASHER M6 2
4 3106226 SCREW HEX HD M6 x 1 - 16 2
5 10020A0160N BUSH ACCELERATOR PEDAL 1
6 10020A0180N SPRING RETURN ACCELERATOR PEDAL 1
7 6110114 PLAIN WASHER M10 1
8 7032204 COTTER PIN 3.2 x 20mm 1
9 10020A0810N LEVER ASSY ACCELERATOR PEDAL 1
10 10020A0270N PIVOT ACCELERATOR FOOT PLATE 1
11 10020A0290N SPRING RETURN FOOT PLATE 1
12 10020A0330N BUSH FOOT PLATE 1
GROUP 1203 - ACCELERATOR LINKAGE

13 10020A0300N SLEEVE 1
14 6106208 PLAIN WASHER M6 1
15 7025202 PIN COTTER 2.5 x 14 1
16 10020A0280N FOOT PLATE ASSY ACCELERATOR PEDAL 1
17 10020A0310N RUBBER PAD FOOT PLATE 1
18 036623 PIN CLEVIS 1
19 6105206 WASHER PLAIN M5 1
20 7002210 PIN COTTER 2 x 20 1
21 10020A0230N ASSY ACCELERATOR CABLE (BALL END) 1
22 089897 BALL END ASSY 1
23 0A11775 PLAIN WASHER G7.94mm (5/16") 2
24 5108206 NUT HEX M8 x 1.25 2
25 035963 RUBBER STOPPER 2
26 5306202 NUT NYLOC M6 x 1 (P TYPE) 1
(COMMON FOR ISUZU & NGT - 520 T/M)

1203.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1203.2
GROUP 1301 - RADIATOR AND HOSES

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0304AB0131N RADIATOR ASSY 1
2 2108232 BOLT HEX HD M8 x 1.25 - 35 1
3 028552 WASHER PLAIN 2
4 028550 COLLAR INSULATOR 1
5 028551 CUSHION RADIATOR SUPPORT 2
6 6508212 LOCK WASHER SPRING M8 1
7 5108206 NUT HEX M8 x 1.25 1
8 0304BG0010N INSULATOR RADIATOR MTG BOTTOM 2
9 028761 SPACER RADIATOR RET CUP ASSY 2
10 00A6360 PEDAL SHANK DRAFT PAD WASHER 2
11 5110208 NUT HEX M10 x 1.5 2
12 0304FB0040N SHROUD RADIATOR 1
GROUP 1301 - RADIATOR AND HOSES

13 3106208 SCREW HEX M6 x 1 - 20 4


14 G120380 LOCK WASHER SPRING G6.35mm (1/4") 4
15 G120392 PLAIN WASHER G6.35mm (1/4") 4
16 0304DB0300N HOSE RADIATOR OUTLET 1
17 0304DB0290N HOSE RADIATOR INLET 1
18 062140 CLIP WORM TYPE NO 2 (42 - 55) 4
19 0304DB0460N WATER RECOVERY TANK ASSY 1
20 3108206 SCR HEX HD M8 x 1.25 - 20 1
21 6108212 WASHER PLAIN M8 1
22 5308202 NYLOC NUT M8 x 1.25 1
23 0304DB0510N HOSE RAD TO WATER RECOVERY TANK 1
24 0304AB0230N PRESSURE CAP RADIATOR 1
25 0304EB0431N DRAIN COCK 1

1301.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1301.2
GROUP 1401 - EXHAUST SYSTEM

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0903AA2440N EXHAUST PIPE ASSEMBLY 1
2 0901BA0200N EXPANSION CHAMBER 1
3 0901AA1180N MUFFLER ASSEMBLY COMPLETE 1
4 0903AA2680N TAIL PIPE ASSEMBLY 1
5 0903BA0191N GASKET EXHAUST 1
6 0903BA0211N GASKET CATALYTIC CONVERTER 2
7 7903201048 BOLT HEX HD M10 x 1.5 - 35 4
8 6510214 LOCKWASHER SPRING M10 4
9 6110214 PLAIN WASHER M10 4
10 09030A0030N U BOLT 2 DIA 1
11 09030A0040N CLAMP U BOLT 2 IN DIA 1
12 028552 WASHER PLAIN M8 3
13 6508212 LOCK WASHER SPRING M8 3
GROUP 1401 - EXHAUST SYSTEM

14 5108206 NUT HEX M8 x 1.25 3


15 09030A0060N BRACKET MOUNTING REAR PIPE 1
16 077591 RUBBER INSULATOR EXHAUST 3
17 55080A0010N COMBI SCREW M8 x 1.25 - 25 3

1401.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1401.2
GROUP 1501 - ALTERNATOR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1402AA2881N ALTERNATOR 55 AMP 1
2 024821 STUD ALTERNATOR 1
3 024822 PIVOT ALTERNATOR 1
4 7903032023 NUT HEX M10 x 150 4
5 6510214 LOCKWASHER SPRING M10 4
6 6110214 PLAIN WASHER M10 4
7 024626 SCREW HEX HD M8 x 1.25 - 20 1
8 7903057005 ELASTIC WASHER M8 1
9 G120393 PLAIN WASHER G7.93mm (5/16") 1
10 056887 BOLT M10 x 1.5 - 130mm 1
11 0306DB0030N SPACER ALTERNATOR 1
12 0306DB0010N SPACER ALTERNATOR BRACE 1

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1501.1
GROUP 1501B - ALTERNATOR (MICO)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1402AA2721N DRIVE END SHIELD 1
2 1402AA1131N DEEP GROOVE BALL BEARING 1
3 1402AA1141N COVER PLATE 1
5 1402AA1151N FLAT HEAD SCREW 4
6 1402AA2981N ROTOR 1
9 1402AA1171N SPACER RING 1
10 1402AA1181N DEEP GROOVE BALL BEARING 1
11 1402AA2741N COLLECTOR, RING END 1
12 1402AA2751N RECTIFIER 1
13 1402AA1211N 'O' RING 1
17 1402AA2991N TRANSISTOR REGULATOR 1
18 1402AA2761N STATOR 1
20 1402AA1251N CHEESE HEAD SCREW 1
GROUP 1501B - ALTERNATOR (MICO)

21 1402AA1251N CHEESE HEAD SCREW 3


24 1402AA1252N CHEESE HEAD SCREW 2
26 1402AA1281N SPRING WASHER 2
27 1402AA1291N HEXAGON NUT 2
32 1402AA2771N INSULATING WASHER 1
34 1402AA2781N WASHER 1
35 1402AA2791N SPRING WASHER 1
37 1402AA2801N HEXAGON NUT 1
38 1402AA2811N INSULATING PART 1
41 1402AA1341N INSULATING WASHER 1
42 1402AA1351N INSULATING WASHER 1
42 1402AA1351N WASHER 1
43 1402AA1361N HEXAGON NUT 2
44 1402AA3001N CONNECTOR HOUSING 1
45 1402AA1381N SPRING WASHER 2
46 1402AA1391N INSULATING WASHER 1
47 1402AA1401N SPRING WASHER 2
48 1402AA1411N WASHER 1
49 1402AA2821N HEXAGON NUT 1
51 1402AA1421N SPRING WASHER 1
52 1402AA1431N HEXAGON NUT 1
53 1402AA3011N FAN 1
54 1402AA3021N PULLEY 1
56 1402AA1461N SEAL 1
57 1402AA1481N VACUUM PUMP ASSEMBLY 1
57/005 1402AA3061N NON RETURN VALVE (VACUUM PUMP) 1
1

CONTINUE …

1501B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1501B.2
GROUP 1501B - ALTERNATOR (MICO)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
58 1402AA1511N VACUUM PUMP END COVER 1
59 1402AA1521N VANE (FOR VACUUM PUMP) 3
61 1402AA1531N HEXAGON SCREW 3
62 1402AA2831N SPRING WASHER 3
63 1402AA1551N WASHER 3
64 1402AA1561N 'O' RING 1
65 1402AA1571N 'O' RING 1
68 1402AA2841N BANJO 1
70 1402AA1591N FLAT SEAL RING 2
71 1402AA1601N VACUUM PUMP ROTOR 1
75 1402AA3031N BANJO ASSEMBLY 1
80 1402AA1621N CLAMP 1
99 1402AA1631N SPRING WASHER 2
GROUP 1501B - ALTERNATOR (MICO)

100 1402AA1641N WASHER 2


106 1402AA3041N SUPPRESSION CAPACITOR 1
110 1402AA3051N FUSE 2
112 1402AA1631N SPRING WASHER 1
113 1402AA1671N CHEESE HEAD SCREW 1
114 1402AA1681N HEXAGON NUT 1
117 1402AA1691N WASHER 1
118 1402AA1701N SPRING WASHER 1
119 1402AA1711N HEXAGON NUT 1
801 1402AA1721N CARBON BRUSH SET
807 1402AA1731N COLLECTOR RING

1501B.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1501B.4
GROUP 1502 - STARTER MOTOR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 091971 STARTER MOTOR (LUCAS) 1
1 091970 STARTER MOTOR (MICO) 1
1 0307CB0471N STARTER MOTOR (GEAR REDUCTION) 1
2 024630 BOLT FLANGED M10 x 1.5 - 25 3
3 7903055007 LOCKWASHER SPRING M10 3

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1502.1
GROUP 1502A - STARTER MOTOR (LUCAS MAKE)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0307CG0011N MAIN TERMINAL 1
1A 0307CG0021N MAIN TERMINAL 1
2 0307CG0031N TERMINAL BASE ASSEMBLY 1
3 0307CG0041N SPINDLE ASSEMBLY 1
4 0307CG0051N PLUNGER RETURN SPRING 1
5 0307CG0061N SEALING REING (SOL) 1
6 0307CG0071N SOLENOID SWITCH 1
7 0307CG0081N PLUNGER ASSEMBLY 1
7A 0307CG0091N SHROUD 1
8 0307CG0101N SCREW, SOL FIXING 3
GROUP 1502A - STARTER MOTOR (LUCAS MAKE)

9 0307CG0111N CONNECTOR 1
10 0307CG0121N SEAL 1
11 0307CG0131N SEALING RING (C E & D E) 2
12 0307CG0141N INTER BRACKET ASSEMBLY 1
13 0307CG0151N OIL SEAL 1
14 0307CG0161N ENGAGING LEVER ASSEMBLY 1
15 0307CG0171N JUMP RING - PINION 1
16 0307CG0181N SPRING - PINION 1
17 0307CG0191N GROMMET 1
18 0307CG0201N NUT, PIVOT 1
19 0307CG0211N PIVOT PIN 1
20 0307CB0481N FIXING BRACKET ASSEMBLY 1
21 0307CG0231N BEARING BUSH (FIXIG BRACKET) 1
22 0307CG0241N BEARING BUSH (INTER BRACKET) 1
23 0307CG0251N OPERATING PLATE (PINION) 1
24 0307CB0491N DRIVE ASSEMBLY 1
25 0307CG0271N THRUST COLLAR 1
26 0307CG0281N JUMP RING 1
27 0307CG0291N END COVER 1
28 0307CG0301N SEAL (END COVER) 1
29 0307CG0311N 'C' WASHER 1
31 0307CG0321N SPRING (END COVER) 1
32 0307CG0331N C E BRACKET ASSEMBLY 1
33 0307CG0341N BRUSH SET 1
34 0307CG0351N BRUSH CARRIER ASSEMBLY 1
35 0307CG0361N LEAD ASSEMBLY 1

CONTINUE…

1502A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1502A.2
GROUP 1502A - STARTER MOTOR (LUCAS MAKE)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
36 0307CG0371N GROMMET 1
37 0307CG0381N FIELD COIL ASSEMBLY 1
38 0307CG0391N ARMATURE ASSEMBLY 1
39 0307CG0401N NUT (FIXING STUD) 2
40 0307CG0411N FIXING STUD 2
41 0307CG0421N BEARING BUSH (C R BRKT) 1
42 0307CG0431N BRUSH SPRING 4
43 0307CG0441N STOP WASHER 1
44 0307CG0451N INSULATOR YOKE 1
45 0307CG0461N POLE SHOE 4
GROUP 1502A - STARTER MOTOR (LUCAS MAKE)

47 0307CG0471N SCREW (B G FIXING) 2

CONTINUE…

1502A.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1502A.4
GROUP 1502B - STARTER MOTOR (MICO MAKE)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0307CB0501N ARMATURE 1
2 0307CB0511N INTERMIDATE BEARING 1
3 0307CB0521N CLUTCH DRIVE 1
4 0307CB0531N SPRING RING 1
5 0307CB0541N STOP RING 1
7 0307CB0551N SINTERED BUSH 1
9 0307CB0561N SCREW COUNTERSUNK 1
10 0307CB0571N WASHER 1
11 0307CB0581N HEXAGONAL NUT 1
14 0307CB0591N THREADED PIN 2
GROUP 1502B - STARTER MOTOR (MICO MAKE)

17 0307CB0601N COUNTERSUNK SCREW 3


18 0307CB0611N 'O' RING 2
19 0307CB0621N 'O' RING 2
23 0307CB0631N EXCITATION WINDING 1
25 0307CB0641N COUNTERSUNK SCREW 4
27 0307CB0651N MOUNTING FLANGE 1
28 0307CB0661N BRUSH HOLDER 1
29 0307CB0671N SPRING RING 4
30 0307CB0681N COMMUTATOR END COVER 1
30/2 0307CB0691N SINTERED BUSH 1
31 0307CB0701N SPACING WASHER 2
32 0307CB0711N HEXAGONAL NUT 2
34 0307CB0721N COMPENSATING WASHER 0.5mm A/R
34 0307CB0731N COMPENSATING WASHER 0.7mm A/R
34 0307CB0751N COMPENSATING WASHER 0.9mm A/R
34 0307CB0741N COMPENSATING WASHER 1.1mm A/R
34 0307CB0761N COMPENSATING WASHER 1.3mm A/R
35 0307CB0771N LOCKING WASHER 1
36 0307CB0781N SEALING RING 1
37 0307CB0791N CAP 1
38 0307CB0801N HEXAGONAL HEAD SCREW 2
39 0307CB0811N SPRING WASHER 1
40 0307CB0821N HEXAGONAL NUT 1
41 0307CB0831N HEXAGONAL NUT 1
42 0307CB0841N SPRING WASHER 1
43 0307CB0851N HEXAGONAL NUT 1
45 0307CB0861N SPRING WASHER 1
67 0307CB0871N 'O' RING 2
68 0307CB0881N WASHER 2
800 0307CB0891N CARBON BRUSH SET 1
803 0307CB0901N FORK LEAVER 1
804 0307CB0911N SOLENOID SWITCH 1
805 0307CB0921N DRIVE END FLANGE 1

1502B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1502B.2
GROUP 1503 - HEAD LIGHT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1701AA0170N HEAD LAMP ASSY (AUTOPAL) 2
1 1701AA0171N HEADLAMP ASSY (LUMAX) (OPTIONAL) 2
2 074443 BULB 12V, 60/55W (H-4 P43T) 2
3 074514 RUBBER BOOT 2
4 1701CA0010N PARKING BULB 12V, 4W 2
4 17000A0051N PARKING BULB 12V, 4W (OPTIONAL) 2
5 1701CA0040N BULB HOLDER BA9S 2
6 1701AA0010N H/L REFLECTOR WITH LENS 2
7 G159920 SCR PAN HD M/C M10 - 24 x 12mm (1/2") 8
8 G138479 LOCKWASHER EXTN M10 8
17010A0010N KIT, SPARE BULB HALOGEN 1
19000A0040N BOX SPARE BULB 2

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1503.1
#
GROUP 1504A - INDICATING LAMP GROUP 1504A - INDICATING LAMP

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
FRONT TURN SIGNAL LIGHT
1 028533 FRONT TURN SIGNAL LAMP LH 1
1 028534 FRONT TURN SIGNAL LAMP RH 1
2 17000A0011N BULB 12V - 21W 2
3 1701BA0040N FRONT TURN REFLECTOR WITH LENS LH 1
3 1701BA0050N FRONT TURN REFLECTOR WITH LENS RH 1

SIDE MARKER LIGHT


4 028354 MARKER LAMP LH 1
4 028355 MARKER LAMP RH 1
5 1701EA0030N BULB 12V - 3.4W CAP LESS 2
6 059330 SCREW SPECIAL M4 x 0.7 4
7 6505206 LOCKWASHER SPRING M5 4
8 5104206 NUT HEX M4 x 0.7 4

NUMBER PLATE LIGHT


9 094682 LAMP ASSEMBLY REGISTRATION PLATE 1
10 076760 CABLE ASSEMBLY REGISTRATION PLATE 1
11 17000A0031N BULB 12V - 10W 1

PLATE REGISTRATION REAR


12 0119DF0050N PLATE REGISTRATION REAR 1
13 6106208 PLAIN WASHER M6 2
14 6506208 SPRING LOCK WASHER M6 2
15 3106226 SCREW HEX HD M6 x 1.0 - 16 2

ROOF LIGHT
16 097614 ASSEMBLY ROOF LAMP 1
17 17000A0041N BULB FESTOON 12V - 5W 1
18 3306212 SCREW PAN HD SLOTTED M6 x 1.0 - 25 2
19 17020A0010N GLASS ROOF LAMP 1

WARNING TRIANGLE ASSEMBLY


20 19000A3392N WARNING TRIANGLE ASSEMBLY 1
20 19000A3391N WARNING TRIANGLE ASSEMBLY 1
20 19000A3393N WARNING TRIANGLE ASSEMBLY 1

1504A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1504A.2
GROUP 1504B - HIGH MOUNTED STOP LAMP GROUP 1505 - TAIL, STOP. TURN SIGNAL AND REVERSE LIGHT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 1703AA0010N HI MOUNTED STOP LAMP 1 1 17030A0030N REAR COMB LAMP RH 1
1 1703AA0241N STOP LAMP ASSEMBLY (OPTIONAL) 1 1 17000A0281N REAR COMB LAMP RH (OPTIONAL) 2
2 1703AA0040N FLANGE SCREW ST14 PAN PH 2 1 17030A0040N REAR COMB LAMP LH 2
3 1703AA0050N PLASTIC FASTENER (NIFCO:3B14) 2 1 17000A0291N REAR COMB LAMP LH (OPTIONAL) 1
2 074274 HOUSING AND CABLE ASSEMBLY LH 1
2 074275 HOUSING AND CABLE ASSEMBLY RH 1
3 17000A0011N BULB 12V - 21W 4
4 17000A0021N BULB 12V - 21/5W 2
5 074456 GASKET TAIL STOP LIGHT 2
6 074276 LENS TAIL STOP LIGHT LH 1
6 074277 LENS TAIL STOP LIGHT RH 1

1504B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1505.1
#
GROUP 1507 - BATTERY HOLD DOWN & CABLE GROUP 1507 - BATTERY HOLD DOWN & CABLE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1401BA0130N TRAY BATTERY 1
2 3108224 SCREW HEX HD M8 x 1.25 - 20 5
3 6508212 LOCKWASHER SPRING M8 6
4 6108212 WASHER PLAIN M8 6
5 070651 SUPPORT BATTERY TRAY BOTTOM 1
6 2108260 BOLT HEX HD M8 x 1.25 - 35 1
7 029791 REST BUTTON BATTERY TRAY 2
8 1401BA0160N BRACKET BATTERY HOLD DOWN 1
9 1401BA0170N NUT WING 2
10 083782 ASSEMBLY BATTERY CABLE NEGATIVE 1
11 071778 ASSEMBLY BATTERY CABLE POSITIVE 1
12 071777 CAP POSITIVE CABLE 1
13 098780 EARTH CABLE 1
14 14010A0021N SEPARATOR - BATTERY TRAY 1

1507.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1507.2
GROUP 1508 - HORN

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 089146 HORN ASSEMBLY 1
2 6508212 LOCK WASHER SPRING M8 2
3 6108212 WASHER PLAIN M8 2
4 3108226 SCREW HEX HD M8 x 1.25 - 25 2

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1508.1
GROUP 1509 - WINDSHIELD WIPER MOTOR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 069259 WIPER MOTOR ASSEMBLY LINK TYPE 1
1 0116EA0271N WIPER MOTOR - LINK TYPE (OPTIONAL) 1
2 029554 SUPPORT BRACKET- WIPER MOTOR MTG 1
3 3105208 SCREW HEX HD M5 x 0.8 - 14 3
4 6505206 LOCKWASHER SPRING M5 3
5 6106208 PLAIN WASHER M6 4
6 6506208 SPRING LOCK WASHER M6 4
7 3106228 SCREW HEX HD M6 x 1.0 - 20 4
8 028417 WIPER LINKAGE KIT 1
9 028419 WIPER ARM ASSEMBLY 2
10 028418 WIPER BLADE ASSEMBLY 2
GROUP 1509 - WINDSHIELD WIPER MOTOR

028417 KIT LINKAGE WIPER MOTOR 1


CONSIST OF :
074386 1 - LEVER WIPER MOTOR TO LINK NS
074388 1 - SPRING LOCK WASHER
074387 1 - HEX NUT
074389 2 - DUST SEAL WIPER MOTOR LINK
1 - LINK ASSEMBLY WIPER MOTOR NS
LEVER TO WHEEL BOX
1 - ASSY WHEEL BOX & LEVER CENTER
074392 2 - RUBBER WASHER WHEEL BOX NS
074393 2 - RETAINER WSHR WHEEL BOX NUT NS
069261 2 - NUT HEX WHEEL BOX
1 - LINK ASSEMBLY, WHEEL BOX TO NS
WHEEL BOX
074395 2 - DUST SEAL, WIPER MOTOR LINK
074396 1 - ASSEMBLY WHEEL BOX AND LEVER

1509.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1509.2
GROUP 1509A - WIPER MOTOR SERVICABLE COMPONENTS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0116EN0011N NUT, ROTARY LINK 1
2 0116EN0021N ROTARY LINK 1
3 0116EN0031N SCREW, MOUNTING PLATE 3
4 0116EN0041N MOUNTING BRACKET 1
5 0116EN0051N RUBBER SHROUD 1
6 0116EN0061N THRUST SCREW 1
7 0116EN0071N NUT, THRUST SCREW 1
GROUP 1509A - WIPER MOTOR SERVICABLE COMPONENTS

8 0116EN0081N GEAR BOX & BEARING ASSEMBLY 1


9 0116EN0091N BELLIVELI WASHER 1
10 0116EN0101N GEAR & SLIP RING ASSEMBLY 1
11 0116EN0111N COVER SEAL 1
12 0116EN0121N COVER PLATE ASSEMBLY 1
13 0116EN0131N COVER FIXING SCREW 3
14 0116EN0141N PLUG MOULDING 1
15 0116EN0151N 'O' RING 1
16 0116EN0161N SCREW, BRUSH PLATE 2
17 0116EN0171N BRUSH PLATE 1
18 0116EN0181N ARMATURE ASSEMBLY 1
19 0116EN0191N BALL 1
20 0116EN0201N SCREW, YOKE FIXING 2
21 0116EN0211N YOKE & BEARING ASSEMBLY 1
22 0116EN0221N PROTECTIVE CAP 1
23 0116EN0231N LEAD ASSEMBLY 1
24 0116EN0241N SPINDLE ASSEMBLY - I 1
25 0116EN0251N TANDEM LINK (LONG) 1
26 0116EN0261N PRIMARY LINK (SHORT) 1
27 0116EN0271N SPINDLE ASSEMBLY - II 1

1509A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1509A.2
GROUP 1510 - WIRING HARNESS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1105AA0011N COMBINATION SWITCH 1
1 1105AA0031N COMBINATION SWITCH (OPTIONAL) 1
2 3305208 SCR PAN HD SLTD M5 x 0.8 - 16 4
3 6105206 WASHER PLAIN M5 4
4 094677 ENGINE COMPARTMENT LAMP 1
5 17000A0011N BULB 12V - 21W 1
6 6106208 PLAIN WASHER M6 2
7 6506208 WASHER SPRING M6 2
8 5106208 NUT HEX HD M6 x 1 2
9 099340 COLUMN COVER 1
10 0114AK0030N KIT, LOCK WITH COMMON KEY 1
069111 2 - ASSY KEY & LOCK CYLINDER LH
069112 1 - ASSY KEY & LOCK CYLINDER RH
074086 1 - ASSY LOCK CYL FUEL TANK LID
GROUP 1510 - WIRING HARNESS

099418 1 - IGN SWITCH WITH STRG LOCK


0114AK0010N 1 - LOCK ASSEMBLY GLOVE BOX
11 088409 SPACER STEERING LOCK 1
12 097552 MECH STOP LIGHT SWITCH 1
13 028741 BRACKET BENT LEVER (8 RP) 1
14 3306208 SCREW PAN HD M6 4
15 038525 CLIP, W/HARNESS STEERING COLUMN 2
16 070252 FUSE 15 AMP BLADE TYPE 1
1705CA0031N SWITCH DOOR LIGHT NS
CONSIST OF :
20 1705CA0041N 1 - DUST COVER
21 1705CA0051N 1 - DOOR LIGHT SWITCH SUB ASSY
17 083780 SWITCH OIL PRESS SIG INDICATOR 1
18 13100A0011N SWITCH PARK BRAKE 1
19 1801FA0360N BLADE TYPE FUSE 7.5 AMP 1
19 070251 BLADE TYPE FUSE 10 AMP 1
19 070252 BLADE TYPE FUSE 15 AMP 1
081177 CHASSIS WIRING HARNESS 1
098399 PIG TAIL HARNESS REV LIGHT SWITCH 1
1801BA0040N ROOF LAMP WIRING HARNESS 1
1801BA0170N INSTRUMENT WIRING HARNESS 1
1801AA0340N ECU WIRING HARNESS - EURO II 1
1801CA1960N WIRING HARNESS BODY 1

1510.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1510.2
GROUP 1510 - WIRING HARNESS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 029886 MTG BRKT FOR FUSE BOX 1
2 028750 WIPE AND WASH RELAY 1
3 088587 RELAY ASSEMBLY HEAD LAMP 2
3 18000A0300N RELAY ASSY HEAD LAMP (OPTIONAL) 1
4 3306212 SCREW PAN HD SLTD M6 x 1 - 25 3
5 6306208 WASHER INT TOOTH M6 3
6 6106208 PLAIN WASHER M6 5
7 3106226 SCREW HEX M6 x 1 - 16 2
8 088454 IC BASED FLASHER 1
8 13050A0011N IC BASED FLASHER (OPTIONAL) 1
8 13050A0012N IC BASED FLASHER (OPTIONAL) 1
9 3305208 SCREW PAN HD SLTD M5 x 0.8 - 16 4
10 6505206 SPRING LOCK WASHER M5 4
11 6105206 WASHER PLAIN M5 4
GROUP 1510 - WIRING HARNESS

12 1805AA0242N EGR CONTROLLER 1

1510.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1510.4
GROUP 1601 - INSTRUMENTS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1301AA0901N INSTRUMENT CLUSTER 1
2 089673 ASSEMBLY FLEXIBLE CABLE - 2WD 1

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1601.1
#
GROUP 1602 - WINDSHIELD WASHER GROUP 1602 - WINDSHIELD WASHER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 19000A3661N KIT WINDSHIELD WASHER 1
1 19000A3662N KIT WINDSHIELD WASHER (OPT) 1
CONSIST OF :
5 074280 1 - TUBE TEE TO MOTOR 1
6 19000A4201N 1 - TEE 3 WAY 1
7 19000A4211N 1 - TUBE RH TEE TO NOZZEL 1
8 19000A4221N 1 - TUBE LH TEE TO NOZZEL 1
9 19000A4231N 2 - ASSEMBLY NOZZEL SINGLE JET 2
10 19000A4241N 1 - MOTOR ASSEMBLY 1
2 3306206 SCREW SLTD PAN HD M6 x 1 - 14 2
3 6306208 WASHER INTERNAL TOOTH M6 2
4 6106208 PLAIN WASHER M6 2

1602.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1602.2
GROUP 1700 - TRANSMISSION ASSEMBLY

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0703AD1050N TRANSMISSION ASSY NGT 520 - BOLERO 1

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1700.1
GROUP 1701A - TRANSMISSION HOUSING AND ATTACHING

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0703BD0450N ASSEMBLY FRONT HOUSING INT PLATE 1
2 024626 FLANGE BOLT M8 x 1.25 - 20 6
3 0703BD0430N REAR HOUSING 2WD 1
4 0703BD0440N BEARING RETAINER PLATE 1
5 0703FD0220N SPEEDO DRIVEN GEAR 16T NGT 520 1
6 060345 OIL SEAL SPEEDO DRIVEN GEAR 1
7 071562 SLEEVE SPEEDOMETER 1
8 7910030169 BREATHER 1
GROUP 1701A - TRANSMISSION HOUSING AND ATTACHING

9 0703BD0480N RAIL END SEALING CAP 2


10 0502DA0360N FILLER PLUG 1
11 7903075044 PLUG M12 x 1.25 3
12 7903062030 SEAL N/S 1
13 0703CD0920N REVERSE CONTACT SWITCH 1
14 0502DA0370N DRAIN PLUG 1
15 0703CA0261N STUD M10 x 1.5 - 60 2
16 0703CA0271N HEX FLANGE BOLT M10 x 1.5 - 55 8
17 0703BD0460N CLUTCH RELEASE BEARING SLEEVE 1
18 3108224 BOLT HEX HD M8 x 1.25 - 20 3
19 7903057005 ELASTIC WASHER M8 3

1701A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1701A.2
GROUP 1702 - SELECTION BIASING GROUP 1703 - SHAFT RAIL AND FORKS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0703CD0980N ADAPTER PIVOT 1 1 0703CD1030N FORK AND RAIL ASSEMBLY 1ST & 2ND 1
2 0703CD1010N PLUNGER RETURN 2 2 0703CD1040N FORK AND RAIL ASSY 3RD & 4TH 1
3 0703CD1090N BIASING SPRING 5TH & REV 1 3 0703CD0970N FORK AND RAIL ASSY 5TH & REV 1
4 0703CD1080N BIASING SPRING 1ST & 2ND 1 4 7903067342 DOWEL PIN SPRING 6X25 4
5 07030D0310N SIDE COVER PLATE 2 5 052359 STEEL BALL 4
6 3106224 BOLT M6 x 1.0 - 10 4 5 7903090022 STEEL BALL (OPT) 4
7 6106208 PLAIN WASHER M6 4 6 0703CD1060N PIN 4 - 12 1
7 7836174000 FINGER INTERLOCK 1
8 7836279000 SPRING LOCKING 3
9 7903075044 PLUG M12 x 1.25 2
10 0703CD0131N ROLL PIN (6 - 20) 2

1702.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1703.1
GROUP 1704 - DRIVE SHAFT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0703DD1570N INPUT GEAR ASSEMBLY V4 1
2 0703DD1580N MD GEAR BEARING (6307 2RSRN C3 ) 1
3 0703DD1450N ADJUSTER SHIM MD GEAR 1
0703DD2600N SELECTIVE SHIM MD GEAR 0.90
0703DD1940N SELECTIVE SHIM MD GEAR 0.95
0703DD1930N SELECTIVE SHIM MD GEAR 1.00
0703DD1920N SELECTIVE SHIM MD GEAR 1.05
0703DD1450N SELECTIVE SHIM MD GEAR 1.10
0703DD1740N SELECTIVE SHIM MD GEAR 1.15
0703DD1750N SELECTIVE SHIM MD GEAR 1.20
0703DD1760N SELECTIVE SHIM MD GEAR 1.25
0703DD1770N SELECTIVE SHIM MD GEAR 1.30
0703DD1780N SELECTIVE SHIM MD GEAR 1.35
0703DD1790N SELECTIVE SHIM MD GEAR 1.40 *
0703DD1800N SELECTIVE SHIM MD GEAR 1.45
GROUP 1704 - DRIVE SHAFT

0703DD1810N SELECTIVE SHIM MD GEAR 1.50


0703DD1900N SELECTIVE SHIM MD GEAR 1.55
0703DD1820N SELECTIVE SHIM MD GEAR 1.60
0703DD1830N SELECTIVE SHIM MD GEAR 1.65
0703DD1840N SELECTIVE SHIM MD GEAR 1.70
0703DD1850N SELECTIVE SHIM MD GEAR 1.75
0703DD1860N SELECTIVE SHIM MD GEAR 1.80
0703DD2860N SELECTIVE SHIM MD GEAR 1.85
0703DD8870N SELECTIVE SHIM MD GEAR 1.90
(* OPTIONAL AS REQUIRED)
4 0703DD1890N SNAP RING MD GEA BEARING SP80 1
5 0703DD1540N BELLEVELLE WASHER - MD GEAR BRG 1
6 0703DD1530N CIRCLIP MD GEAR 1

1704.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1704.2
GROUP 1705 - MAIN SHAFT DRIVE GEAR & SYNCHRONIZER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0703DD1350N MAIN SHAFT 2WD 1
2 0703DD1620N ROLLER BEARING MAIN SHAFT PILOT DIA 1
3 7903066036 CIRCLIP 32 - 7 1
4 7903058015 WASHER ELASTIC 1
5 0703ED0610N SYNCRO PACK 3RD & 4TH NGT 520 1
6 0703DD2740N ASSY 3RD GEAR OUTPUT SHAFT V4 1
7 9151061380 NEEDLE CAGE 40.2 x 44.2 x 30 3
8 0703DD2730N ASSY 2ND GEAR OUTPUT SHAFT V4 1
GROUP 1705 - MAIN SHAFT DRIVE GEAR & SYNCHRONIZER

9 0703ED0600N SYNCRO PACK 1ST & 2ND NGT 520 1


10 0703DD1870N SPACER 1ST GEAR 1
11 0703DD1270N ASSY 1ST GEAR OUTPUT SHAFT V4 1
12 0703DD1440N SPACER 1ST GEAR INT BRG 3.0 1
0703DD2830N SPACER 1ST GEAR INT BRG 2.50
0703DD2840N SPACER 1ST GEAR INT BRG 2.55
0703DD2850N SPACER 1ST GEAR INT BRG 2.60
0703DD1950N SPACER 1ST GEAR INT BRG 2.65
0703DD1960N SPACER 1ST GEAR INT BRG 2.70
0703DD1970N SPACER 1ST GEAR INT BRG 2.75
0703DD1980N SPACER 1ST GEAR INT BRG 2.80
0703DD1990N SPACER 1ST GEAR INT BRG 2.85
0703DD2000N SPACER 1ST GEAR INT BRG 2.90 *
0703DD2010N SPACER 1ST GEAR INT BRG 2.95
0703DD2020N SPACER 1ST GEAR INT BRG 3.05
0703DD2030N SPACER 1ST GEAR INT BRG 3.10
0703DD2040N SPACER 1ST GEAR INT BRG 3.15
0703DD2050N SPACER 1ST GEAR INT BRG 3.20
0703DD2060N SPACER 1ST GEAR INT BRG 3.25
0703DD2070N SPACER 1ST GEAR INT BRG 3.30
0703DD2080N SPACER 1ST GEAR INT BRG 3.35
(* OPTIONAL AS REQUIRED)
13 0703DD1580N MD GEAR BEARING (6307 2RSRN C3 ) 1
14 0703DD1890N SNAP RING MD GEA BEARING SP80 1
15 9603489380 DRIVEN GEAR - REVERSE 1
16 0703DD1390N SLEEVE OUTPUT SHAFT 1
17 9153656880 5TH DRIVEN GEAR 1
18 7903066114 CIRCLIP 68 - 3 (O/P SHAFT RR BRG) 1
19 9159501780 CYLINDRICAL ROLLER BRG 5TH GEAR 1
20 07000D0361N LIP SEAL 40D58E10 1
21 07000A0210A COMPANION FLANGE NUT TYPE (2WD) 1
22 0A1028 COMPANION FLANGE NUT WASHER 1
23 020178 NYLOC NUT G19.05mm - 16 (3/4" - 16) 1
24 51100A0050N BOLT HEX 4

1705.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1705.2
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0703DD2260N COUNTER SHAFT V4 NGT520 1
2 0703DD1460N SPACER COUNTER SHAFT FRONT BRG 1
7834186000 ADJ SPACER C'SHAFT FRONT 2.25 1
7834187000 ADJ SPACER C'SHAFT FRONT 2.30 1
7834188000 ADJ SPACER C'SHAFT FRONT 2.35 1
7834189000 ADJ SPACER C'SHAFT FRONT 2.40 1
7834190000 ADJ SPACER C'SHAFT FRONT 2.45 1
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

7834191000 ADJ SPACER C'SHAFT FRONT 2.50 1


7834192000 ADJ SPACER C'SHAFT FRONT 2.55 1
7834193000 ADJ SPACER C'SHAFT FRONT 2.60 1
7834194000 ADJ SPACER C'SHAFT FRONT 2.65 1
7834195000 ADJ SPACER C'SHAFT FRONT 2.70 1
7834196000 ADJ SPACER C'SHAFT FRONT 2.75 1
7834197000 ADJ SPACER C'SHAFT FRONT 2.80 1
7834198000 ADJ SPACER C'SHAFT FRONT 2.85 1
7834199000 ADJ SPACER C'SHAFT FRONT 2.90 * 1
7834200000 ADJ SPACER C'SHAFT FRONT 2.95 1
7834201000 ADJ SPACER C'SHAFT FRONT 3.00 1
7834202000 ADJ SPACER C'SHAFT FRONT 3.05 1
7834203000 ADJ SPACER C'SHAFT FRONT 3.10 1
7834204000 ADJ SPACER C'SHAFT FRONT 3.15 1
7834205000 ADJ SPACER C'SHAFT FRONT 3.20 1
7834206000 ADJ SPACER C'SHAFT FRONT 3.25 1
7834256000 ADJ SPACER C'SHAFT FRONT 3.30 1
7834257000 ADJ SPACER C'SHAFT FRONT 3.35 1
7834258000 ADJ SPACER C'SHAFT FRONT 3.40 1
(* OPTIONAL AS REQUIRED)
3 0703DD1590N COUNTER SHAFT FRONT BEARING 1
4 0703DD1600N COUNTER SHAFT REAR BEARING 1
5 0703BD0440N BEARING RETAINER PLATE 1
6 0703DD1370N 5TH REV SUB - SHAFT 1
7 SF0601036 CIRCLIP EXT - LUG 52 x 1.5 x PH 1
8 0703ED0350N SYNCHRONIZER ASSEMBLY 5TH & REV 1
9 9151433080 NEEDLE CAGE N/S - 5TH DRIVING GEAR 1
10 0703DD0360N ASSY 5TH DRIVE GEAR (2WD) 1
11 0703DD1480N SPACER 5TH INPUT GEAR 1

CONTINUE…

1706.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1706.2
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
12 7910029041 ADJ SHIM SUB SHAFT BEARING 1
7910028076 ADJ SHIM SUB SHAFT 1.00 1
7910028077 ADJ SHIM SUB SHAFT 1.05 1
7910028078 ADJ SHIM SUB SHAFT 1.10 1
7910028079 ADJ SHIM SUB SHAFT 1.15 1
7910028080 ADJ SHIM SUB SHAFT 1.20 1
7910028081 ADJ SHIM SUB SHAFT 1.25 1
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

7910028082 ADJ SHIM SUB SHAFT 1.30 1


7910028083 ADJ SHIM SUB SHAFT 1.35 1
7910028084 ADJ SHIM SUB SHAFT 1.40 1
7910028085 ADJ SHIM SUB SHAFT 1.45 1
7910028086 ADJ SHIM SUB SHAFT 1.50 1
7910028087 ADJ SHIM SUB SHAFT 1.55 1
7910028088 ADJ SHIM SUB SHAFT 1.60 1
7910028089 ADJ SHIM SUB SHAFT 1.65 * 1
7910028090 ADJ SHIM SUB SHAFT 1.70 1
7910028091 ADJ SHIM SUB SHAFT 1.75 1
7910028092 ADJ SHIM SUB SHAFT 1.80 1
7910028093 ADJ SHIM SUB SHAFT 1.85 1
7910028094 ADJ SHIM SUB SHAFT 1.90 1
7910028095 ADJ SHIM SUB SHAFT 1.95 1
7910028096 ADJ SHIM SUB SHAFT 2.00 1
0703DD2650N ADJ SHIM SUB SHAFT 2.05 1
0703DD2660N ADJ SHIM SUB SHAFT 2.10 1
0703DD2670N ADJ SHIM SUB SHAFT 2.15 1
0703DD2680N ADJ SHIM SUB SHAFT 2.20 1
0703DD2690N ADJ SHIM SUB SHAFT 2.25 1
0703DD2700N ADJ SHIM SUB SHAFT 2.30 1
0703DD2710N ADJ SHIM SUB SHAFT 2.35 1
0703DD2720N ADJ SHIM SUB SHAFT 2.40 1
(* OPTIONAL AS REQUAIRED)
13 0703DD1610N SUB SHAFT REAR BEARING 1
14 0703DD1380N IDLER SHAFT 1
15 0703DD1730N IDLER GEAR ASSEMBLY 1
16 024630 FLANGE BOLT 2

1706.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1706.4
#
GROUP 1707 - TRANSMISSION SHIFT LEVER GROUP 1707 - TRANSMISSION SHIFT LEVER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0706AD0450N SHIFT LEVER BOTTOM - BOLERO 1
2 038525 CLIP WIRING HARNESS STRG COLUMN 2
3 0703CD1020N GROMMET BOTTOM LEVER 1
4 092658 PIVOT PIN 2
5 0703CD1000N PLATE PIVOT SPRING RETENTION 1
6 0703CD1100N SPRING SHIFT LEVER 1
7 092660 NYLON BUSH 1
8 7903067078 ELASTIC COTTER PIN 8 -18 1
9 024626 FLANGE BOLT M8 x 1.25 - 20 3

1707.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1707.2
GROUP 1901 - PROPELLER SHAFT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0501AA1121N PROPELLER SHAFT ASSY REAR 1
2 51100A0050N BOLT HEX HD 4
3 G103321 LOCK WASHER SPRING G9.53mm (3/8'') 4
4 0501EA0030N PROP SHAFT LOCKNUT TRANS END 4
5 0501EA0040N PROP SHAFT LOCKNUT AXLE END 4
038166 KIT, UNIVERSAL JOINT JOURNAL (2WD) 1
CONSIST OF :
038148 1 - JOURNAL ASSEMBLY NS
038167 4 - BEARING ASSEMBLY NS
038168 4 - SNAP RING NS
G271287 2 - GREASE NIPPLE NS

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 1901.1
GROUP 2001A - FRONT AXLE (2WD)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0503AA0720N FRONT AXLE ASSEMBLY 2WD 1
0503AA1720N FRONT AXLE ASSEMBLY 2WD (OPT) 1
1 027516 TUBE ASSEMBLY, FRONT AXLE 2WD 1
2 027512 SPLIT RING SEAT, UPPER BALL JOINT 2
027539 ASSY STRG KNUCKLE & BALL JOINT LH 1
CONSIST OF :
3 027507 1 - STEERING KNUCKLE LH
4 027511 1 - LOWER BALL JOINT
5 027515 1 - CIRCLIP LOWER BALL JOINT
6 027510 1 - UPPER BALL JOINT
027540 ASSY STRG KNUCKLE & BALL JOINT RH 1
CONSIST OF :
3 027508 1 - STEERING KNUCKLE RH
GROUP 2001A - FRONT AXLE (2WD)

4 027511 1 - LOWER BALL JOINT


5 027515 1 - CIRCLIP LOWER BALL JOINT
6 027510 1 - UPPER BALL JOINT
7 027513 NUT, UPPER BALL JOINT 2
8 027514 NUT, LOWER BALL JOINT 2
9 7032218 COTTER PIN 3.2 x 45 2
10 038237 WHEEL BEARING SPINDLE - FRONT 2
11 G181637 BOLT HEX HD G9.52 x 25.4mm 12
(3/8" - 24 x 1")
12 G108580 SPRING LOCK WSHR HD G9.53mm (3/8") 12
13 5110208 NUT HEX M10 x 1.5 2
14 027533 STOPPER BOLT 2
15 027522 PLUG, FRONT AXLE TUBE 2

2001A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2001A.2
GROUP 2002 - REAR AXLE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0502AA2340N REAR AXLE ASSEMBLY 3.73R 1
0502AA2540N REAR AXLE ASSEMBLY 3.73R (OPT) 1
1 092702 ASSY REAR AXLE TUBE LH 1
1 092703 ASSY REAR AXLE TUBE RH 1
2 0502DA0340N GEAR CARRIER COVER ASSEMBLY 1
3 0503DA0010N GASKET GEAR CARRIER COVER ASSY 1
4 G180075 BOLT HEX HEAD G7.93 x 15.87mm
(5/16" - 18 x 5/8") 8
5 G180077 BOLT HEX. HEAD G7.93 x 19.05mm
(EAD 5/16" - 18 x 3/4") 2
6 087798 RATIO TAG 3.73 AXLE 1
7 0502DA0360N FILLER PLUG 1
8 0502DA0800N DRIVE GEAR AND PINION PAIR (3.73R) 1
CONSISTS OF:
052888 1 - HYPOID DRIVE GEAR 41/11T 3.73R NS
GROUP 2002 - REAR AXLE

0502DA0750N 1 - PINION HYPOID DRIVE 11T 3.73R NS


019408 KIT- CONE, ROLLER & CUP, DIFF BRG 2
CONSISTS OF:
9 052980 1 - DIFFERENTIAL BEARING CUP NBC NS
10 052979 1 - DIFFERENTIAL BEARING CONE NBC NS
11 639959 DIFF ADJ SHIM 0.0762mm (0.003") A/R
11 639960 DIFF ADJ SHIM 0.127mm (0.005") A/R
11 639961 DIFF ADJ SHIM 0.254mm (0.010") A/R
11 639962 DIFF ADJ SHIM 0.762mm (0.030") A/R
11 083908 DIFF ADJ SHIM 0.1778mm (0.007") A/R
12 636553 SHAFT, PINION MATE 1
12 070603 RR AXLE DIFF BEVEL PINION MATE (OPT) 1
13 0502EA0400N PIN SPRING, DIFFERENTIAL 1
0502EA0460N DIFF ASSY 3.73R FULL FLOATING 1
14 052890 DIFFERENTIAL CASE 1
15 917292 BOLT G4.76 x 22.22mm (3/8" x 7/8" UNF) 10
16 802561 LOCK STRAP, AXLE DRIVE GEAR SCR 5
17 0502EA0320N DIFF GR TRST WSHR 0.711mm (0.028") A/R
17 0502EA0330N DIFF GR TRST WSHR 0.762mm (0.030") A/R
17 0502EA0340N DIFF GR TRST WSHR 0.813mm (0.032") A/R
17 0502EA0350N DIFF GR TRST WSHR 0.864mm (0.034") A/R
17 0502EA0360N DIFF GR TRST WSHR 0.914mm (0.036") A/R
17 0502EA0370N DIFF GR TRST WSHR 0.965mm (0.038") A/R
17 0502EA0380N DIFF GR TRST WSHR 1.016mm (0.040") A/R
17 0502EA0390N DIFF GR TRST WSHR 1.067mm (0.042") A/R
18 090559 DIFF BEVEL PINION MATE, THRST WSHR 2

CONTINUE...

2002.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2002.2
GROUP 2002 - REAR AXLE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
012141 KIT- DIFF GEAR AND PINION MATE 1
CONSISTS OF:
19 647062 2 - DIFFERENTIAL BEVEL PINION MATE NS
19 649355 2 - DIFFERENTIAL BEVEL SIDE GEAR NS
20 0502DA0370N DRAIN PLUG 1
21 639969 DRIVE PINION BEARING ADJUSTABLE
SHIM 0.0762mm (0.003") - REAR A/R
21 639970 DRIVE PINION BEARING ADJUSTABLE
SHIM 0.127mm (0.005") - REAR A/R
21 639971 DRIVE PINION BEARING ADJUSTABLE
SHIM 0.254mm (0.010") - REAR A/R
019405 KIT- CONE, ROLLER & CUP PINION
BEARING INNER 1
CONSIST OF :
22 052877 1 - CUP, PINION BEARING INNER NBC NS
GROUP 2002 - REAR AXLE

23 807266 1 - CONE, PINION BRG INNER NBC NS


24 098313 OIL SEAL (CARR END) 2
25 098314 AXLE SHAFT GUIDE 2
26 G179890 BOLT G12.70 x 57.15mm (1/2"UNC x 2 - 1/4") 4
27 052932 BREATHER NIPPLE 1
28 0502EA0210N SPACER PINION BEARING 3.500T A/R
28 0502EA0220N SPACER PINION BEARING 3.550T A/R
28 0502EA0230N SPACER PINION BEARING 3.600T A/R
28 0502EA0240N SPACER PINION BEARING 3.650T A/R
28 0502EA0250N SPACER PINION BEARING 3.700T A/R
28 0502EA0260N SPACER PINION BEARING 3.750T A/R
28 0502EA0270N SPACER PINION BEARING 3.800T A/R
28 0502EA0280N SPACER PINION BEARING 3.850T A/R
28 0502EA0290N SPACER PINION BEARING 3.900T A/R
28 0502EA0300N SPACER PINION BEARING 3.950T A/R
28 0502EA0310N SPACER PINION BEARING 4.000T A/R
28 0502EA1170N SPACER PINION BEARING 3.525T A/R
28 0502EA1180N SPACER PINION BEARING 3.575T A/R
28 0502EA1190N SPACER PINION BEARING 3.625T A/R
28 0502EA1200N SPACER PINION BEARING 3.675T A/R
28 0502EA1210N SPACER PINION BEARING 3.725T A/R
28 0502EA1220N SPACER PINION BEARING 3.755T A/R
28 0502EA1230N SPACER PINION BEARING 3.825T A/R
28 0502EA1240N SPACER PINION BEARING 3.875T A/R
28 0502EA1250N SPACER PINION BEARING 3.925T A/R
28 0502EA1260N SPACER PINION BEARING 3.975T A/R

CONTINUE...

2002.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2002.4
GROUP 2002 - REAR AXLE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
28 0502EA1310N SPACER PINION BEARING 3.250T A/R
28 0502EA1320N SPACER PINION BEARING 3.275T A/R
28 0502EA1330N SPACER PINION BEARING 3.300T A/R
28 0502EA1340N SPACER PINION BEARING 3.325T A/R
28 0502EA1350N SPACER PINION BEARING 3.350T A/R
28 0502EA1360N SPACER PINION BEARING 3.375T A/R
28 0502EA1370N SPACER PINION BEARING 3.400T A/R
28 0502EA1380N SPACER PINION BEARING 3.425T A/R
28 0502EA1390N SPACER PINION BEARING 3.450T A/R
28 0502EA1400N SPACER PINION BEARING 3.475T A/R
28 0502EA2100N SPACER PINION BEARING 3.100T A/R
28 0502EA2110N SPACER PINION BEARING 3.125T A/R
28 0502EA2120N SPACER PINION BEARING 3.150T A/R
28 0502EA2130N SPACER PINION BEARING 3.175T A/R
28 0502EA2140N SPACER PINION BEARING 3.200T A/R
GROUP 2002 - REAR AXLE

28 0502EA2150N SPACER PINION BEARING 3.225T A/R


019402 KIT- CONE, ROLLER & CUP PINION
BEARING OUTER 1
CONSIST OF :
29 052879 1 - CUP, PINION BEARING OUTER NBC NS
30 052878 1 - CONE, PINION BRG OUTER NBC NS
31 075871 OIL SLINGER 1
32 0502CA0131N SEAL PINION REAR AXLE 1
33 036991 SHIELD DUST 1
34 0502EA1090N COMPANION FLANGE, AXLE 1
35 00A1028 COMPANION FLANGE NUT WASHER 1
36 020178 NYLOC NUT G19.05mm (3/4" - 16) 1
36 801367 NYLOC NUT G19.05mm (3/4" - 16) (OPT) 1
37 000A852 WHEEL BEARING SPINDLE - REAR 2
38 G181374 BOLT HEX HEAD G9.52 x 38.1mm 12
(3/8" - 24 x 1 - 1/2")
39 G123920 LOCKWASHER SPRING G 9.53mm (3/8") 28
40 G120369 NUT HEX G9.52mm (3/8" - 24) 12
41 092706 REAR AXLE SHAFT LH 1
41 092707 REAR AXLE SHAFT RH 1
42 083065 HEX BOLT HEAD G9.52mm (3/8" - 24) 16

2002.5 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2002.6
GROUP 2101 - STEERING GEAR AND MOUNTINGS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1101AA0361N STEERING GEAR ASSY WITH DROP ARM 1
2 080652 BOLT STEERING GEAR MOUNTING 4
3 6112216 PLAIN WASHER M12 4
4 6512216 LOCK WASHER SPRING M12 4
5 080656 UNIVERSAL JOINT 2
6 2108262 BOLT HEX HD 4
7 5308202 NUT NYLOC 4
8 098294 INTERMEDIATE SHAFT 1
9 098536 GROMMET STEERING COLUMN BOTTOM 1
10 098535 BRKT SUPPORT STRG COLUMN BOTTOM 1
GROUP 2101 - STEERING GEAR AND MOUNTINGS

11 3108206 BOLT HEX HD M8 x 1.25 - 20 4


12 6508212 LOCK WASHER SPRING M8 4
13 6108212 WASHER PLAIN M8 4
14 039587 STEERING COLUMN CLAMP 1
15 G123798 BOLT HEX HD G7.93 x 44.45mm (5/16") 1
16 G120393 WASHER PLAIN G7.94mm (5/16") 2
17 G120214 LOCK WASHER SPRING G7.94mm (5/16") 1
18 G120368 NUT HEX G7.93mm (5/16 - 24) 1
(STRG COLUMN CLAMP ATTACHING)
19 028214 UPPER COLUMN 1
20 080680 ANTI SQUEAK STRG COLUMN SUPPORT 1
21 088822 CONTACT PLATE HORN BUTTON 1
22 1106BA0011N COVER PAD 1
23 088824 SCREWS 4
24 020234 STEERING WHEEL WASHER SPECIAL 1
25 020165 STEERING WHEEL NUT SPECIAL 1
26 075348 STEERING WHEEL ASSEMBLY 1
27 088826 DOWEL PINS 2
28 088823 SPRINGS 4

2101.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2101.2
#
GROUP 2101A - SERVICEABLE COMPONENTS OF STEERING GEAR GROUP 2101A - SERVICEABLE COMPONENTS OF STEERING GEAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1101AA0361N STEERING GEAR ASSEMBLY 1
1 1101AA0381N BOX SUB ASSEMBLY 1
MAIN CASE / BOX CASTING NS
2 1101AA0030N ROCKER SHAFT BUSH 2
1101AA0551N WORM AND MAIN NUT ASSEMBLY 1
CONSISTS OF:
3 1 - WORM NS
4 1 - MAIN NUT NS
5 1 - TRANS TUBE 63.5mm PITCH (2 - 1/2") NS
6 1 - TRANS TUBE 38.1mm PITCH (1 - 1/2") NS
7 1 - TRANSFER TUBE RETAINER NS
8 099914 2 - TOOTH LOCK WASHER
9 099915 2 - C R P HEAD SCREW
10 099913 STEEL BALLS 7.137mm 74
11 1101AA0210N BEARING 2
12 1101AA0411N SECTOR SHAFT 1
13 1101AA0170N COVER PLATE SUB ASSEMBLY 1
14 099922 BUSH (COVER PLATE) 1
15 1101AA0100N ADJUSTER 1
16 1101AA0150N SPACER 1
17 1101AA0110N SHIMS 0.203mm (0.008") A/R
18 1101AA0120N SHIMS 0.101mm (0.004") A/R
19 1101AA0130N SHIMS 0.050mm (0.002") A/R
20 1101AA0140N SHIMS 0.076mm (0.003") A/R
21 1101AA0160N INTERNAL CIRCLIP 1
22 099923 OIL PLUG 1
23 1101AA0190N SCREW PLUG 1
24 099932 LOCK NUT (ADJUSTER) 1
25 099938 LOCK NUT (DROP ARM) 1
26 1101AA0200N LOCK NUT (SCREW PLUG) 1
27 099931 JOINT WASHER (COVER PLATE) 1
28 099934 BOLT (COVER PLATE) 3
29 1101AA0240N SPRING WASHER (COVER PLATE) 3
30 099935 OIL SEAL (SECTOR SHAFT) 1
31 099936 OIL SEAL (WORM) 1
32 1101AA0220N DUST SEAL 1
33 099937 TAB WASHER (DROP ARM) 1
34 097881 DROP ARM 1

2101A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2101A.2
GROUP 2101D - SERVICEABLE COMPONENTS OF RESERVOIR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 1102CA0921N TANK BODY AND BRACKET ASSEMBLY 1
3 027913 FILTER AND END COVER ASSEMBLY 1
4 027914 SEAL BOTTOM 1
5 1102CA0911N SPRING 1
7 027916 COVER ASSEMBLY 1
9 027917 SPECIAL SCREW ASSEMBLY 1
10 027918 DIP STICK ASSEMBLY (NYLON) 1
GROUP 2101D - SERVICEABLE COMPONENTS OF RESERVOIR

027920 SERVICE KIT 1


CONSISTS OF :
2 027899 1 - VALVE SEAT NS
6 027900 1 - COVER SEAL NS
8 027901 1 - STEEL RUBBER WASHER NS
11 027902 1 - 'O' RING NS

2101D.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2101D.2
GROUP 2103 - STEERING TIE ROD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 099141 MASTER TIE ROD ASSEMBLY 1
2 084852 ASSEMBLY CONNECTING TIE ROD 1
3 099805 TIE ROD SOCKET ASSEMBLY LEFT M18 1
4 099806 TIE ROD SOCKET ASSEMBLY RIGHT M18 2
5 099807 MASTER TIE ROD SOCKET ASSEMBLY 1
6 000A837 SOCKET ASSEMBLY CLAMP 2
7 2108262 BOLT HEX HD M8 x 1.25 - 40 2
8 6508212 LOCK WASHER SPRING M8 2
9 5108206 NUT HEX M8 x 1.25 2
10 074294 COVER, DUST, TIE ROD SOCKET 4
11 020231 WASHER SPECIAL 4
12 074298 NUT HEX HD M12 x 1.5 4
13 7025212 PIN COTTER 2.5 x 25 4
GROUP 2103 - STEERING TIE ROD

14 099808 TIE ADJUSTING HEX SLEEVE 1


15 099809 LOCK NUT RH M18 2
16 099810 LOCK NUT LH M18 1
17 099998 STEERING DAMPNER 1
18 020154 NYLOC NUT G11.11mm (7/16'' - 20) T TYPE 1
19 2108260 BOLT HEX HD M8 x 1.25 - 35 4
20 6108212 WASHER PLAIN M8 4
21 6508212 LOCK WASHER SPRING M8 4
22 028262 BRKT STRG DAMPNER ON CONROD 1
23 058974 SPECIAL BOLT STEERING DAMPNER 1
24 G120395 WASHER PLAIN ID G11.11mm 2
(7/16" x 15/32")

2103.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2103.2
GROUP 2104 - STABILIZER BAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 084840 STABILIZER BAR FRONT 1
1 0401EA0231N STABILIZER BAR FRONT (OPT) 1
084842 ASSY LINK STABILISER BAR 1
CONSIST OF:
8 084843 2 - LINK STABILIZER BAR
060480 4 - STABILISER BAR FERRULE NS
10 G137218 COTTER PIN 3.96 x 31mm (5/32" x 1 - 1/4") 2
0401BA1750N KIT, STABILISER BAR LINK 2
CONSIST OF:
11 097645 1 - STUD STABILIZER BAR
084842 1 - ASSEMBLY LINK STABILISER BAR
7 097964 2 - BUSHING
9 G131016 2 - PLAIN WASHER ID G16.67mm (21/32")
12 5312204 1 - NYLOC NUT M12 x 1.25
GROUP 2104 - STABILIZER BAR

6 6112216 2 - PLAIN WASHER M12


2 084841 1 - BUSHING STABILIZER BAR
3 060479 1 - STABILIZER CLAMP
4 6510214 2 - LOCKWASHER SPRING M10
5 099105 2 - SPECIAL BOLT HEX HD M10 x 1.5 - 25

2104.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2104.2
GROUP 2201 - HAND BRAKE (PARKING BRAKES ON REAR WHEELS)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 06050A0210N LEVER ASSEMBLY PARK BRAKE 1
2 0605BA0291N CABLE PARKING BRAKE FRT (7S) 1
2 0605BA0292N CABLE PARKING BRAKE FRT - 7S (OPT) 1
2 0605BA0331N CABLE ASSY PARK BRAKE FRT (8S) 1
2 0605BA0332N CABLE ASSY PARK BRAKE FRT (8S) (OPT) 1
3 06050A0200N BRACKET ROLLER HOLD DOWN 1
GROUP 2201 - HAND BRAKE (PARKING BRAKES ON REAR WHEELS)

4 068266 ROLLER PARK BRAKE 1


5 068362 CIRCLIP HAND BRAKE CABLE FRONT 1
6 0605BA0341N CABLE PARKING BRAKE REAR 1
6 0605BA0342N CABLE PARKING BRAKE REAR 1
7 068153 WIRE CLIP 2
8 069504 CABLE SUPPORT PLATE 1
9 028023 GROMMET PARKING BRAKE 1
10 3106226 SCREW HEX HD M6 x 1 - 16 3
11 6506208 SPRING LOCK WASHER M6 3
12 6106208 PLAIN WASHER M6 3
13 06050A0350N BRACKET GUIDE CABLE FRONT 1
14 06050A0360N BRACKET GUIDE CABLE REAR 1
15 6110214 PLAIN WASHER M10 1

2201.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2201.2
#
GROUP 2202 - FRONT DRUM BRAKE GROUP 2202 - FRONT DRUM BRAKE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0601BA0481N FRONT BRAKE ASSEMBLY RH 1
0601BA0041N DRUM BRAKE ASSY FRONT RH (OPT) 1
0601BA0491N FRONT BRAKE ASSEMBLY LH 1
0601BA0051N DRUM BRAKE ASSY FRONT LH (OPT) 1
1 0601BA0601N PLATE BACKING FRONT LH 1
2 0601BA0621N PLATE BACKING FRONT RH 1
3 032271 ASSEMBLY BRIDGE PIPE LH & RH 2
4 0601BA0561N LINED SHOE (LH & RH) 4
0601BA0581N KIT LINING SET (STD) 1
CONSIST OF :
04 - LINING NS
52 - RIVET NS
5 033279 SHOE SPRING RETURN (AUXILIARY) 4
6 032278 SPRING SHOE 4
7 055876 WHEEL CYLINDER ASSEMBLY LH 2
8 055877 WHEEL CYLINDER ASSEMBLY RH 2
036372 KIT WHEEL CYLINDER - MINOR 4
CONSIST OF :
9 055879 01 - GLAND SEAL NS
10 012569 01 - DUST COVER NS
0601BA0401N KIT WHEEL CYLINDER - MAJOR 4
9 055879 01 - GLAND SEAL NS
10 012569 01 - DUST COVER NS
11 055880 01 - PISTON NS
12 055933 01 - SPRING NS
13 055934 BLEED SCREW 2
14 G181637 BOLT HEX HD G9.52 x 25.4mm 12
(3/8" - 24 x 1")
15 G123920 LOCKWASHER SPRING G9.53mm (3/8") 12

2202.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2202.2
GROUP 2202B - WHEEL BRAKE REAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0602BA2761N REAR BRAKE ASSY LH AUTO ADJUSTER 1
0602BA2771N REAR BRAKE ASSY RH AUTO ADJUSTER 1
1 0602BA3201N BACK PLATE ASSEMBLY REAR - LH 1
1 0602BA3211N BACK PLATE ASSEMBLY REAR - RH 1
2 0602BA3241N SPRING, WHEEL CYLINDER END 2
3 0602BA3251N SPRING, SHOE RETURN 2
4 0602BA3261N SPRING ADJUSTER 4
5 031133 WHEEL CYLINDER ASSY RR LH/RH 2
032284 KIT, RR WHEEL CYLINDER MINOR 1
CONSIST OF :
6 2 - CUP SEAL NS
7 2 - DUST COVER NS
GROUP 2202B - WHEEL BRAKE REAR

8 1 - DUST CAP NS
0602BA2521N KIT, RR WHEEL CYLINDER MAJOR 1
CONSIST OF :
6 2 - CUP SEAL NS
7 2 - DUST COVER NS
8 1 - DUST CAP NS
9 1 - PLUNGER NS
10 1 - SPRING ASSEMBLY NS
11 1 - SEAL RETAINER NS
0602BA3271N KIT, LINED SHOE 2
CONSIST OF :
12 1 - LINED SHOE ASSEMBLY - LEADING NS
13 1 - LINED SHOE ASSEMBLY - TRAILING NS
48 - RIVET NS
0602BA3281N KIT, LINING SET (STD) 1
011919 KIT, BRAKE SHOE HOLD DOWN 2
CONSIST OF :
14 4 - CUP WASHER NS
15 2 - PINS NS
16 2 - SPRING NS
012657 KIT, BOLT & WASHER ASSEMBLY 1
CONSIST OF :
17 4 - LOCK WASHER NS
18 4 - SET SCREW NS
19 0602BA3291N PUSH ROD ASSEMBLY - LH 1
19 0602BA3301N PUSH ROD ASSEMBLY - RH 1

CONTINUE...

2202B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2202B.2
GROUP 2202B - WHEEL BRAKE REAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0602BA3311N KIT LEVER - PAWL LH
CONSIST OF :
20 1 - LEVER - PAWL LH NS
21 1 - LOCK WASHER LH NS
22 1 - WAVE WASHER NS
23 1 - DOWEL PIN NS
0602BA3321N KIT LEVER - PAWL RH
CONSIST OF :
20 1 - LEVER - PAWL RH NS
21 1 - LOCK WASHER RH NS
22 1 - WAVE WASHER NS
23 1 - DOWEL PIN NS
GROUP 2202B - WHEEL BRAKE REAR

24 0602BA3331N GROMMET COLLAPSING 1


25 0602BA3341N GROMMET 1
0602BA3351N KIT, LEVER ASSEMBLY LH 1
26 1 - LEVER ASSEMBLY LH NS
27 1 - SPRING PLATE NS
28 1 - RETAINING PLATE NS
0602BA3361N KIT, LEVER ASSEMBLY RH 1
26 1 - LEVER ASSEMBLY RH NS
27 1 - SPRING PLATE NS
28 1 - RETAINING PLATE NS
29 012655 BLEED SCREW 2

2202B.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2202B.4
GROUP 2204 - BRAKE MASTER CYLINDER AND RESERVOIR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0607AA0691N BOOSTER ASSY DIA 178 WITH 23.81 TMC 1
0607AA0751N LSC38 BOOSTER WITH 23.81 TMC 1
2 0607AA0851N SERVO ASSEMBLY (LSC 38) 1
06060A0371N KIT, SERVO 1
CONSIST OF :
3 029634 1 - FILTER NS
029635 1 - GROMMET - NRV NS
GROUP 2204 - BRAKE MASTER CYLINDER AND RESERVOIR

1 - SEAL ASSY VACUUM NS


4 1 - DUST COVER NS
1 - GREASE SACHET NS
0606AA1281N KIT, MASTER CYLINDER - MAJOR 23.81 1
CONSIST OF :
5 1 - PLUNGER ASSEMBLY - SECONDARY NS
6 1 - PLUNGER ASSEMBLY - PRIMARY NS
7 1 - CIRCLIP NS
8 1 - WASHER NS
9 1 - STOP PIN NS
10 2 - SEAL FLUID TANK NS
11 1 - SEALING RING NS
0606AA1311N KIT, MASTER CYLINDER - MINOR 1
CONSIST OF :
8 1 - WASHER NS
10 2 - SEAL FLUID TANK NS
11 1 - SEALING RING NS
12 2 - SEAL RECUPERATING NS
13 2 - SHIM SEAL NS
14 2 - SEAL GLAND NS
15 6508212 LOCK WASHER SPRING M8 2
16 5108206 NUT HEX HD M8 x 1.25 2
17 0606AA1261N MASTER CYLINDER ASSEMBLY 1
0607AA0341N KIT, NON RETURN VALVE 1
CONSIST OF:
18 064334 1 - GROMMET NS
19 064333 1 - ASSEMBLY NON RETURN VALVE NS
20 097612 FLUID RESERVOIR 1
21 RETAINER NS
22 0606CA0350N HOSE VACUUM PUMP TO BOOSTER 1

2204.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2204.2
GROUP 2205 - BRAKE PEDAL

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0606BA1060N ASSEMBLY BRAKE PEDAL 1
2 081805 PEDAL PAD COVER 1
3 036422 BUSH 2
4 0606BA1240N SPRING RETRACTING 2

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2205.1
GROUP 2206A - BRAKE TUBES

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0606CA8901N TUBE COILED 1
1 0606CA0840N BRAKE TUBE (STRAIGHT LENGTH) 1
2 0606CA8891N TUBE COILED REAR 1
2 0606CA0860N BRAKE TUBE (STRAIGHT LENGTH) 1
3 081890 FRONT BRAKE HOSE 2
4 0606CA0410N TUBE FRT HOSE TO FRT BRAKE LH 1
4 0606CA1020N TUBE FRT HOSE TO FRT BRKT(ST LENG) 1
5 092819 BR TUBE FRT TEE TO HOSE LH(ST LENG) 1
5 092818 BR TUBE FRT TEE TO HOSE LH(ST LENG) 1
6 011639 TEE REAR 3 WAY 2
7 3106214 BOLT HEX HD M6 x 1 - 35 2
8 0606CA0400N TUBE FRT HOSE TO FRT BRAKE RH 1
8 0606CA1020N TUBE FRT HOSE TO FRT BRKT (ST LENG) 1
9 092820 BR TUBE FRT TEE TO HOSE RH 1
GROUP 2206A - BRAKE TUBES

9 097630 BR TUBE FRT TEE TO HOSE RH (ST LENG) 1


10 0606CA2380N TUBE COILED REAR TO CONNECTOR 1
10 0606CA2371N TUBE COILED RR TO CON (ST LENG) 1
11 020164 UNION INV FLARED TUBE G6.35mm (1/4") 2
12 0606CA0690N TUBE CONNECTOR TO RR HOSE 1
12 0606CA0680N BR TUBE CHASSIS BRKT TO RR (ST LENG) 1
13 011631 BRAKE HOSE ASSEMBLY 1
14 6506208 SPRING LOCK WASHER M6 2
15 0606CA0300N BRAKE TUBE REAR TEE TO WHEEL RH 1
15 0606CA0290N TUBE REAR TEE TO WHEEL RH (ST LENG) 1
16 0606CA0310N BRAKE TUBE REAR TEE TO WHEEL LH 1
16 074252 BR TUBE REAR T TO RR BR LH (ST LENG) 1
17 6106208 PLAIN WASHER M6 2
18 804201 CLIP AXLE TUBE BRAKE TUBE H/DOWN 2
19 033839 SPECIAL WASHER 3
20 011644 LOCKWASHER BRAKE HOSE SECURING 6
21 011645 NUT LOCK HOSE SECURING 5
22 011642 GASKET, BRAKE HOSE 3
23 081528 BRAKE TUBE CLIP 6
1 0606CA9890N TUBE COILED FRONT 1
1 0606CA9900N BRAKE TUBE 1
2 0606CA9910N TUBE COILED REAR 1
2 0606CA9920N BRAKE TUBE * 1
10 0606CB0080N TUBE COILED REAR TO CONNECTOR 1
10 0606CB0090N TUBE REAR TO CONNECTOR 1
0606CB0020N BRAKE TUBE GP VALVE TO COILED RR 1
(* 8S ONLY)

2206A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2206A.2
GROUP 2301A - WHEEL AND ATTACHING PARTS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0404AA0131N WHEEL RIM 6J x 15 5
1 0404AA0321N WHEEL RIM 6J x 15 (SSWL) 5
2 097871 WHEEL BOLT 20
3 097882 NUT HEX M14 x 1.5 23
4 028102 BRAKE DRUM FRONT 2
4 097872 BRAKE DRUM REAR 2
5 028260 FRONT WHEEL HUB 2WD 2
5 097870 REAR WHEEL HUB 2
6 0502CA0080N OIL SEAL HUB 4
7 083152 INNER WHEEL BEARING CUP (SKF) 4
GROUP 2301A - WHEEL AND ATTACHING PARTS

7 090189 INNER WHEEL BEARING CUP (IMP) 4


7 917773 INNER WHEEL BEARING CUP (NBC) 4
8 083151 INNER WHEEL BEARING CONE (SKF) 4
8 090188 INNER WHEEL BEARING CONE (IMP) 4
8 052880 INNER WHEEL BEARING CONE (NBC) 4
9 083150 OUTER WHEEL BEARING CUP (SKF) 4
9 090187 OUTER WHEEL BEARING CUP (IMP) 4
9 925447 OUTER WHEEL BEARING CUP (NBC) 4
10 083149 OUTER WHEEL BEARING CONE (SKF) 4
10 090186 OUTER WHEEL BEARING CONE (IMP) 4
10 925446 OUTER WHEEL BEARING CONE (NBC) 4
11 000A865 LOCKWASHER, WHEEL BRG, FRONT 4
12 000A866 NUT, RETAINING, WHEEL BEARING 8
13 099825 TOOTHED LOCK WASHER 4
14 090708 'O' RING BIG (2WD) 4
15 090707 HUB COVER (2WD) 2
16 0502CA0070N DUST SHIELD -HUB REAR 2
17 G181643 BOLT HEX HD G9.52 x 38.1mm 12
(3/8" - 24 x 1 - 1/2")
18 G123920 LOCKWASHER SPRING G9.53mm (3/8") 12
19 G120369 NUT HEX G9.52mm (3/8" - 24) 12
20 G123920 LOCKWASHER SPRING G9.53mm (3/8") 6
21 G122126 BOLT HEX HD G9.52 x 22.22mm(3/8" -16 x 7/8") 6
22 098442 WHEEL HUB COVER (2WD) 4
23 029975 SPACER WHEEL BEARING 27.575 A/R
23 029976 SPACER WHEEL BEARING 27.600 A/R
23 029979 SPACER WHEEL BEARING 27.625 A/R
23 0502CA0500N SPACER WHEEL BEARING 27.500 A/R
23 0502CA0510N SPACER WHEEL BEARING 27.550 A/R
23 0502CA0520N SPACER WHEEL BEARING 27.650 A/R
23 0502CA0530N SPACER WHEEL BEARING 27.675 A/R
24 029978 SHIM 0.075mm A/R
24 029979 SHIM 0.200mm A/R
24 029980 SHIM 0.500mm A/R
25 3206206 SCREW CSK SLOTTED M6 x 1 - 16 2
26 071635 DOWEL PIN 4

2301A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2301A.2
GROUP 2401 - FRAME 2WD (NGT - 520)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0201AD7590N FRAME ASSEMBLY COMPLETE 1
1 097939 ASSY BRKT SPRING SHACKLE FRONT 2
2 084809 BODY OUTRIGGER NO 5 & 2 4
3 6110214 PLAIN WASHER M10 4
4 084777 SPRING BUSHING 4
5 099990 BRACKET DAMPER MTG ON CHASSIS 1
6 097929 ASSY BRKT MTG STABILIZER BAR 1
7 6510214 LOCKWASHER SPRING M10 4
8 029720 ROD MUFFLER MOUNTING FRONT 1
9 097948 ASSY BRKT SHOCK ABSORBER FRONT 2
10 098285 TOWING HOOK FRONT AND REAR 2
11 029776 ASSEMBLY BRACKET ENGINE MTG LH 1
GROUP 2401 - FRAME 2WD (NGT - 520)

12 029777 ASSEMBLY BRACKET ENGINE MTG RH 1


13 097861 ASSY BRKT FRT SPRING RR PIVOT LH 1
14 097866 ASSY BRKT FRT SPRING RR PIVOT RH 1
15 069894 ASSY ENG SUPPT X MEMBER RR (2WD) 1
16 0203AD0220N BRACKET X MEMBER ENGINE REAR RH 1
17 0203AD0230N BRACKET X MEMBER ENGINE REAR LH 1
18 097513 ASSY PLATE NUT RETAINER (2WD) 2
19 084785 BODY OUTRIGGER NO 0 2
20 084805 BODY OUTRIGGER NO 1 2
21 0201AD4950N FRAME ASSY X MEMBER REAR (2WD) 1
22 084878 BODY OUTRIGGER NO 6 2
23 0201AA0800N BRACKET FUEL TANK 2
24 06050A0360N BRKT GUIDE CABLE REAR 1
25 084876 BODY OUTRIGGER NO 3 RH 1
26 084877 BODY OUTRIGGER NO 3 LH 1
27 097864 BRACKET REAR SPRING FRONT PIVOT RH 1
28 097863 BRACKET REAR SPRING FRONT PIVOT LH 1
29 084791 ASSY BRKT SHOCK ABSORBER REAR 2
30 0903CA0110N BRACKET MUFFLER SUPPORT REAR 1
31 099240 BRACKET BRAKE TEE MOUNTING 1
32 02000D0120N SPECIAL BOLT HEX HD M10 x 1.5 4

2401.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2104.2
GROUP 2502A - FRONT SPRING AND SHOCK ABSORBER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 084818 ASSEMBLY, FRONT SPRING COMPLETE 2
2 084777 SPRING BUSHING 1
3 912593 BUSH, PIVOT END 1
4 097932 SPRING PIVOT PIN 2
5 6116220 PLAIN WASHER M16 6
6 5316202 NUT NYLOC M16 x 1.5 6
7 097946 AXLE BUMPER FRONT 2
8 098369 CLIP SPRING (2WD) 4
GROUP 2502A - FRONT SPRING AND SHOCK ABSORBER

9 084814 ASSY, SPRING CLIP PLATE FRONT RH 4


10 080149 NYLOCK NUT G12.70mm (1/2" - 20) 8
11 2116282 BOLT HEX HD M16 x 1.5 - 110 4
12 081624 SHACKLE PLATE 4
13 089945 SHOCK ABSORBER FRONT 2
14 070175 BUSH SHOCK ABSORBER 4
15 G120389 WASHER PLAIN G12.7mm (1/2") 4
16 5312204 NYLOC NUT M12 x 1.25 4
17 G191758 GREASE NIPPLE G3.1mm (1/8") NPTF 2

2502A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2502A.2
GROUP 2502B - REAR SPRING AND SHOCK ABSORBER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 089943 ASSY REAR LEAF SPRING COMPLETE 2
2 084777 BUSH SILENT BLOCK 4
3 912593 BUSH PIVOT END 1
4 097932 SPRING PIVOT PIN 2
5 6116220 PLAIN WASHER M16 6
6 5316202 NUT NYLOC M16 x 1.5 6
7 097946 AXLE BUMPER 2
8 081642 CLIP SPRING 4
GROUP 2502B - REAR SPRING AND SHOCK ABSORBER

9 084835 ASSEMBLY SPRING CLIP PLATE REAR RH 1


9 084836 ASSEMBLY SPRING CLIP PLATE REAR LH 1
10 080149 NYLOCK NUT G12.70 mm (1/2 - 20) 8
11 2116282 BOLT HEX HD M16 x 1.5 - 110 4
12 04000A0250N SHACKLE PLATE 80 4
13 089944 SHOCK ABSORBER REAR 2
14 070175 BUSH SHOCK ABSORBER 4
15 G120389 WASHER PLAIN G12.7mm (1/2") 4
16 5312204 NYLOC NUT M12 x 1.25 4
17 G191758 GREASE NIPPLE G3.1mm NPTF STRAIGHT 2
0402BA0350N KIT - REAR SUSPENSION MOUNTING 1
CONSIST OF :
081642 4 - CLIP SPRING REAR
084835 1 - ASSY SPRING CLIP PLATE REAR RH
084836 1 - ASSY SPRING CLIP PLATE REAR LH
04000A0250N 4 - SHACKLE PLATE 80
2116282 6 - BOLT HEX HEAD
084777 4 - BUSH SILENT BLOCK
0402BA0340N KIT - SHOCK ABSORBER BUSHING REAR 1
CONSIST OF :
G120389 4 - WASHER SHOCK ABSORBER
070175 BUSH SHOCK ABSORBER

2502B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2502B.2
GROUP 2601 - HOOD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 28346CED ASSEMBLY BONNET - CED 1
2 029546 CENTRAL LOCK UNIT UPPER 1
3 6106208 PLAIN WASHER M6 8
4 3106226 SCREW HEX HD M6 x 1 - 16 8
5 028330 ASSEMBLY BONNET HINGE LH 1
6 028530 ASSEMBLY COVER BONNET HINGE 2
7 6110214 PLAIN WASHER M10 8
8 6510214 LOCKWASHER SPRING M10 8
9 3110208 SCREW HEX HD M10 x 1.25 - 30 8
10 028333 ASSEMBLY REINF PLATE 4
11 028334 ASSEMBLY BONNET HINGE RH 1
12 3108226 SCREW HEX HD M8 x 1.25 - 25 4
13 6508212 LOCK WASHER SPRING M8 4
14 6108212 WASHER PLAIN M8 4
15 028326 WEATHER STRIP BONNET RIGHT 1
16 028325 WEATHER STRIP BONNET LEFT 1
GROUP 2601 - HOOD

17 028302 WEATHER STRIP BONNET FRONT 1


18 028709 WEATHER STRIP BONNET REAR 1
19 6506208 SPRING LOCK WASHER M6 8
01060K0980N KIT - P U FOAM BONNET 1
CONSIST OF :
029436 1 - P U FOAM BONNET INNER LH
029437 1 - P U FOAM BONNET INNER RH
029438 1 - P U FOAM BONNET OUTER LH
028439 1 - P U FOAM BONNET OUTER RH

2601.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2601.2
GROUP 2602A - FENDER RIGHT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0102CN0350A FENDER ASSY COMPLETE RH - CED 1
2 028470 FILLER STRIP (FENDER TO DASH) 1
3 028468 ASSY RETAINER PLATE FENDER MTG 1
4 G120214 SPRING LOCK WASHER G7.94mm (5/16") 5
5 G446363 PLAIN WASHER ID G9.53mm (3/8'') 5
6 5108206 NUT HEX M8 x 1.25 5
7 072998 STAY BRKT VERT DASH TO FENDER RH 1
8 6110214 PLAIN WASHER M10 2
9 6510214 LOCKWASHER SPRING M10 2
10 7903201045 BOLT HEX HD M10 x 1.5 - 20 2
11 073000 HORI BRKT DASH PNL EXTN TO PDR RT 1
12 979727 BRACKET HOOD PROP RET 1
13 0102EK0010N STAY ROD BONNET 1
14 028367 HOLDER BONNET STAY ROD 1
GROUP 2602A - FENDER RIGHT

15 3306206 SCREW SLOTTED PAN HD M6 x 1 - 14 2


16 6506208 SPRING LOCK WASHER M6 2
17 097573 GRIP HANDLE ROD HOOD PROP 1
18 3108226 SCREW HEX HD M8 x 1.25 - 25 2

2602A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2602A.2
GROUP 2602B - FENDER LEFT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0102CF0080A FENDER ASSY COMPLETE LH - CED 1
2 028470 FILLER STRIP (FENDER TO DASH) 1
3 028468 ASSY RETAINER PLATE FENDER MTG 1
4 G120214 SPRING LOCK WASHER G7.93mm (5/16") 5
5 G446363 PLAIN WASHER G9.25mm ID (3/8") 5
6 5108206 NUT HEX M8 x 1.25 5
7 072997 STAY BRKT VERT DASH TO FENDER LH 1
8 6110214 PLAIN WASHER M10 2
9 6510214 LOCKWASHER SPRING M10 2
10 7903201045 BOLT HEX HD M10 x 1.5 - 20 2
11 072999 STAY BRKT HOR DASH TO FENDER LH 1
12 3108226 SCREW HEX HD M8 x 1.25 - 25 2
GROUP 2602B - FENDER LEFT

2602B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2602B.2
GROUP 2603 - RADIATOR GUARD AND GRILL

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0102BN0020X RADIATOR GRILL BLACK 1
2 3306206 BOLT HEX HD M6 x 1 - 25 8
3 6506208 SPRING LOCK WASHER M6 30
4 6106208 PLAIN WASHER M6 30
5A 028651 HEAD LAMP BEZEL LH CHROME PLATED 1
5B 028652 HEAD LAMP BEZEL RH CHROME PLATED 1
6 029551 CS CRRS TAP SCR 10x16-44mm (1 - 3/4") 4
7 28368CED FACIA ASSEMBLY - CED 1
8 3106226 SCREW HEX HD M6 x 1 - 16 20
9 0102DN1560A AIR DEFL FRAME ASSY COMP - CED 1
10 028408 ASSEMBLY LOCK PLATE BONNET 1
GROUP 2603 - RADIATOR GUARD AND GRILL

11 029557 BONNET BUFFER 2


12 6508212 LOCK WASHER SPRING M8 17
13 039330 NUT PROJ WELD HEX M8 x 1.25 2
16 3108226 SCREW HEX HD M8 x 1.25 - 20 9
18 G446363 PLAIN WASHER ID G9.53mm (3/8") 11

2603.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2603.2
GROUP 2603 - RADIATOR GUARD AND GRILL

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
14 0102FN0010N COVER HEAD LAMP RH 1
14 0102FN0020N COVER HEAD LAMP LH 1
15 029547 BONNET CENTRAL LOCK LOWER UNIT 1
17 5108206 NUT HEX M8 x 1.25 6
19 029550 LOCK PLATE (BONNET) 1
20 029548 CABLE BONNET RELEASE 1
21 3106226 SCREW HEX HD M6 x 1 - 16 1
22 19000A1660N TIE ROD ASSY DASH TO FRONT END 2
23 6108212 WASHER PLAIN M8 4
GROUP 2603 - RADIATOR GUARD AND GRILL

2603.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2603.4
#
GROUP 2604 - FOOT STEPS SIDE AND REAR GROUP 2604 - FOOT STEPS SIDE AND REAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 028609 ASSEMBLY SIDE FOOTSTEP LH 1
1 028610 ASSEMBLY SIDE FOOTSTEP RH 1
2 6110214 PLAIN WASHER M10 8
3 6510214 LOCKWASHER SPRING M10 8
4 7903201045 BOLT HEX HD M10 x 1.5 - 20 8
5 083034 ASSEMBLY REAR STEP 1
6 3108228 SCREW HEX HD M8 x 1.25 - 30 4
7 G120394 PLAIN WASHER G9.53mm (3/8") 4
8 G120382 LOCK WASHER SPRING G9.53mm (3/8'') 4
9 5108206 NUT HEX M8 x 1.25 4

2604.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2604.2
GROUP 2605 - BODY MOUNTINGS (NGT - 520)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
MOUNTING NO. '0' LH AND RH
067974 SPECIAL BOLT M10 x 1.5 - 52 2
6510214 LOCKWASHER SPRING M10 2
02020D0080N WASHER PLAIN 2
02020D0040N INSULATOR BODY MOUNTING UPPER 2
02020D0050N INSULATOR BODY MOUNTING LOWER 2
02020D0060N SPACER BODY MOUNTING 2

MOUNTING NO. '1' LH AND RH


067974 SPECIAL BOLT M10 x 1.5 - 52 2
6510214 LOCKWASHER SPRING M10 2
GROUP 2605 - BODY MOUNTINGS (NGT - 520)

02020D0080N WASHER PLAIN 2


02020D0040N INSULATOR BODY MOUNTING UPPER 2
02020D0050N INSULATOR BODY MOUNTING LOWER 2
02020D0060N SPACER BODY MOUNTING 2

MOUNTING NO. '2' LH AND RH


067974 SPECIAL BOLT M10 x 1.5 - 52 2
6510214 LOCKWASHER SPRING M10 2
02020D0080N WASHER PLAIN 2
02020D0040N INSULATOR BODY MOUNTING UPPER 2
02020D0050N INSULATOR BODY MOUNTING LOWER 2
02020D0060N SPACER BODY MOUNTING 2

MOUNTING NO. '3' LH AND RH


7903001856 BOLT HEX HD M10 x 1.5 - 80 2
6510214 LOCKWASHER SPRING M10 2
02020D0080N WASHER PLAIN 2
02020D0040N INSULATOR BODY MOUNTING UPPER 2
02020D0050N INSULATOR BODY MOUNTING LOWER 2
02020D0070N SPACER BODY MOUNTING 2

MOUNTING NO. '4' LH AND RH


067974 SPECIAL BOLT M10 x 1.5 - 52 2
6510214 LOCKWASHER SPRING M10 2
02020D0080N WASHER PLAIN 2
02020D0040N INSULATOR BODY MOUNTING UPPER 2
02020D0050N INSULATOR BODY MOUNTING LOWER 2
02020D0060N SPACER BODY MOUNTING 2

2605.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2605.2
GROUP 2605 - BODY MOUNTINGS (NGT - 520)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
MOUNTING NO. '5' LH AND RH
067974 SPECIAL BOLT M10 x 1.5 - 52 2
6510214 LOCKWASHER SPRING M10 2
02020D0080N WASHER PLAIN 2
02020D0040N INSULATOR BODY MOUNTING UPPER 2
02020D0050N INSULATOR BODY MOUNTING LOWER 2
02020D0060N SPACER BODY MOUNTING 2

MOUNTING NO. '6' LH AND RH


067982 SNUBBER BODY HOLD DOWN 2
GROUP 2605 - BODY MOUNTINGS (NGT - 520)

FUEL TANK MOUNTING


067982 SNUBBER BODY HOLD DOWN 2

RADIATOR GUARD HOLD DOWN


02020D0110N BOLT HEX HD G11.11 x 76.20mm 2
(7/16" - 20 x 3)
00A6360 PEDAL SHANK DRAFT PAD WASHER 2
02020D0060N SPACER BODY MTG 2
02020D0040N INSULATOR UPPER 2
02020D0050N INSULATOR LOWER 2
02020D0080N WASHER PLAIN 2
7903234004 NYLOC NUT M10 x 1.5 2

2605.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2605.4
GROUP 2606 - ASSEMBLY INSTRUMENT PANEL

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0112AN0040N INSTRUMENT PANEL ASSEMBLY (2WD) 1
2 3108224 SCREW HEX HD M8 x 1.25 - 20 2
3 01050K0360A STRIKER PLATE 1
4 6108212 WASHER PLAIN M8 8
5 5308202 NYLOC NUT M8 x 1.25 6
6 028617 GRAB HANDLE 1
7 029404 GLOVE BOX 1
8 029663 STAY TUBE IP SUPPORT CENTER 2
9 3106228 SCREW HEX HEAD M6 x 1.0 - 20 2
10 6506208 SPRING LOCK WASHER M6 2
GROUP 2606 - ASSEMBLY INSTRUMENT PANEL

11 6106208 PLAIN WASHER M6 2


12 G120394 PLAIN WASHER 2
13 3106214 SCREW HEX HEAD M6 x 1.0 - 35 2
14 01050K0290A CAP POWER WINDOW SWITCH 6
15 01050K0210A SCREW M 4 x 15 MUSHROOM 4
16 028535 LOUVER SIDE 2
17 028557 LOUVER SIDE DUCT RH (A/C ONLY) 1
18 028556 LOUVER SIDE DUCT LH (A/C ONLY) 1
19 028536 LOUVER CENTER ASSEMBLY 1
20 029402 SWITCH PLATE 1
21 01050K0300A CAP CIGAR LIGHTER 1
22 028800 STEERING COVER 1
23 029410 ASH TRAY 2
24 0114AK0010N ASSEMBLY GLOVE BOX LOCK (JAY) 1
25 01050K0310A CAP A/C SWITCH 2
26 01050K0430A CAP LED 1
27 029407 RADIO EXTENSION BOX 1
28 029403 ASSY INSTRUMENT PANEL MTG CAP 1
CONSISTS OF:
01050K0070G 1 - IP CAP NO 1 NS
01050K0080G 1 - IP CAP NO 2 NS
01050K0090G 1 - IP CAP NO 3 NS
01050K0100G 1 - IP CAP NO 4 NS
01050K0110G 1 - IP CAP NO 5 NS
01050K0120G 1 - IP CAP NO 6 NS
29 028799 CLUSTER RING 1

2606.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2606.2
GROUP 2607 - BODY SHELL ASSEMBLY

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0101AN0460A BODY SHELL ASSEMBLY WITHOUT 1
DOORS *
(* FOR NGT 520 7 SEATER)
1 0101AN0510N BODY SHELL ASSEMBLY WITHOUT * 1
DOORS
(* FOR NGT 520 8 SEATER)
28305CED PANEL COWL TOP - CED 1
0101CN0380A PANEL ASSEMBLY DASH - CED 1
28445CED ASSY FRONT PILLAR INNER LH - CED 1
28446CED ASSEMBLY A PILLAR INNER RH - CED 1
0101BN2140A FLOOR ASSEMBLY FRONT - CED * 1
(* FOR NGT - 520)
GROUP 2607 - BODY SHELL ASSEMBLY

0101BN0140A FLOOR ASSEMBLY CENTRE - CED 1


0101AK0030A FLOOR ASSEMBLY REAR - CED 1
67641CED ASSEMBLY CTR PILLAR INNER LH - CED 1
67642CED ASSEMBLY CTR PILLAR INNER RH - CED 1
98703CED ASSEMBLY BODY SIDE OUTER RH - CED 1
98704CED ASSEMBLY BODY SIDE OUTER LH - CED 1
0W34212CED PNL BODY SIDE INNER LH - CED 1
97649CED ASSY PANEL BODY SIDE INNER RH - CED 1
28768CED ASSEMBLY FRT PILLAR OUTER LH - CED 1
28769CED ASSEMBLY FRT PILLAR OUTER RH - CED 1

2607.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2607.2
GROUP 2608 - DOORS AND FITTINGS (FRONT)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 87601CED ASSEMBLY FRONT DOOR LH - CED 1
1 67540CED ASSEMBLY FRONT DOOR RH - CED 1
2 01000A0040N HINGE ASSEMBLY FRONT DOOR 4
3 6508212 LOCK WASHER SPRING M8 20
4 078993 PHILLIPS TRUS HD SCREW M8 x 1.25 - 16 20
28 0105EK0020N ARM REST ASSEMBLY FRONT RH 1
28 0105EK0030N ARM REST ASSEMBLY FRONT LH 1
29 0105EK0070N SLOTTED COUNTERSUNK TAPPING SC 4
30 SF0201047 SCREW HEX M6 x 1 - 25 8
31 01030K0040N DOOR CHECK BELT 2
32 01030K0050N REINF PLATE CHECK BELT 2
GROUP 2608 - DOORS AND FITTINGS (FRONT)

7 SF0401030 WASHER PLAIN M6 8


40 092835 ASSEMBLY TRIM PAD FRONT DOOR RH 1
40 092836 ASSEMBLY TRIM PAD FRONT DOOR LH 1
41 080559 ASSEMBLY CLIP TRIM PAD 16
46 067707 GLASS WINDOW FRONT DOOR LH 1
46 067708 GLASS WINDOW FRONT DOOR RH 1
42 067719 ASSY WEATHER STRIP FRT DOOR LH 1
42 067720 ASSY WEATHER STRIP FRT DOOR RH 1
42 0107GN0031N W/STRIP DOOR SEAL FRT DOOR LH * 1
42 0107GN0021N W/STRIP DOOR SEAL FRT DOOR RH 1
(* CUT OFF No. 32H70243 ONWARDS)
43 029200 WEATHER STRIP FRONT DOOR LH 1
43 029201 WEATHER STRIP FRONT DOOR RH 1
44 074974 GLASS RUN CHANEL FRONT DOOR 2
9 7903057013 ELASTIC WASHER M6 16
10 6106208 PLAIN WASHER M6 16
11 7903001681 SCREW HM 6 x 1.00 - 10 16
55 067515 ASSY RET GLASS RUN CHNL BOT RR RH 1
55 067516 ASSY RET GLASS RUN CHNL BOT RR LH 1
56 067509 ASSY RET GLASS RUN CHNL BOT FRT LH 1
56 067510 ASSY RET GLASS RUN CHNL BOT FRT RH 1
57 059274 CLIP TRIM WEATHER STRIP 72
58 SF0402029 WASHER SPRING M6 8

2608.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2608.2
#
GROUP 2608 - DOORS AND FITTINGS (FRONT) GROUP 2608 - DOORS AND FITTINGS (FRONT)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
5 087757 ASSEMBLY LOCK DOOR FRONT LH 1
5 087758 ASSEMBLY LOCK DOOR FRONT RH 1
6 0114DG0540N SCREW CSK PH X-RECESS M/ENCAP 8 6
7 6106208 PLAIN WASHER M6 6
8 0114DN0020N DOOR HANDLE INNER ASSEMBLY RH 1
8 0114DN0030N DOOR HANDLE INNER ASSEMBLY LH 1
9 7903057013 ELASTIC WASHER M6 6
10 6106208 PLAIN WASHER M6 4
11 7903001681 SCREW HEX HD M6 x 1 - 16 6
12 067715 COVER HANDLE INNER LH 1
12 067716 COVER HANDLE INNER RH 1
13 3206202 SCREW SLOTTED C/SUNK M6 x 1 -10 2
14 039751 CLIP ATTACH DOOR LOCK LINK 4
15 067938 ASSEMBLY HANDLE DOOR OUTER LH 1
15 067953 ASSEMBLY HANDLE DOOR OUTER RH 1
16 6306208 WASHER INT TOOTH M6 4
17 5106206 NUT HEX M6 x 1 4
18 039855 CLIP SNAP LINK DOOR LOCK 2
19 039856 PIN, LINK DOOR LOCK HANDLE 2
24 039780 SPACER DOOR STRIKER 2
25 039779 ASSEMBLY DOOR STRIKER 2
26 6608212 WASHER EXT TOOTH C/S M8 4
27 3208204 SCREW C/S SLTD M8 x 1.25 - 16 4
33 069111 ASSEMBLY LOCK CYLINDER LH 1
33 069112 ASSEMBLY LOCK CYLINDER RH 1
34 068492 CLIP RET LOCK CYLINDER 3
35 039751 CLIP ATTACH DOOR LOCK RING 4
36 088249 LINK KEY CYLINDER TO DOOR LOCK RH 1
36 088250 LINK LOCK CYLINDER TO DOOR LOCK LH 1
37 068409 CLIP ATTACH FRONT DOOR LOCK LINK 4
38 080143 LINK LOCK FRONT DOOR RET INNER LH 1
38 080144 LINK LOCK FRONT DOOR RET INNER RH 1
39 080145 LINK LOCK FRONT DOOR RET INNER LH 1
39 080146 LINK LOCK FRONT DOOR RET INNER RH 1

2608.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2608.4
GROUP 2608 - DOORS AND FITTINGS (FRONT)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
47 080004 ASSY WINDOW REGULATOR FRT DR LH 1
47 080005 ASSY WINDOW REGULATOR FRT DR RH 1
48 074553 ASSY BOTTOM CHANEL WINDOW REG RH 1
48 074554 ASSY BOTTOM CHANEL WINDOW REG LH 1
49 039742 WEATHER STRIP, GLASS BOTTOM CHNL 4
50 0105FN0012N REVEAL MOULDING ASSY FRONT DOOR 4
51 034365 CLIP BEADING 24
52 039744 ESCUTCHEON HANDLE WINDOW REG 2
53 039743 HANDLE WINDOW REGULATOR 2
54 3205204 SCREW C/S SLTD M5 x 8 - 12 2
9 7903057013 ELASTIC WASHER M6 12
GROUP 2608 - DOORS AND FITTINGS (FRONT)

10 6106208 PLAIN WASHER M6 12


11 7903001681 SCREW HEX HD M6 x 1 - 10 12

2608.5 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2608.6
GROUP 2609 - DOORS AND FITTINGS (REAR)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 99301CED ASSEMBLY REAR DOOR LH - CED 1
1 99303CED ASSEMBLY REAR DOOR RH - CED 1
2 01000A0050N HINGE ASSEMBLY REAR DOOR 4
3 6508212 LOCK WASHER SPRING M8 24
4 078993 PHILLIPS TRUS HD SCREW M8 x 1.25 - 16 24
28 0105EK0020N ARM REST ASSEMBLY REAR RH 1
28 0105EK0030N ARM REST ASSEMBLY REAR LH 1
29 01030K0040N DOOR CHECK BELT 2
30 01030K0050N REINF PLATE CHECK BELT 2
31 SF0201047 SCREW HEX M6 x 1 - 25 4
7 SF0401030 WASHER PLAIN M6 4
GROUP 2609 - DOORS AND FITTINGS (REAR)

32 0105EK0070N SLOTTED COUNTERSUNK TAPPING SC 4


35 092833 ASSEMBLY TRIM PAD FRONT DOOR RH 1
35 092834 ASSEMBLY TRIM PAD FRONT DOOR LH 1
36 080559 ASSEMBLY CLIP TRIM PAD 16
38 067828 GLASS QUARTER REAR DOOR LH 1
38 067827 GLASS QUARTER REAR DOOR RH 1
39 099315 W/STRIP QUARTER GLASS REAR DOOR 2
40 099328 GLASS RUN CHANEL REAR DOOR FRONT 2
41 029203 WEATHER STRIP REAR DOOR LH 1
41 029202 WEATHER STRIP REAR DOOR RH 1
42 067741 WEATHER STRIP REAR DOOR 2
42 0107GN0011N W/STRIP DOOR SEAL REAR DOOR * 2
(* CUT OFF No. 32H70243 ONWARDS)
52 067517 ASSY RET GLASS RUN CHAN RR BOT RH 1
52 067518 ASSY RET GLASS RUN CHAN RR BOT LH 1
53 SF0211001 SCREW M4 4
54 067914 BRKT RETAINER GLASS RUN CHNL 2
9 7903057013 ELASTIC WASHER M6 2
11 7903001681 SCREW HEX M6 x 1 -10 2
55 099326 ASSY RET GLASS RUN CHAN RR CTR RH 1
55 099327 ASSY RET GLASS RUN CHAN RR CTR LH 1
9 7903057013 ELASTIC WASHER M6 4
11 7903001681 SCREW HEX M6 x 1 - 10 4
45 067734 GLASS, WINDOW REAR DOOR 2
56 SF0402029 WASHER SPRING M6 4

2609.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2609.2
#
GROUP 2609 - DOORS AND FITTINGS (REAR) GROUP 2609 - DOORS AND FITTINGS (REAR)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
5 087759 LATCH ASSEMBLY REAR DOOR LH 1
5 087760 LATCH ASSEMBLY REAR DOOR RH 1
6 0114DG0540N SCREW CSK PH X-RECESS M/ENCAP 8 6
7 6106208 PLAIN WASHER M6 6
8 0114DN0020N DOOR HANDLE INNER ASSEMBLY RH 1
8 0114DN0030N DOOR HANDLE INNER ASSEMBLY LH 1
9 7903057013 ELASTIC WASHER M6 6
10 6106208 PLAIN WASHER M6 6
11 3106226 SCR HEX HD M6 x 1 - 16 6
12 067715 COVER HANDLE INNER LH 1
12 067716 COVER HANDLE INNER RH 1
13 3206202 SCREW SLOTTED C/SUNK M6 x 1 - 10 2
14 039751 CLIP ATTACH DOOR LOCK LINK 2
15 067938 ASSEMBLY HANDLE DOOR OUTER LH 1
15 067953 ASSEMBLY HANDLE DOOR OUTER RH 1
16 6306208 WASHER INTERNAL TOOTH M6 4
17 5106206 NUT HEX M6 x 1 4
18 039855 CLIP SNAP LINK DOOR LOCK 4
19 039856 PIN, LINK DOOR LOCK HANDLE 2
24 039780 SPACER DOOR STRIKER 2
25 039779 ASSEMBLY DOOR STRIKER 2
26 6608212 WASHER EXT TOOTH C/S M8 4
27 3208204 SCREW C/S SLTD M8 x 1.25 - 16 4
33 080143 LINK LOCK FRONT DOOR RET INNER LH 1
33 080144 LINK LOCK FRONT DOOR RET INNER RH 1
34 080145 LINK LOCK FRONT DOOR RET INNER LH 1
34 080146 LINK LOCK FRONT DOOR RET INNER RH 1
37 039751 CLIP ATTACH DOOR LOCK LINK 2

2609.3 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2609.4
GROUP 2609 - DOORS AND FITTINGS (REAR)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
43 039743 HANDLE WINDOW REGULATOR 2
44 3205204 SCREW C/S SLTD M5 x 0.8 - 12 2
46 039744 ESCUTCHEON HANDLE WINDOW REG 2
47 067731 ASSY WINDOW REGULATOR LH (RR DR) 1
47 067732 ASSY WINDOW REGULATOR RH (RR DR) 1
48 034365 CLIP BEADING 20
49 039742 WEATHER STRIP, GLASS BOTTOM CHNL 4
50 0105FN0042N REVEAL MOULDING ASSY REAR DR OTR 2
50 0105FN0052N REVEAL MOULDING ASSY REAR DR INR 2
51 067783 ASSY BOTTOM CHNL RR WINDOW REG RH 1
51 067784 ASSY BOTTOM CHNL RR WINDOW REG LH 1
GROUP 2609 - DOORS AND FITTINGS (REAR)

2609.5 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2609.6
GROUP 2610 - BACK DOOR AND FITTINGS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 99307CED ASSEMBLY BACK DOOR WELDING - CED 1
5 7903055007 SPRING LOCKWASHER M10 6
8 088399 W/STRIP BACK DOOR FIXED GLASS 1
9 088317 GLASS BACK DOOR 1
11 067742 W/STRIP DOOR SEAL BACK DOOR 1
23 097697 ASSEMBLY SPARE TYRE ATT BRACKET 1
24 097882 WHEEL NUT M14 3
25 097702 VIBRATION DAMPNER UPPER 25mm 2
26 098929 VIBRATION DAMPNER 35mm 1
27 3108212 SCREW HEX HD M8 x 1.25 - 35 1
28 G446363 PLAIN WASHER G9.25mm ID (3/8") 3
29 097698 SPACER WHEEL BRACKET 2
35 074355 SCREW HEX HEAD 6
59 088265 COVER BACK DOOR HANDLE 1
67 3108210 SCREW HEX HD M8 x 1.25 - 30 2

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2610.1
#
GROUP 2610 - BACK DOOR AND FITTINGS GROUP 2610 - BACK DOOR AND FITTINGS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
19 039779 ASSEMBLY DOOR STRIKER 1
20 039780 SPACER DOOR STRIKER 1
21 3208204 SCREW C/S SLTD M8 x 1.25 - 16 2
22 6608212 WASHER EXT TOOTH C/S M8 2
39 087761 LATCH ASSEMBLY BACK DOOR 1
41 6608212 WASHER EXT TOOTH C/S M8 3
42 067773 ASSEMBLY HANDLE DOOR INNER RH 1
14 3106206 SCREW HEX HD M6 x 1 - 16 3
15 7903057013 ELASTIC WASHER M6 3
43 067716 COVER INNER HANDLE 1
44 3206202 SCREW SLOTTED C/SUNK HD M6 x 1 - 10 1
45 039751 CLIP ATTACH DOOR LOCK LINK 2
46 088339 BACK DOOR HANDLE OUTER 1
47 5106206 NUT HEX M6 x 1 3
52 5306204 NYLOC NUT M6 1
53 069111 ASSEMBLY KEY & LOCK CYLINDER LH 1
54 068492 CLIP LOCK CYLINDER 1
55 088248 LINK KEY CYLINDER TO DOOR LOCK ASSY 1
56 068409 CLIP RETAINER DOOR LOCK LINK 2
57 069214 BACK DOOR LOCK LINK 1
58 088261 BACK DOOR LOCK LINK INNER 1

2610.2 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2610.3
#
GROUP 2610 - BACK DOOR AND FITTINGS GROUP 2610 - BACK DOOR AND FITTINGS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
2 097551 ASSEMBLY HINGE BACK DOOR UPPER 1
3 097550 ASSEMBLY HINGE BACK DOOR LOWER 1
4 7903201047 SCREW HEX M10 x 1.5 - 30 13
5 7903055007 SPRING LOCKWASHER M10 13
6 098644 SOCKET CSK SCREW M10 x 1.5 - 30 3
7 G138479 LOCKWASHER EXTN M10 3
12 060469 WEDGE MALE 1
13 068301 SHIM WEDGE 1
14 3106226 SCREW HEX HD M6 x 1 - 16 2
15 7903057013 ELASTIC WASHER M6 2
16 6106208 PLAIN WASHER M6 2
17 060468 WEDGE FEMALE 1
18 060472 SPACER WEDGE BACK DOOR 1
30 028297 ASSEMBLY DOOR CHECK ARM 1
31 662407 PIN DOOR CHECK ARM 1
32 099317 GROMMET BACK DOOR WIRING 1
33 068413 PLUG PLASTIC HINGE HOLES 2
34 087986 ASSEMBLY BACK DOOR TRIM PAD 1
36 080559 ASSEMBLY TRIM PAD CLIP 14
37 0105CN0140N GRIP HANDLE BEIGE 1
38 089941 SCREW DOOR HANLE INNER 2
60 074141 RUBBER BUTTON DOOR REST 1
61 028284 BACK DOOR SUPPORT TOP 1
62 028285 BACK DOOR SUPPORT BOTTOM 1
63 0114DG0540N SCREW CSK PH X-RECESS M/ ENCAP 8 2
64 6120423 LOCK WASHER TH G6.35mm (1/4") 2
65 3306208 SCREW SLTD PAN HD M6 x 1 - 16 2
66 6506208 WASHER SPRING M6 2

2610.4 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2610.5
GROUP 2611 - BODY TRIMMING

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 028414 WIND SHIELD GLASS FRONT 1
2 028415 WEATHER STRIP WIND STRIP GLASS 1
3 01090F0010N MIRROR REAR VIEW 1
3 0109AF0011N MIRROR ASSY REAR VIEW INSIDE (OPT) 1
4 0114DG0540N SCREW C/S SLTD M5 x 0.8 - 12 8
5 0108FN0170A SPARE WHEEL COVER HARD 1
5 0108FN0170B SPARE WHEEL COVER HARD 1
5 0108FN0170C SPARE WHEEL COVER HARD 1
5 0108FN0170D SPARE WHEEL COVER HARD 1
5 0108FN0170E SPARE WHEEL COVER HARD 1
5 0108FN0170F SPARE WHEEL COVER HARD 1
6 088631 REAR VIEW MIRROR RH 1
6 0109BK0020A REAR VIEW MIRROR RH (OPTIONAL) 1
6 088630 REAR VIEW MIRROR LH 1
GROUP 2611 - BODY TRIMMING

6 0109BK0030A REAR VIEW MIRROR LH (OPTIONAL) 1


7 059785 SCREW PAN HD SLTD M6 x 1 - 14 4
8 0105DF0010N ASSEMBLY SUNVISOR LH (W/O MIRROR) 1
8 028454 ASSEMBLY SUNVISOR RH 1
9 028431 RETAINER SUNVISOR 2
10 0105CN0140N GRIP HANDLE BEIGE 3
11 089941 SCREW DOOR HANDLE INNER 6
12 088543 ASSEMBLY WINDOW SLIDING LH 1
12 088544 ASSEMBLY WINDOW SLIDING RH 1
13 067833 W/STRIP BODY SIDE WINDW REAR LH 1
13 067834 W/STRIP BODY SIDE WINDW REAR RH 1
14 067835 W/S FILLER SIDE GLASS 2
15 087990 ASSY TRIM PAD BODY SIDE LH 1
15 087989 ASSY TRIM PAD PNL BODY SIDE INNER RH 1
16 080559 ASSY TRIM PAD CLIP 8
17 067881 ASSY VENTILATOR COVER LH 1
17 067882 ASSY VENTILATOR COVER RH 1
18 0108BK0120N MAHINDRA LOGO 1
19 0001AN0031N DECAL DI TURBO 2
20 0114DG0540N SCREW CSK PH X-RECESS M/ ENCAP 8 6
0108EK0330A KIT CLADDING ASSY(BLACK PIGMENTED)
CONSIST OF :
0108EK0340A 2 - CLADDING ASSY FENDER FRONT
0108EK0350A 2 - CLADDING ASSY COWL SIDE
0108EK0360A 2 - CLADDING ASSY FRONT DOOR
0108EK0370A 2 - CLADDING ASSY 'B' PILLAR
0108EK0380A 2 - CLADDING ASSY REAR DOOR
0108EK0390A 2 - CLADDING ASSY BODY SIDE REAR
0108EK0400A 2 - CLADDING ASSY BACK DOOR SIDE

2611.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2611.2
GROUP 2612 - PLATES AND COVERS (2WD) GROUP 2612 - PLATES AND COVERS (2WD)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
FOR NGT 520 TRANSMISSION
0105AK1530N TRANSMISSION COVER ASSEMBLY 2WD 1
1 029887 GROMMET COVER TRANSMISSION 1
2 097588 PLATE RETAINER (GROMMET TRANS) 1
3 0105AK1540N COVER TRANSMISSION FLOOR 1
4 0105AN1170N RUBBER SEALING TRANSMISSION COVER 1
5 3306210 SCREW SLTD PAN HD M6 x 1 - 20 4
6 6506208 WASHER SPRING M6 4
7 5106206 NUT HEX M6 x 1 4
8 3306206 SCREW SLTD PAN HD M6 x 1 - 14 6
9 6306208 WASHER INTERNAL TOOTH L M6 6
10 6106208 PLAIN WASHER M6 6
11 059268 COVER REAR FLOOR PANEL 1

2612.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2612.2
GROUP 2613 - DRIVER SEAT GROUP 2614 - FRONT PASSENGER SEAT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0110AK0100N DRIVER SEAT ASSEMBLY 1 1 0110AN0031N SEAT ASSEMBLY CO-DRIVER (7 STR) 1
1 0110AK0350N DRIVER SEAT ASSEMBLY (8 STR, IFS) 1 1 0110AK0360N SEAT ASSEMBLY CO-DRIVER (8 STR, IFS) 1
2 074355 SCREW HEX HEAD 4 1 0110AK0110N SEAT ASSEMBLY CO-DRIVER (8 STR) 1
2 01100K0030N SCREW HEX HEAD (8 STR, IFS) 1 2 074355 SCREW HEX HEAD 4
3 01100A0020N SPRING LOCK WASHER M10 4 3 01100A0020N SPRING LOCK WASHER M10 4
4 01100A0010N PLAIN WASHER M10 4 4 01100A0010N PLAIN WASHER M10 4
5 0110AK0180N HEAD REST 1 5 0110AK0180N HEAD REST 1
6 0110AK0130N RECLINER ASSEMBLY RH 1 6 0110AK0140N RECLINER ASSEMBLY RH 1
7 0110AK0230N SLIDER ASSEMBLY ACTIVE 1 7 0110AK0230N SLIDER ASSEMBLY ACTIVE 1
8 0110AK0250N SLIDER ASSEMBLY PASSIVE 1 8 0110AK0250N SLIDER ASSEMBLY PASSIVE 1

2613.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2614.1
GROUP 2615 - MIDDLE PASSENGER SEAT GROUP 2616 - SIDE PASSENGER SEAT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0110FK0020N SEAT ASSEMBLY MIDDLE 1 1 0110DK0040N SIDE SEAT ASSEMBLY RH 1
1 0110CK0100N SEAT ASSEMBLY MIDDLE ( 8 STR, IFS ) 1 1 0110DK0050N SIDE SEAT ASSEMBLY LH 1
2 074355 SCREW HEX HEAD 4 2 2108262 BOLT HEX HD M8 x 1.25 - 40 * 2
3 01100A0020N SPRING LOCK WASHER M10 4 2 3108228 SCREW HEX HD M8 x 1.25 - 30 6
4 01100A0010N PLAIN WASHER M10 4 3 6508212 LOCKWASHER SPRING M8 8
4 6108212 WASHER PLAIN M8 8
5 031670 VIBRATION DAMPER SIDE SEAT LEG 2
( * FOR 7 AND 8 SEATER, RIGID ONLY)
1 0110EK0140N SEAT ASSEMBLY SIDE RH 1
1 0110EK0150N SEAT ASSEMBLY SIDE LH 1
2 3108214 SCREW HEX HD M8 x 1.25 - 40 * 8
3 6508212 LOCK WASHER SPRING M8 8
4 6108212 WASHER PLAIN M8 8
5 031670 VIBRATION DAMPER SIDE SEAT LEG 2
( * FOR 8 SEATER, IFS ONLY)

2615.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2616.1
GROUP 2617A - FRONT BUMPER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0119AF0070D BUMPER ASSEMBLY FRONT 1
BLACK POWDER COATED
1 028401 BUMPER ASSEMBLY FRONT JVC GREY 1
1 01190A0060P BUMPER ASSEMBLY FRONT 1
BLACK POWDER COATED
2 028572 BRACKET BUMPER MOUNTING LH 1
2 028573 BRACKET BUMPER MOUNTING RH 1
3 G120388 WASHER PLAIN G11.11mm ID (7/16") 6
4 6510214 LOCKWASHER SPRING M10 6
5 7903201045 BOLT HEX HD M10 x 1.5 - 20 6
6 5108206 NUT HEX M8 x 1.25 2
7 2308204 CAP HD SQ NK BLOT M8 x 1.25 - 20 2
8 6108212 WASHER PLAIN M8 2
9 6508212 LOCKWASHER SPRING M8 2
GROUP 2617A - FRONT BUMPER

2617A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2617A.2
GROUP 2617B - REAR BUMPER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0119BK0490N BUMPER ASSEMBLY REAR RH 1
2 089434 ASSY REAR BUMPER WITH MTG BRKT LH 1
3 0119BK0060N BUMPER CORNER REAR RH 1
4 0119BK0070N BUMPER CORNER REAR LH 1
5 G126373 BOLT CARRIAGE G7.93 x 38.1mm 2
(5/16" - 18 x 1 - 1/2")
6 G446363 PLAIN WASHER G9.25mm ID (3/8") 4
7 G120214 SPRING LOCK WASHER 5/16" 8
8 G120376 NUT HEX G7.93 - 18 (5/16") 2
9 2308204 CAP HD SQ NK BOLT M8 x 1.25 - 20 4
10 5108206 NUT HEX M8 x 1.25 6
11 3108224 SCREW HEX HD M8 x 1.25 - 20 12
12 6508212 LOCK WASHER SPRING M8 16
13 6108212 WASHER PLAIN M8 16
GROUP 2617B - REAR BUMPER

14 0119BA0010N TIE ROD X MEMBER TO REAR BUMPER 2

2617B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2617B.2
#
GROUP 2618A - FENDER EXTENSION GROUP 2618A - FENDER EXTENSION

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0108BN0040B FRT FENDER EXTENSION RH BLACK (PU) 1
1 0108BN0050B FRT FENDER EXTENSION LH BLACK (PU) 1
2 G159947 SCREW PAN HD M/C M10 - 24 x 19mm (3/4") 10
3 G120391 WASHER PLAIN M10 10
4 G120392 PLAIN WASHER G6.35mm (1/4") 10
5 G120361 NUT HEX M10 - 24 10
6 0108BK0340N MUD FLAP FRONT FENDER RH 1
6 0108BK0350N MUD FLAP FRONT FENDER LH 1
7 3106226 SCREW HEX HD M6 x 1 - 16 4
8 G120380 LOCK WASHER SPRING G6.35mm (1/4") 4
9 099488 SPECIAL WASHER 4

2618A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2618A.2
#
GROUP 2618B - REAR WHEEL ARCH AND MUD FLAP GROUP 2618B - REAR WHEEL ARCH AND MUD FLAP

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
1 0108EA0040B WHEEL ARCH EXTENSION RH 1
1 0108EA0050B WHEEL ARCH EXTENSION LH 1
2 G159947 SCREW PAN HD M/C M10 - 24 x 19mm (3/4") 6
3 G120391 WASHER PLAIN M10 6
4 G138479 LOCKWASHER EXTERNAL TOOTH M10 6
5 G120361 NUT HEX M10 6
6 0108FK0260N MUD FLAP WHEEL ARCH RH 1
6 0108FK0270N MUD FLAP WHEEL ARCH LH 1
7 G162009 PAN HEAD CROSS REC TPG SCR M12 4
8 099488 SPECIAL WASHER, ACC CABLE 4
9 0108FK0280N MUD FLAP WHEEL ARCH FRONT RH 1
9 0108FK0290N MUD FLAP WHEEL ARCH FRONT LH 1
10 2106250 BOLT HEX HD M6 x 1 - 25 4
11 099488 SPECIAL WASHER 8
12 G120380 LOCK WASHER SPRING G6.35mm (1/4") 4
13 5106206 NUT HEX M6 x 1.0 4

2618B.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2618B.2
GROUP 2618C - ORNAMENTS GROUP 2619 - TOOLS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0108EK0180N BADGING 'BOLERO' 2 0002BA0010N TOOL KIT 1
CONSISTS OF :
1 088838 1 - SCREW JACK ASSY
2 0002BA0040N 1 - D E O SPANNER 12mm x 13mm
3 0002BA0030N 1 - D E O SPANNER 8mm x 10mm
4 094815 1 - SLIP JOINT PLIER
5 0002BA0050N 1 - SCREW DRIVER
6 0002BA0020N 1 - BAG TOOL KIT
7 094813 WHEEL WRENCH 21mm 1

2618C.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2619.1
#
GROUP 2620 - FLOOR TRIMMING

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV


PART NO.
0105AN1271N FLOOR MATTING - 2WD (7S) 1
0105AN0990N KIT FLOOR MATTING - 4WD 1
0105AN0512N KIT FLOOR MATTING - 2WD (8S) 1
0105AN0511N KIT FLOOR MATTING - 2WD (OPTIONAL) 1
0105AN0531N FLOOR MATTING FRONT LH 1
0105AN0831N FLOOR MATTING FRONT RH 1
0105AN0561N FLOOR MATTING REAR FLOOR FRONT 1
0105AN0571N FLOOR MATTING REAR FLOOR REAR 1
0105AN0861N FLOOR MATTING CENTER FLOOR 1
0105AN0841N FLOOR MATTING T/M COVER (2WD) 1
0105AK1120N KIT, CARPET MOULDED 1
0105CN0160N KIT, UPHOLSTERY 1
01060K0450N ANTI VIBRATION PAD DASH PANEL 3
01060K0500N ANTI VIBRATION PAD SMALL 3
01060K0750N KIT FELT 1
0105AN1291A - 2WDFLOOR
(8S) MATTING - 2WD (8S) 1

BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2620.1
GROUP 2621A - SEAT BELT DRIVER & CO-DRIVER GROUP 2621C - SEAT BELT MIDDLE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0105AK0800N KIT, SEAT BELT W/O SWITCH (7 SEATER) 2 1 0120AN0061N SEAT BELT ASSY REAR STATIC (GRAY) 1
1 0105AK0801N KIT, SEAT BELT W/O SWITCH (OPT) 2 1 0120AN0062N SEAT BELT ASSY REAR STATIC (OPT) 1
1 080383 KIT SEAT BELT ASSEMBLY (8 SEATER) 1
2 0107FA0010N PLUG SEAT BELT 1

2621A.1 BOLERO RHD DIESEL MDI TC 3200 2WD VER 1 FEB - 2005 2621C.1

You might also like