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Mahindra Bolero City Pikup Manual M2dicr d25 Bs6
Mahindra Bolero City Pikup Manual M2dicr d25 Bs6
Mahindra Bolero City Pikup Manual M2dicr d25 Bs6
MAN-00888
MAINTENANCE MANUAL
BOLERO CITY PIKUP
m2DICR D25 BS6
Revision — 1
MAY - 2020
Published by — Service Engineering
Technical Hub
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Table of Content
1 About the Maintenance Manual.................................................................................................. 5
2 Maintenance Schedule ............................................................................................................... 10
3 Lubrication Chart ......................................................................................................................... 12
4 Maintenance Parts List............................................................................................................... 14
5 779-MAT-0010 Engine Oil Level - Inspect / 0.02 HRS ......................................................... 15
6 779-MAT-0020 / Engine Oil - Replace / 0.23 HRS .................................................................. 18
7 779-MAT-0030 / Engine Oil Filter - Replace / 0.08 HRS ...................................................... 25
8 779-MAT-0040 / Valve Clearance - Check & Adjust / 0.5 HRS .......................................... 28
9 779-MAT-0050 / Accessory Drive Belts - Inspect / 0.05 HRS ............................................ 35
10 779-MAT-0070 / Accessory Drive Belts - Replace / 0.16 HRS ........................................ 49
11 779-MAT-0090 / Coolant - Inspect / 0.03 HRS ...................................................................... 55
12 779-MAT-0100 / Coolant - Replace / 0.42 HRS .................................................................... 59
13 779-MAT-0110 / Air Filter Element - Clean / 0.15 HRS ....................................................... 63
14 779-MAT-0120 / Air Filter Element - Replace / 0.1 HRS..................................................... 67
15 779-MAT-0140 / Fuel Filter Element - Replace / 0.2 HRS .................................................. 70
16 779-MAT-0150 / Water In Fuel Filter - Clean / 0.05 HRS .................................................... 75
17 779-MAT-0230 / Exhaust Pipe Mountings & Damage / Leakage - Inspect / 0.05
HRS ........................................................................................................................................ 77
18 779-MAT-0260 / Transmission Oil - Replace / 0.18 HRS ................................................... 80
19 779-MAT-0340 / Rear Axle Oil - REPLACE / 0.18 HRS ....................................................... 83
20 779-MAT-0370 / Brake & Clutch Fluid Level And Leak - Inspect / 0.05 HRS................ 86
21 779-MAT-0390 / Brake & Clutch Fluid - Replace / 0.6 HRS............................................... 91
22 779-MAT-0430 / Front Brake Pads/ Calipers - Inspect / 0.38 HRS ................................101
23 779-MAT-0440 / Rear Brake Drum And Lining - Inspect / 0.38 HRS ............................107
24 779-MAT-0450 / Parking Brake Operation - Inspect / 0.13 HRS .................................... 110
25 779-MAT-0470 / Suspension Bushes / Arms & Links - Inspect / 0.1 HRS .................. 112
26 779-MAT-0500 / Power Steering Fluid Level - Inspect / 0.03 HRS ................................ 116
27 779-MAT-0510 / Wheel Alignment / 0.4 HRS ...................................................................... 118
28 779-MAT-0520 / Tyre Rotation / 0.25 HRS...........................................................................125
29 779-MAT-0550 / Battery Health Checkup / 0.1 HRS .........................................................126
30 779-MAT-0560 / All Lights, Horns, Wipers And Washers - Check / 0.03 HRS ...........131
31 779-MAT-0570 / Head Lamp Aiming - Check & Adjust / 0.2 HRS..................................138
32 779-MAT-0610 / Tyre Pressure - Check And Adjust / 0.15 HRS ....................................140
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Page 3
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the
Page 4 present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre
of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• The maintenance manual outlines the correct standard operating procedures (SOPs) for
carrying out maintenance operations in a Mahindra BOLERO CITY PIKUP vehicle.
• Carrying out the specified periodic maintenance operations, is crucial for safe and trouble-
free operation of the vehicle.
• The recommended maintenance schedule/ operations are published in the owner’s
handbook.
• This manual covers the correct method of carrying out the maintenance operations, using
the correct process/procedures, tools, parts and lubricants. The manual consists of
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 5
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. All visible components in an illustration are shown Light Bluish Green in colour.
2. Main component to be attended for removal or refit are shown in Saffron Red colour.
3. The fasteners and component’s which needs to removed before removing the main
component is shown in Dark Green colour.
4. The special tools/ spanners used to remove or refit are shown in Puce/ Purple brown
colour.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 6 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1.5.3 Safety
1. When working with 2 or more persons, be sure to check safety for one another.
2. When working with engine running, make sure to provide ventilation for exhaust fumes in
the workshop.
3. If working on high temperature, high pressure, rotating, moving or vibrating parts, you
should wear appropriate safety gear and take extra care not to injure yourself or others.
4. When jacking up the vehicle, be sure to support the specified location with a safety
stand.
5. When lifting up the vehicle, use appropriate safety equipment.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 7
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 8 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Symbol Denotation
Locate/ Show
Move/ Fit
Turn Clockwise
Turn anti-clockwise
Inspection
Wrong practice
Right Practice
LOCTITE
LOCTITE
0000 Sealant Application
Assembly Sequence
Torque Tightening
Tightening Sequence
SOAP
SOLUTION
Lubrication Symbol (Soap oil)
OIL
Lubrication Symbol (oil)
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 9
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
2 Maintenance Schedule
779 — BOLERO CITY PIK-UP
Distance Covered in km x 1000
FREE
MAINTENANCE ITEM PAID SERVICE
CHANGE INTERVAL SERVICE
10 20 30 40 50 60 70 80 90 100
Engine
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 10 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Legends
I =Inspect / correct, Replace if worn out / faulty R = Replace C =Clean
A = Adjust as Necessary * - On chargeable basis
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 11
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
3 Lubrication Chart
Ca-
System paci- Specifi-
Lubricant Remarks
ty cation
Manual MAHINDRA
"MAXIMILE 0.6 Special Manual Transmission Fluid
Steering
SYNCHRO UV2" liters
Oil NEW GENERATION GENUINE TRANSMISSION OIL
MAHINDRA
In case of non-availability of Genuine fluid,
Power "MAXIMILE POWER
0.8 SHELL MAKE "SPIRAX S3 ATF MD3" / CALTEX
Steering STEERING FLUID"
liters MAKE "TEXAMATIC 1888" can be used. NO
Oil GENUINE POWER
OTHER BRANDS RECOMMENDED
STEERING FLUID
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 12 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 13
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Verify part numbers with electronics parts catalogue before placing the order.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 14 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
1. Position the vehicle on a flat level surface.
2. Stop the engine.
3. Unlatch and lift the hood to access the engine oil dipstick.
Engine Oil Level - Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 15
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Engine oil should be checked cold or 4. Pull out the dip stick slowly and check for
allow time for the oil to drain back into pan the oil level mark between Maximum and
before checking to prevent overfilling. Minimum level - if found below minimum
level, top up with recommended oil.
2. Pull out the dip stick gauge and wipe it
dry with a clean cloth.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 16 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 17
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
22 mm Ring spanner 01
— Tray 01
Preliminary Activities/Conditions
• Position the Vehicle on a flat level surface.
• Place the gear selector in neutral and set the parking brake.
• Run the engine for two to three minutes until warm. Stop the engine.
• Check for the oil level, which should be in between the MAX & MIN level.
Engine Oil Replacement
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 18 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 19
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. The sealing surfaces on drain plug and 5. Open the oil fill cap.
crankcase should be clean and free of burrs,
nicks or scratches.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 20 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Always use "MAXMILE ULTRA" genuine engine oil. This is specially developed for
BS VI vehicle engine’s optimum performance and fuel efficiency.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 21
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
1. Position the vehicle on a flat level surface.
2. Stop the engine.
3. Unlatch and lift the hood to access the engine oil dipstick.
Engine Oil Level - Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 22 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Engine oil should be checked cold or 4. Pull out the dip stick slowly and check for
allow time for the oil to drain back into pan the oil level mark between Maximum and
before checking to prevent overfilling. Minimum level - if found below minimum
level, top up with recommended oil.
2. Pull out the dip stick gauge and wipe it
dry with a clean cloth.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 23
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 24 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
Preliminary Activities/Conditions
• Place the vehicle on a 2 post lift.
• Open the Hood.
Engine Oil filter Replacement
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 25
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 26 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Using a clean dry cloth, clean the filter 5. Check the engine oil level. For additional
sealing surface on the crankcase. information refer to Engine oil level
inspection section.
2. Lubricate the O-ring on the new filter with
a film of fresh engine oil. Check to make sure 6. Start the engine and check for Oil
the o-ring is in good condition. leakage/ seepage at:
• Oil filter joint.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 27
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 28 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 29
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Bring no. 1 piston at TDC. 3. Adjust the tappet clearance of 1st/ 2nd/
4th /6th valves, as per procedure mentioned
2. For bring no. 1 piston at TDC, match the below.
pointer to Damper pulley white marking and Serial no’s starting from front side of
Ensure no 4 cylinder rockers at dancing engine.
/rocking position.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 30 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 31
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• The engine should be turned only in the direction of rotation by using the crank
shaft pulley bolt and ensure to re-torque the pulley bolt after adjustment.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 32 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 33
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
4. Rotate the damper pulley to 180° further 7. Turn the engine 180° further in the
in the direction of engine rotation (2nd direction of engine rotation (3rd cylinder
cylinder rockers at dancing / rocking rockers at dancing / rocking position). Adjust
position). Adjust tappet of 3rd cylinder valves tappet of 2nd cylinder valves as per
as per specifications. specifications.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 34 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
• Position the vehicle on a 2 post/ 4 post lift.
• Open the bonnet.
Drive Belt (Alternator/Water Pump) - Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 35
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Causes:
Continuous exposure to high temperatures
and the stress of bending around the pulleys
leads to cracking.
Cracks begin at the rib top and grow to the
cord line. As a rule, if cracks appear 1 or 2
cm apart, 80% of the life is gone and the belt
should be replaced.
2. Chunk-Out
Appearance:
Pieces or chunks of rubber material have
come off the belt. When chunk-out has
occurred, a belt can fail at any moment. Belt
should be replaced immediately.
Causes:
Chunk-out can happen when several cracks
in one area move parallel to the cord line.
Heat, age and stress are the primary
contributors.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 36 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
3. Pilling
Appearance:
Belt material wears off from the ribs and
builds up in the belts grooves.
Causes:
There are a number of causes, including
misalignment, new belt on worn pulleys, lack
of tension or a combination of these factors.
4. Gravel Penetration
Appearance:
Small pinholes are visible on the backside of
the belt. Bumps may be visible and fabric
around the holes can be frayed.
Causes:
Granular gravel or pebble gravel is wedged
between the belt groove (s) and pulley ridge
(s).
Causes:
Pulley misalignment is a common cause of
premature belt failure. Misalignment forces
the belt to twist while running, causing
premature wear.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 37
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
6. Oil Contamination
Appearance:
The belt surface is flaky, sticky or swollen.
Causes:
Oil and grease are a rubber compound’s
worst enemies, weakening the compound’s
bonds and making the belt soft and spongy.
Eventually, such a belt will slip, create heat
and fail.
7. Abrasion
Appearance:
The backside of the belt appears very shiny
or glazed. In advance stages, the fabric or
even the cord becomes exposed and gets
damaged.
Causes:
When in motion, the belt makes contact with
the foreign objects in its path such as a
flange or bolt. This may be caused by
improper belt tension or by belt flutter
(vibrations) on longer span lengths between
two pulleys.
8. Rib Separation
Appearance:
The belt rib shears off or begins to separate
from the belt base.
Causes:
The belt is not correctly positioned. One of
the belt ribs is placed outside the pulley
groove, causing a belt rib to run without a
supporting or aligning pulley groove.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 38 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Causes:
A foreign object — such as a pebble — in the
pulley will cause uneven wear and cut into
the belt and break the tensile cords.
Causes:
A large foreign object between the belt and
pulley can cut into the belt and break the
tensile cords. Tensile break may occur but go
unnoticed when the belt is forced or pried on
during installation. Other possible causes
may be severe shock loads or a blocked
pulley and/or accessory.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 39
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
It is recommended to remove & check the drive belts thoroughly if any abnormality
noticed.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 40 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 41
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
• Position the vehicle on a 2 post/ 4 post lift.
• Open the bonnet.
Drive Belt (Power Steering) - Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 42 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Causes:
Continuous exposure to high temperatures
and the stress of bending around the pulleys
leads to cracking.
Cracks begin at the rib top and grow to the
cord line. As a rule, if cracks appear 1 or 2
cm apart, 80% of the life is gone and the belt
should be replaced.
2. Chunk-Out
Appearance:
Pieces or chunks of rubber material have
come off the belt. When chunk-out has
occurred, a belt can fail at any moment. Belt
should be replaced immediately.
Causes:
Chunk-out can happen when several cracks
in one area move parallel to the cord line.
Heat, age and stress are the primary
contributors.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 43
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
3. Pilling
Appearance:
Belt material wears off from the ribs and
builds up in the belts grooves.
Causes:
There are a number of causes, including
misalignment, new belt on worn pulleys, lack
of tension or a combination of these factors.
4. Gravel Penetration
Appearance:
Small pinholes are visible on the backside of
the belt. Bumps may be visible and fabric
around the holes can be frayed.
Causes:
Granular gravel or pebble gravel is wedged
between the belt groove (s) and pulley ridge
(s).
Causes:
Pulley misalignment is a common cause of
premature belt failure. Misalignment forces
the belt to twist while running, causing
premature wear.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 44 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
6. Oil Contamination
Appearance:
The belt surface is flaky, sticky or swollen.
Causes:
Oil and grease are a rubber compound’s
worst enemies, weakening the compound’s
bonds and making the belt soft and spongy.
Eventually, such a belt will slip, create heat
and fail.
7. Abrasion
Appearance:
The backside of the belt appears very shiny
or glazed. In advance stages, the fabric or
even the cord becomes exposed and gets
damaged.
Causes:
When in motion, the belt makes contact with
the foreign objects in its path such as a
flange or bolt. This may be caused by
improper belt tension or by belt flutter
(vibrations) on longer span lengths between
two pulleys.
8. Rib Separation
Appearance:
The belt rib shears off or begins to separate
from the belt base.
Causes:
The belt is not correctly positioned. One of
the belt ribs is placed outside the pulley
groove, causing a belt rib to run without a
supporting or aligning pulley groove.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 45
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Causes:
A foreign object — such as a pebble — in the
pulley will cause uneven wear and cut into
the belt and break the tensile cords.
Causes:
A large foreign object between the belt and
pulley can cut into the belt and break the
tensile cords. Tensile break may occur but go
unnoticed when the belt is forced or pried on
during installation. Other possible causes
may be severe shock loads or a blocked
pulley and/or accessory.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 46 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
It is recommended to remove & check the drive belts thoroughly if any abnormality
noticed.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 47
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 48 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
Preliminary Activities/Conditions
• Position the Vehicle on a 2/4 post lift.
• Place the gear selector in neutral and set the parking brake.
Accessory Drive Belt (Alternator/Water Pump) Replace
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 49
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
10.1.1 Removal
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 50 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
10.1.2 Installation
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 51
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
Preliminary Activities/Conditions
• Position the Vehicle on a 2/4 post lift.
• Place the gear selector in neutral and set the parking brake.
• Remove alternator belt.
Accessory drive Belt (Power Steering) Replace
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 52 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
10.2.1 Removal
1. Remove Accessory Drive Belt 4. Remove the belt from the vehicle.
(Alternator/Water Pump). For additional
information refer to Accessory Drive Belt
(Alternator/Water Pump) R&R section.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 53
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
10.2.2 Installation
1. Refit the power steering belt in place. 4. Refit Accessory Drive Belt (Alternator/
Water Pump).For additional information refer
to Accessory Drive Belt (Alternator/Water
Pump) R&R section.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 54 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 55
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Inspect the radiator pressure cap for any 4. Inspect the recovery tank outlet pipe for
damage or coolant leakage. Rectify the any coolant leakage, also check the recovery
leakage if found. tank for any damage. If found any damage or
leak, rectify.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 56 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
6. Inspect the thermostat housing outlet 8. Inspect for coolant leakage at radiator
connection for coolant leakage. Also check outlet. Also check the mounting spring band
the mounting hose clamp for any damage, clamp for any damage, replace the spring
replace the hose clamp if found damaged or band clamp if found damaged or loose.
loose.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 57
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Do not overfill the system; allow free space in the recovery tank for expansion of the
fluid.
• Do not replace the OEM radiator pressure cap with a non-standard pressure cap.
These will not allow the recovery system to function properly, causing the engine to
overheat and a limited warranty claim to be denied.
• Never remove the radiator cap when the engine is hot.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 58 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 59
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Position the Vehicle on 2 post lift/ 4 post 5. Refit the radiator drain plug back and
lift. tight it properly.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 60 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Fill the recommended coolant in radiator 3. Check coolant level in recovery tank and
up to neck level and MAX level in recovery in radiator, add coolant to MAX level.
tank by using funnel.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 61
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Use of a non-standard pressure cap will not allow the recovery system to function
properly. Mahindra dealer can provide the correct replacement part.
• Do not overfill the system; allow free space in the recovery tank for expansion of the
fluid.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 62 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 63
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The air filter element should be inspected and replaced from time to time, when driving
under the following conditions:
• Unpaved road.
• Dusty air-polluted road.
• Long-term driving in rainy weather.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 64 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 65
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Refit the air filter element gently inside 4. Close the bonnet.
the air cleaner housing.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 66 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 67
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The air filter element should be inspected and replaced from time to time, when driving
under the following conditions:
• Unpaved road.
• Dusty air-polluted road.
• Long-term driving in rainy weather.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 68 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Refit the air filter element gently inside 4. Close the bonnet.
the air cleaner housing.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 69
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
- Bench vice 01
Preliminary Activities/Conditions
• Position the vehicle on a flat surface.
• Open the bonnet.
Fuel Filter Element — Replace
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 70 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Ensure that the fuel is drained from filter assembly before the fuel filter element is
removed.
• Do not hold fuel filter body part and avoid damage to the fuel filter body.
1. Press the lock and disconnect fuel filter 3. Using a 12 mm socket spanner remove
inlet and outlet fuel lines. fuel filter assembly mounting bolts and then
gently pullout and remove the fuel filter
assembly.
All are quick fix connectors, press gently 4. Use two approx. 2– 3 inches long size
and remove it carefully; avoid damages. M12 bolts and nuts to hold fuel filter
assembly in a bench vice as shown in
2. Press the lock and disconnect the illustration.
electrical connector.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 71
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
5. Using 36 mm ring/socket spanner, rotate 8. Take out the filter element from the fuel
the fuel filter bottom cover in anti-clockwise filter housing.
direction and loosen.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 72 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Insert the filter element correctly into the 3. Tighten the filter body using 36 mm
housing. socket spanner to specified torque value.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 73
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 74 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
• Position the vehicle on a flat surface.
• Open the bonnet.
Water In Fuel Filter - Clean
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 75
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Connect the transparent pipe to the drain 4. Start the engine and check for any leaks.
plug outlet of the fuel filter assembly.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 76 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 77
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 78 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
4. Check the joint between front pipe 5. Check the joint between turbocharger
converter for leakage, if found leakage then and EATS for leakage,, if found leakage then
replace the gasket and torque tighten the replace the gasket and torque tighten the
nuts to specified value. nuts to specified value.
Torque : 25 ± 5 Nm
• Do not work when the exhaust system is hot. Failure to follow this instruction will
result in personal injury.
• Check all the exhaust joints for leakage and correct fittings. If leakage is found,
check the exhaust pipe gasket. Replace if required.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 79
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
8 mm Square bit 01
Preliminary Activities/Conditions
• Position the vehicle on a 2/4 post lift.
Transmission Oil Level & Leak Inspection & Replacement
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 80 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 81
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Clean the oil level & drain plug and 4. Tighten the oil level plug in the
surrounding area. transmission, Torque tighten the plug to
specified value.
2. Refit the drain plug. Torque tighten the
drain plug to specified value.
Torque: 47 ± 7 Nm
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 82 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
10 mm Allen Key 01
Preliminary Activities/Conditions
• Place the vehicle on a 2/4 post lift.
Rear Differential Oil Level & Leak Inspection
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 83
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Place a tray beneath the drain plug for collecting the oil while draining.
• Ensure entire oil is drained before filling the new oil.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 84 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Torque: 47 ± 7 Nm
Torque: 47 ± 7 Nm
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 85
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
1. Position the vehicle on level ground/ 2 post lift /4 post lift.
Brake/ Clutch Fluid – Level & Leak Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 86 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Apply the brake forcefully for a few 4. Check for brake fluid leakage at front
seconds and check for fluid leakage at below caliper flexible hose end on bundy tube (Both
fittings. RH & LH).
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 87
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Inspect the level of the brake fluid before each operation and look for leaks if the
brake fluid is found to be low.
• After opening a bottle of brake fluid, always discard any unused portion. Never store
or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs
moisture from the air. The moisture causes the boiling temperature of the brake fluid
to drop, which can lead to early brake fade and the possibility of accident or severe
injury.
• Use recommended fluid & do not mix different brand fluids.
• Use the same brand fluid for top up.
• The brake fluid reservoir cap/ container should not be opened with dirty hands.
• Avoid direct water spray on reservoir while washing engine compartment.
• Always use “Maximile DOT 3” brake fluid.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 88 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Clutch bundy tube connection to master 4. Flexible hose joint on slave cylinder.
cylinder.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 89
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 90 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
9 mm Ring spanner 01
Preliminary Activities/Conditions
1. Position the vehicle on a 2 post lift /4 post lift.
2. Open the bonnet.
Brake & Clutch Fluid - Replace
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 91
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Always use recommended fluid and do not mix different brand fluids.
• Always use fresh and clean fluid from a sealed container.
• Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding
screw is opened). Air in the system will be further compressed into small bubbles
and distributed throughout the hydraulic system and will result in additional
bleeding operations.
• Do not reuse the drained fluid.
• Fluid level in the reservoir must be at MAX level at the start of bleeding and should
be checked after bleeding each brake circuit and top up as required.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 92 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Open brake fluid reservoir cap. 4. Using a 9 mm ring spanner loosen all the
bleeding nipples and allow the entire fluid to
get drained.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 93
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Position the vehicle on level ground /2 6. With the help of a 9 mm ring spanner,
post lift /4 post lift. loosen the bleeding screw and drain the
clutch fluid completely.
2. Open the bonnet.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 94 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 95
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• At all times during the bleeding process, it has to be ensured that the fluid level in
the reservoir does not drop below minimum.
• Refer the below illustration for the bleeding sequence
The below illustration is applicable for BOLERO CITY PIKUP
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 96 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Carry-out bleeding as per bleeding 3. Press and release the brake pedal 3 - 4
sequence mentioned in above illustration. times slowly to the full stroke and hold the
• Rear left wheel. pedal in depressed condition.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 97
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 98 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
3. Operate clutch pedal 3 or 4 times slowly 6. Close the bleed screw properly
to the full stroke.
7. Remove bleeding tube and place the
dust cap on bleeding screw.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 99
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Check brake/Clutch pedal for sponginess. If found spongy, repeat the entire
procedure of bleeding.
• Check and ensure there is no leakage from brake an/Clutch pipes and joints.
• Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid
does contact the paint, wash it off immediately with water.
• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
• The brake fluid reservoir cap/ container should not be opened with dirty hands.
• Avoid direct water spray on reservoir while washing engine compartment.
• Always use “Maximile DOT 3” brake fluid.
• During the bleeding operation ensure the container and pipe used is of transparent
for better visual.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 100 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
21 mm Wheel Spanner 01
12 mm Socket spanner 01
Preliminary Activities/Conditions
1. Position the vehicle on a 2 post lift /4 post lift.
Brake Pads / Caliper Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 101
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 102 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Disc Thickness
• Clean and Inspect the brake discs for
signs of cracks, excessive wear or
corrosion, warping or other damage.
Inspect the disc thickness before assembling
the caliper back to the carrier.
• Actual thickness of disc= 21 mm.
• Wear limit = 2 mm.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 103
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• While inserting the pads between the carrier and disc care should be taken that the
friction material should be towards the disc.
• Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and
rectify.
• Before inserting the pads ensure that caliper is returned fully to its position. (Push
the caliper inside if necessary.)
• Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard
particles of sandpaper will be deposited in lining and may damage disc. When pad
lining requires correction, replace it with a new one.
• While fitting the guide pin ensure that the straight portion of the pin matches with
the ear of the calliper body.
• The Pads in the Pad kit should be replace on the respective caliper i.e. assemble <
RH > marked pads on RH Caliper and < LH > marked pads on LH Caliper.
• Always ensure that the anti rattle pad clips are replaced whenever the pads are
replaced.
• Do not apply grease on anti rattle clips.
• Always replace all four brake pads at a time, If the pads are to be reused make sure
they are assembled back in the same position as they were when removed i. e.,
inboard pad on to the piston side and outboard pad to the wheel side. This is
possible only when at the time of removal these pads are marked for their positions
and kept aside. Never lubricate the pad seating areas as it may lead to jamming.
• After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to
make the pads align properly.
• It is recommended to apply light braking during the road test and avoid heavy and
continuous braking during the initial 200 kms of run or until the new pads are
performing satisfactorily.
• Never lubricate the pad seating areas as this may lead to jamming.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 104 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Fix both the anti-rattle clips back in its 3. Move the caliper downwards and bring
position. back to its original position.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 105
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Brake Pads and Disk need to be Inspected for excess wear and replace as needed.
• If any pad is worn out (inboard /outboard) then replace both the pads.
• If pads on one wheel only are worn, even then replace the other wheels also.
• DO NOT use grease to the pad shims/ anti-rattle shims.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 106 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
21 mm Wheel Spanner 01
— Star Screwdriver 01
Preliminary Activities/Conditions
1. Position the vehicle on a 2 post lift /4 post lift.
Rear Brake Drum And Lining - Inspect
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 107
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 108 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 109
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
Preliminary Activities/Conditions
1. Position the vehicle on a 2 post lift /4 post lift.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 110 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
3. Using a 10 mm open end spanner, 5. Tighten the adjusting nut till the rear
slightly loosen the lock nut and then loosen wheels can no longer be rotated using hands,
the adjusting nut fully. and tighten the lock nut.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 111
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
1. Position the Vehicle on 4 post lift.
1. Check shock absorber bushes, stabilizer bar bushes, stabilizer bar link bushes, bump
stop for wear & tear, cracks and shift, replace if necessary.
2. Check the leaves spring links bushes for any damage/ crack or deterioration. Replace
the bushes if found any.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 112 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Check the leaves spring links bushes for any damage/ crack or deterioration. Replace
the bushes if found any.
2. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 113
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 114 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• While tightening the link & torquing ensure that wheels are resting on the ground/ 4
post lift. If it is not done, the ride quality will get adversely affected.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 115
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 116 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Check Power Steering fluid level , if found less than MIN mark, top up to MAX mark.
• Always maintain fluid level at MAX mark on reservoir.
1. Fluid reservoir outlet and return hose 3. Pressure pipe and return pipe banjo bolts
connection to reservoir. on steering gear.
2. Power steering pump inlet and outlet 4. Steering gear Input shaft oil seal area,
connection. drop arm shaft area and power steering
pump housing.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 117
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
18 mm Ring spanner 01
Preliminary Activities/Conditions
• Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications.
Vehicle to be run for some distance before starting the wheel alignment. This will settle the
load on each tyre.
• Ensure that the turn table & roller plate move freely to avoid suspension block & no rocking
of turn tables.
• Check for any damage of the rims or bushes & suspension joints/ wheel end for play.
• Ensure that the front turntables & rear plates are at the same level.
• Do the setting of steering wheel for Straight Ahead Position (SAP) and lock the steering
column rotation.
• Refer the wheel alignment specification chart for the front Suspension.
• Refer below decision tree for wheel alignment:
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 118 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 119
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• If above sequence is not followed, it will lead to incorrect wheel alignment even
though individual adjustments are done correctly.
Run Out Compensation
• Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation.
• Refer wheel alignment equipment manufacturer's guide lines while doing run-out
compensation.
Steering Straight Ahead Position Setting Procedure
Refer the procedure given below for SAP setting:
1. Keep the wheels on turntables of the wheel alignment machine.
2. Rotate the steering wheel to LHS lock position.
3. From LHS lock position, rotate steering wheel to RHS Lock position.
4. Count the number of turns of steering wheel from LHS to RHS lock position.
5. From RHS lock position, rotate steering wheel exactly half the number of turns towards
LHS.
6. Lock the steering wheel.
7. If the steering straight ahead does not match the wheel straight ahead, then adjust the
OBJ of the desired side.
• Ensure that the silent bushes in the front suspension are in satisfactory condition.
• Ensure that the front suspension fasteners are tightened to specified torque.
• Ensure that there is no play in steering linkages and suspension ball joints.
• Follow instruction manual of wheel aligning system manufacturer.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 120 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Not
Caster 4° 00’ 3⁰ 30’ 4⁰ 30’ 4° 3.5⁰ 4.5⁰ adjusta-
ble
Not
KPI
9⁰ 00’ 8⁰ 30’ 9⁰ 30’ 9⁰ 8.5⁰ 9.5⁰ adjusta-
/SAI
ble
Toe-In
(Individ- (+) 0⁰ 6’ (+) 0⁰ 4’ (+) 0⁰ 8’ (+) 0.1⁰ (+) 0.07⁰ (+) 0.13⁰ Adjusta-
ual) ble
Toe-In Adjusta-
(+) 0⁰ 12’ (+) 0⁰ 8’ (+) 0⁰ 16’ (+) 0.2⁰ (+) 0.13⁰ (+) 0.27⁰
(Total) ble
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 121
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• Front tyre should have uniform wear and inflated to recommended pressure.
• Ensure that hub play is correct.
• Ensure that the front suspension fasteners are tightened to specified torque.
• Ensure that there is no play in steering linkages and suspension ball joints.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 122 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 123
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Using a 13 mm open end & ring spanner 3. After adjusting the length of tie rod,
loosen master tie rod end lock clamp bolts & recheck toe in values and then tightening
nuts both side. lock clamp bolts & nuts with 13 mm open end
& ring spanner.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 124 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
• Position the vehicle on 2 post lift.
Tires on the front and rear axles of vehicles operate at different loads and perform different
steering, handling, and braking functions. For these reasons, they wear at unequal rates and
develop irregular wear patterns. Rotation will increase tread life, help to maintain mud, snow,
and wet traction levels, and contribute to a smooth, quiet ride.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 125
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 126 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
When you start a new test, the last test results in memory are overwritten. Remember
to record or print the results if you need to retain them.
1. Open the bonnet. 6. Press the Enter button and confirm the
APPLICATION by selecting the
2. Connect the MDX - 650P battery tester “AUTOMOTIVE” in the tester using
to battery terminals connecting probes on the navigation button Up or Down.
battery posts respectively.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 127
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
8. Press the Enter button and confirm the 9. Press the Enter button and get the
BATTERY STANDARD by selecting the “JIS” recommended JIS Number value by
in the tester using navigation button Up or pressing button Up or Down.
Down.
Model JIS
Make
Number NUMBER
With ESS
Without ESS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 128 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 129
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Follow the below table for Battery Testing test results condition and remedial action:
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 130 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
If the turn signal lamps on the instrument panel flash faster than normal, there may be
a possibility that one or more of the turn signal lamp bulbs have blown. Replace the
blown bulb immediately.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 131
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The tail lamp, license plate lamp, side marker lamps, instrument panel illumination
lamps and all interior switches are also activated when the Parking lamp is switched
ON.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 132 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Your vehicle head lamps are vented and moisture may be collected on the inside of the
head lamp lens under certain climatic and geographical conditions. This moisture will
evaporate once the head lamps have been switched ON for a few minutes.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 133
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Select the suitable switch position depending on the pay load as advised in the table.
The head lamp leveling should be done when the head lamp low beam is ON.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 134 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Do not leave the Roof lamp in permanent ON mode. This will drain your vehicle battery.
The turn lamps do not work when the hazard warning lamps are operational.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 135
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
30.12 Horn
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 136 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
If you switch off the ignition before switching off the wiper, the blades stop at random
on the windscreen. When the ignition is switched on again, the wiper blades return to
the resting position provided the wipe/wash stalk is in OFF position.
• Do not operate the wipers when the windshield is dry. It may lead to scratches on
the glass
• It is recommended not to use the wiper when the windshield glass is covered with
debris, snow or leaves. Clean the glass before using the wiper to avoid damage to
the wiper blades and glass
• Do not operate the windshield washer for more than 10 seconds or when the
reservoir is empty
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 137
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Tools Required:
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 138 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Keep the vehicle at a distance of 10 meter from the black screen in the dark room.
2. Mark the –1.3% height on the board as shown. i.e. 130mm below the Headlamp centre
height.
3. Headlamp centre height to be measured actual in vehicle.
4. Set both LH & RH headlamp by setting the cut-off pattern at a height marked on the
board/screen.
5. Check the function of system, by operating the switch 0 to 1 and observe the cut-off
pattern movement in down word direction accordingly.
6. At zero position of switch the cut-off should come at –1.3% heights on screen
Select the switch position as per following table for M-1 category vehicles
• If head lamp centre height in BOLERO CITY PIKUP assumed is X mm. So here h(mm)
is the height (X-130mm) below the head lamp centre height. i. e. — 1.3% setting of
cut-off pattern.
• Distance of vehicle from black board is 10 meters.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 139
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• The proper cold tyre inflation pressure is listed in the Tyre Label (Vehicle Placard),
located on the driver's door corner.
MAHINDRA CITY PICK UP TYRE INFLATION PRESSURE (Bar)
215/75 R15 LT
Front 2.4
UNLADEN
Rear 2.4
Front 2.4
LADEN
Rear 3.75
• Never overload your vehicle. Overloading can cause tyre failure, affect vehicle
handling, and increase your stopping distance, resulting in an accident and/or
personal injury.
• Improper inflated tyres can adversely affect vehicle handling or can fail
unexpectedly, resulting in an accident and/or personal injury.
• If the cap is not replaced, dirt and moisture could get into the valve core and cause
air leakage. If you lose a valve cap, buy another and install it as soon as possible.
Vehicle is originally equipped with tires supplied by a reputable manufacturer. If you ever have
any questions regarding your tires, please refer to literature supplied by the tire manufacturer,
or to the separate tire warranty provided by the tire manufacturer. You may also contact the tire
manufacturer or Mahindra directly.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 140 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Refer below sketch for Cabin mounts and its locations on chassis –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 141
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 142 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
Preliminary Activities/Conditions
1. Position the Vehicle on 2 post lift/ 4 post lift.
Oil / Leakage- Inspect Procedure:
1. Lift the vehicle. 3. Check the oil sump and crank case
mating area for any leakage, if found leakage
2. Check the front differential oil cover for refit the oil sump and apply sealant on the
any leakage, if found leakage refit the mating area. Then, torque tighten the bolts to
differential cover and apply sealant on the the specified value
mating area. Then, torque tighten the bolts to Check for leakages at the engine oil drain
the specified value bolt, if found torque tighten the plugs to
Check for leakages at the oil filler and drain specified value.
plugs, if found torque tighten the plugs to
specified value.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 143
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
4. Check the flanging areas of clutch cover 6. Check the flanging areas of the transfer
housing for any leakage, if found leakage case for any leakage, if found leakage refit
refit the clutch cover and apply sealant on the the transfer case and apply sealant on the
mating area. Then, torque tighten the bolts to transfer case mating area. Then, torque
the specified value. tighten the bolts to the specified value.
Check for leakages at the oil filler and drain
plugs, if found torque tighten the plugs to
specified value.
Torque: 30 ± 5 Nm
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 144 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Connect the i-SMART diagnostic tester 5. All ECUs will be analyzed and If screen
and turn the ignition ON. showing No trouble code found then click
finish and close the iSmart.
2. Click the VCI SELECTION.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 145
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 146 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1. Connect the miniSMART ANDROID VCI 3. From the list, select “DTC Fetch”.
on DLC and turn the ignition ON.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 147
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 148 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
• The task list for scheduled maintenance is available in menu pricing system of DMS.
• The maintenance check list given in the upcoming pages can be used by dealers
where DMS is not available.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 149
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 150 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 151
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
WATER IN FUEL
Clean 0.05
FILTER
EXHAUST PIPE
MOUNTINGS & Inspect 0.05
DAMAGE / LEAKAGE
SUSPENSION
BUSHES / ARMS & Inspect 0.1
LINKS
Check and
TYRE PRESSURE Adjust 0.15
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 152 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 153
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
SUSPENSION Inspect
BUSHES / ARMS & 0.1
LINKS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 154 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 155
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
EXHAUST PIPE
MOUNTINGS & Inspect 0.05
DAMAGE/LEAKAGE
Check &
WHEEL ALIGNMENT Adjust 0.40
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 156 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 157
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
SUSPENSION Inspect
BUSHES / ARMS & 0.1
LINKS
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 158 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 159
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
EXHAUST PIPE
MOUNTINGS & DAMAGE/ Inspect 0.05
LEAKAGE
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 160 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 161
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 162 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 163
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 164 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 165
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 166 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 167
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
Page 168 or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.
Maintenance Manual MAN-00888
BOLERO CITY PIKUP MAY - 2020/Rev 1
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Page 169
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2020 Mahindra & Mahindra Ltd.