Mahindra Bolero Camper Camper Gold BS 6

Maintenance Manual
MAN-00880
MAINTENANCE MANUAL
BOLERO CAMPER/
CAMPER GOLD
m2DICR D25 BS6
Revision — 1
MAY - 2020
Published by — Service Engineering
Technical Hub
Maintenance Manual MAN-00880
BOLERO CAMPER/CAMPER MAY - 2020/Rev 1
GOLD
Table of Content
1 About the Maintenance Manual.................................................................................................. 5
2 Maintenance Schedule ............................................................................................................... 10
3 Lubrication Chart ......................................................................................................................... 12
4 Maintenance Parts List............................................................................................................... 14
5 780-MAT-0010 Engine Oil Level - Inspect / 0.02 HRS ......................................................... 15
6 780-MAT-0020 / Engine Oil - Replace / 0.23 HRS .................................................................. 18
7 780-MAT-0030 / Engine Oil Filter - Replace / 0.08 HRS ...................................................... 25
8 780-MAT-0040 / Valve Clearance - Check & Adjust / 0.5 HRS .......................................... 28
9 780-MAT-0050 / Accessory Drive Belts - Inspect / 0.05 HRS ............................................ 35
10 780-MAT-0070 / Accessory Drive Belts - Replace / 0.2 HRS ........................................... 56
11 780-MAT-0090 / Coolant - Inspect / 0.03 HRS ...................................................................... 65
12 780-MAT-0100 / Coolant - Replace / 0.42 HRS .................................................................... 69
13 780-MAT-0110 / Air Filter Element - Clean / 0.15 HRS ....................................................... 73
14 780-MAT-0120 / Air Filter Element - Replace / 0.1 HRS..................................................... 77
15 780-MAT-0140 / Fuel Filter Element - Replace / 0.2 HRS .................................................. 80
16 780-MAT-0150 / Water In Fuel Filter - Clean / 0.05 HRS .................................................... 85
17 780-MAT-0230 / Exhaust Pipe Mountings & Damage / Leakage - Inspect / 0.05
HRS ........................................................................................................................................ 87
18 780-MAT-0260 / Transmission Oil - Replace / 0.18 HRS ................................................... 90
19 780-MAT-0290 / Transfer Case Oil - Replace / 0.18 HRS................................................... 93
20 780-MAT-0300 / Propeller Shaft Sliding Joint And Universel Joint -Lubricate /
0.1 HRS ................................................................................................................................. 96
21 780-MAT-0320 / Front Axle Oil - Replace / 0.18 HRS ......................................................... 97
22 777-MAT-0340 / Rear Axle Oil - REPLACE / 0.18 HRS .....................................................100
23 780-MAT-0350 / Rear Wheel Bearings - Lubricate / 0.8 HRS .........................................103
24 780-MAT-0370 / Brake & Clutch Fluid Level And Leak - Inspect / 0.05 HRS..............108
25 780-MAT-0390 / Brake & Clutch Fluid - Replace / 0.6 HRS............................................. 113
26 780-MAT-0430 / Front Brake Pads/ Calipers - Inspect / 0.38 HRS ................................123
27 780-MAT-0440 / Rear Brake Drum And Lining - Inspect / 0.38 HRS ............................129
28 780-MAT-0450 / Parking Brake Operation - Inspect / 0.13 HRS ....................................132
29 780-MAT-0470 / Suspension Bushes / Arms & Links - Inspect / 0.1 HRS ..................134
30 780-MAT-0500 / Power Steering Fluid Level - Inspect / 0.03 HRS ................................140
31 780-MAT-0510 / Wheel Alignment / 0.4 HRS ......................................................................142
32 780-MAT-0520 / Tyre Rotation / 0.25 HRS...........................................................................154
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written 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.
GOLD
33 780-MAT-0550 / Battery Health Checkup / 0.1 HRS .........................................................155
34 780-MAT-0560 / All Lights, Horns, Wipers And Washers - Check / 0.03 HRS ...........160
35 780-MAT-0570 / Head Lamp Aiming - Check & Adjust / 0.2 HRS..................................167
36 780-MAT-0610 / Tyre Pressure - Check And Adjust / 0.15 HRS ....................................169
37 780-MAT-0630-MAT-0060 / Underbody Nuts & Bolts For Tightness - Inspect / 0.3
HRS ......................................................................................................................................171
38 780-MAT-0680 / Oil Leakage - Inspection / 0.05 HRS ......................................................173
39 780-MAT-0690 / Diagnostic Trouble Code — Check / 0.1 HRS .....................................175
40 Maintenance Check Sheet.....................................................................................................179
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced
by the manufacturer in the production 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.
GOLD
1 About the Maintenance Manual
• The maintenance manual outlines the correct standard operating procedures (SOPs) for
carrying out maintenance operations in a Mahindra BOLERO CAMPER, CAMPER GOLD
vehicles.
• 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
1.1 Maintenance Schedule

The maintenance schedule outlines the operations to be carried out in specified interval such
as specified kilometers or Month ( where applicable). These operations include Adjust (A),
Inspect & Correct (I), Replace (R) & Clean (C). The maintenance periods are specified in
Kilometers (kms).
1.2 Standard Operating Procedures (SOP)

Each maintenance operation is coded by an operation code 780-MAT-XXXX. Here 780 stands
for the model family code, MAT indicating it is a maintenance operation and XXXX the
operation number.
Each maintenance operation is explained step-by-step, in the SOP section of the manual. The
man-hours required to complete the operation is mentioned along with the operation code.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the 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.
GOLD
The correct grade of lubricants /coolants to be used, torque values, special tools are also
mentioned wherever applicable.
1.3 Check Sheets

Check sheets for each service, list outs the operation which need to be carried out by the
technician, when the vehicles report for scheduled maintenance service. These check sheets
need to be attached to the Repair Order.
1.4 Explanation on Colour Codes used in Illustrations
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.
introduced by the 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
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1.5 Good Workshop Practices
1.5.1 Attire/ Dress
1. Always wear clean uniform
2. Wear safety shoes
3. Wear gloves, when required
4. Wear belt cover
1.5.2 Vehicle Protection

Install seat covers, steering wheel cover, fender cover before starting the operations.
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.
1.5.4 Parts and Tools

Before starting the operation, prepare tool stand, MST (Special Tools), gauges, oils and parts
for replacement.
1.5.5 Removed Parts

1. Place removed parts in a separate box to avoid mixing them up with new parts or
contaminating new parts.
2. For non-reusable parts such as gaskets, “O” rings, and self-locking nuts, replace them
with new ones as instructed in the manual.
3. Retain the removed parts for customer inspection, if requested.
4. The removed parts should be packed in clean bags and handed over to the customer.
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1.6 Legend of the Safety Symbols
To emphasize information and procedures regarding safety, use, maintenance, etc., the
following symbols are used throughout the manual.
Term/ Symbol Denotation
DANGER indicates an imminently hazardous

situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.
NOTICE Indicates important information

relevant to the vehicle, the vehicle's use or to
sections of this manual to which particular
attention must be paid for optimum use of the
vehicle.
If you see this symbol, it indicates “no”,

“do not,” “do not do this,” or “never”.
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1.6.1 Legend of the Symbols
Symbol Denotation
Locate/ Show
Move/ Fit
Turn Clockwise
Turn anti-clockwise
Inspection
Wrong practice
Right Practice
LOCTITE
LOCTITE
0000 Sealant Application
Dis - assembly Sequence
Assembly Sequence
Torque Tightening
Tightening Sequence
SOAP
SOLUTION
Lubrication Symbol (Soap oil)
OIL
Lubrication Symbol (oil)
Lubrication Symbol (Semi solid)
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2 Maintenance Schedule
780 — BOLERO CAMPER / CAMPER GOLD
Distance Covered in km x 1000
DESCRIPTION CHANGE INTERVAL 10 20 30 40 50 60 70 80 90 100

Free Service Paid Service
Engine
Replace at first 10000 then at

Every 20000 km R I R I R I R I R I
Change as per the km or 2 years whichever is earlier
Engine Oil Change engine oil in 10000km or 12 months(whichever is earlier), if

the vehicle is continuously operating under severe operating
conditions as mentioned in page NO.17, Note-5 of the Warranty
Information and Maintenance Guide
Replace at first 10000 then at
Engine Oil Filter
Every 20000 km R R R R R
Change along with engine oil
Valve Clearance Adjust First 10000, then every 20000 km A A A A A

Accessory Belt Replace at Every 80000 km I R
Drive Belt - Power Steering Replace at Every 80000 km I R
Replace at every 60000 km
Coolant – Level, Leak and Hoses Change as per the km or 3 year whichever is earlier I I I I I R I I I I
Air, Fuel and Exhaust

Replace at every 30000 km
Air filter element Clean at every 10000 km except replacement C C R C C R C C R C
Fuel Filter element Replace at every 30000 km R R R

Water sediments drain - Fuel Filter As per km or whenever indicator glows I I I I I I I
Transmission
Replace at First 20000, then every 100000 km
Transmission Oil Change as per the km or 3 year whichever is earlier R
Replace at Every 50000 km
Transfer case Oil Change as per the km or 3 year whichever is earlier R R
Propeller Shaft Sliding Joint Lubricate at every service L L L L L L L L L L
Axles, Wheels and Tires
Replace at first 10000, then every 60000 km
Differential Oil–Front Change as per the km or 3 year whichever is earlier R R
Replace at first 10000, then every 60000 km
Differential Oil–Rear Change as per the km or 3 year whichever is earlier R R
Rear Wheel Bearings Lubricate at every 50000 km L L
Tire Rotation * Inspect at every service I I I I I I I I I I
Brakes and Clutch

Replace at first 30000, then at every 40000 km
Brake and Clutch Fluid - Level & Leak Change as per the km or 2 year whichever is earlier I I R I I I R I I I
Brake Pads / Calipers Inspect at every service I I I I I I I I I I
Brake Drum /Lining Inspect at every 20000 km I I I I I
Parking Brake Inspect at every service I I I I I I I I I I
Suspension
Suspension Bushes & Links Inspect at every service I I I I I I I I I I
Steering
Power Steering Fluid - Level & Leak Inspect at every service I I I I I I I I I I
Wheel Alignment* At 40000 km, earlier if abnormal is noticed
Electrical
Battery Health Check Inspect at every service I I I I I I I I I I
All Lamps, Horns, Wipers and Washers Inspect at every service I I I I I I I I I I
Head Lamp Aiming Adjust at First 10000 km A
Final Inspection
Tyre Pressure Inspect at every service I I I I I I I I I I
All nuts and bolts for Tightness Inspect at every service I I I I I I I I I I
Visually Inspect for oil leakage in joints at
Inspect at every service I I I I I I I I I I
every service
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Distance Covered in km x 1000
DESCRIPTION CHANGE INTERVAL 10 20 30 40 50 60 70 80 90 100

Free Service Paid Service
Exhaust Pipe Mountings and Damage/ Inspect at every service I I I I I I I I I I
Leaks
Road Test Inspect at every service I I I I I I I I I I
Check DTC Inspect at every Service & Record in RO/ DMS I I I I I I I I I I
Legends
I =Inspect / correct, Replace if worn out / faulty R = Replace C =Clean
L = Lubricate A = Adjust as Necessary * - On chargeable basis
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3 Lubrication Chart
780 – BOLERO CAMPER / CAMPER GOLD
Ca-
System paci- Specifi-
Lubricant Remarks
ty cation
• Always use "MAXIMILE ULTRA"

genuine engine oil. This is specially
developed for your BSVI vehicle
engine’s optimum performance and
fuel efficiency.
• In extreme cases of emergency
MAHINDRA Special
Engine 7.0 and non-availability of above oil, we
"MAXIMILE ULTRA" Engine
Oil liters suggest to use "Maximile Feo"
Gen-NXT Technology Genuine Engine Fluid
Fluid
engine oil, take the vehicle to nearest
Mahindra Authorised Service centre
and replace the oil with "Maximile
ULTRA"
• No other brand / grade oil
recommended
Brand specific. Use of other brand coolants /

water not recommended for top up. In case of
MAHINDRA
Engine emergency, coolant meeting JIS K2234
"MAXIMILE ULTRA ~8.0
Cooling specification should be used (30% concentration
COOL" liters
GENUINE COOLANT (READY TO USE COOLANT. NO
NEED TO MIX WATER)
diluted with distilled water) and coolant change
period to be reduced as 30,000 km ensure max
level in the radiator and coolant reservoir tank
If Syntec F2 is used, oil change has

Special to be done at every 40,000 km after
MAHINDRA Manual first service. For other than Maximile
Trans- "MAXIMILE SYNTEC 2.0 brand is used, the oil change interval
Trans-
mission F2” liters has to be reduced to 20,000 km if
NEW GENERATION GENUINE TRANSMISSION OIL
mission
Fluid that oil meets minimum of API GL-4
SAE 80W-90 specification
MAHINDRA
Transfer "MAXIMILE 1.6 Special Manual Transmission Fluid
case SYNCHRO UV2" liters
NEW GENERATION GENUINE TRANSMSISSION OIL
For other than maximile brand, the

MAHINDRA Special oil change interval has to be reduced
Rear 1.75 to 20000 km if the oil meets
“MAXIMILE ELITE” Axle
Axle Oil liters minimum of API GL-5 SAE 80W-90
NEW GENERATION GENUINE DIFFERENTIAL FLUID
Fluid
specification
GOLD
For other than maximile brand, the

Front MAHINDRA Special oil change interval has to be reduced
Axle Oil 1.25 to 20000 km if the oil meets
“MAXIMILE ELITE” Axle
(4WD) liters minimum of API GL-5 SAE 80W-90
NEW GENERATION GENUINE DIFFERENTIAL FLUID
Fluid
specification
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
If Maximile DOT 3 brake fluid is not used and in

Brake emergency conditions, use Brake Fluid Meeting
“Maximile DOT 3” 1.00 SAE J1703 FMVSS No.116 DOT 3 or IS 8654
and GENUINE BRAKE & CLUTCH FLUID
liter Type-1 Specification and change it at 20000 km
Clutch
or 2 years whichever earlier
Advise to use only the Genuine grease for better

MAHINDRA As
Wheel life and protection. In emergency Lithium
"MAXIMILE LCG" Req-
Hub Complex Grease Meeting NLGI 2.5 specification
GENUINE WB GREASE
d.
can be used
We do not recommend any supplementary fuel

Diesel confirming to - additive to improve the engine performance.
Recom- Indian standard 57 Avoid using any market available fuel additives
mended IS 1460; 2017 BSVI Lit- as it may harm your engine performance, parts
Fuel specification or ers and emission warranty. Usage of any such
equivalent. additives will not cover your vehicle warranty
claim.
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4 Maintenance Parts List
Sl No Part No Description Quantity
1 0311AAC00260N Cu non asbestos washer dia 16 01
2 0313AAB03061N Air filter element 01
3 S0305D020021N Element - fuel filter 01
4 S0305D020011N O ring - filter bowl 01
5 0306DAB00301N Belt alternator 01
6 0306CAB00161N Belt power steering 01
7 0306AAB00551N Belt compressor 01
Verify part numbers with electronics parts catalogue before placing the order.
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5 780-MAT-0010 Engine Oil Level - Inspect / 0.02 HRS
5.1 Engine Oil Level Checking Procedure
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
GOLD
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.
3. Insert the dip stick gauge into the dip

stick guide fully till the end.
5. Insert the dip stick back and fix properly,

start the engine and check for oil leakage/
seepage at:
• Oil sump & crankcase joint.
• Oil sump drain plug.
• Oil filter joint.
GOLD
• Maintain the oil level in the safe range. Do not overfill.

• Always use "MAXMILE ULTRA" genuine engine oil. This is specially developed for
your BS VI vehicle engine’s optimum performance and fuel efficiency.
• In extreme cases of Emergency and non-availability of above oil, we suggest to use
"Maximile Feo" engine oil, take the vehicle to nearest Mahindra Authorised Service
centre and replace the oil with "Maximile ULTRA"
GOLD
6 780-MAT-0020 / Engine Oil - Replace / 0.23 HRS
Tools Required
Size Type Quantity
22 mm Ring spanner 01
— Tray 01
• 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
Engine Oil – MAHINDRA "MAXMILE ULTRA"

Capacity – 7 Litres.
GOLD
6.1 Engine Oil Draining Procedure
1. Clean the area around the drain plug.
2. Place a drain pan beneath the engine

crankcase.
• Hot oil can cause burns to skin. Do not

allow hot oil to contact skin.
3. Loosen and remove engine oil drain plug

with the help of 22 mm ring spanner by
rotating the drain plug in anti-clockwise
direction.
4. Allow the entire engine oil to get drained.
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6.2 Engine Oil Filling Procedure
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.
2. Verify the sealing washer is on the drain

plug and reinstall the drain plug. Torque
tighten the drain plug to specified value.
6. Fill recommended quantity of engine

fluid.
Torque : 22.5 ± 2.5 Nm
3. Torque tighten the drain plug to specified

value.
4. Pull-out the dip stick completely, so that

air can easily escape while re-filling fresh
engine oil.
7. Refit the oil fill cap.
GOLD
8. Insert the dip stick.
9. Start the engine and check for Oil

leakage/ seepage at:
• Oil pan & crankcase joint.
• Oil pan Drain Plug.
BS VI vehicle engine’s optimum performance and fuel efficiency.
GOLD
6.3 Engine Oil Level Checking Procedure
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
GOLD
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.
3. Insert the dip stick gauge into the dip

stick guide fully till the end.
5. Insert the dip stick back and fix properly,

start the engine and check for oil leakage/
seepage at:
• Oil sump & crankcase joint.
• Oil sump drain plug.
GOLD
• Maintain the oil level in the safe range. Do not overfill.

your BS VI vehicle engine’s optimum performance and fuel efficiency.
• In extreme cases of Emergency and non-availability of above oil, we suggest to use
"Maximile Feo" engine oil, take the vehicle to nearest Mahindra Authorised Service
centre and replace the oil with "Maximile ULTRA"
GOLD
7 780-MAT-0030 / Engine Oil Filter - Replace / 0.08 HRS
Tools Required
Size Type Quantity

- Oil filter wrench 01
• Place the vehicle on a 2 post lift.
• Open the Hood.
Engine Oil filter Replacement
Engine Oil Filter – MAHINDRA Genuine Oil Filter.
GOLD
7.1 Engine Oil Filter Removal Procedure
1. Place shop towels beneath the oil filter.
2. Grip the engine oil filter firmly using an oil

filter wrench, loosen oil filter by rotating in
counter-clockwise direction and remove the
oil filter from engine assembly.
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7.2 Engine Oil Filter Installation Procedure
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:
• Recommend to use only the Mahindra

genuine oil filter for better engine
protection and lubricant life.
3. Place the oil filter in its position.
4. Install the new filter and turn by hand

until the filter gasket contacts the sealing
surface, then turn an additional 1/2 turn.
• The oil filter should be only hand

tightened. No special tool or spanner
to be used.
• Never use wrench or filter tool for
installation. If the oil filter is
overtightened then it cause O ring
distortion or damage, resulting in
engine seizure.
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8 780-MAT-0040 / Valve Clearance - Check & Adjust / 0.5 HRS
8.1 Tappet Clearance - Adjustment Procedure

8.1.1 Rocker Arm Cover Removal
1. Using a hose clip plier, unclip the 3. Using a 10 mm socket/ combination

breather hose clip and detach the hose. spanner, loosen and remove the differential
pressure sensor mounting bolt.
2. Disconnect differential pressure sensor

electrical connector. 4. Using a 10 mm socket/ combination
spanner, loosen and remove the differential
pressure sensor bracket mounting bolts.
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5. Using a 10 mm socket/ combination 8. Adjust the tappet clearance. Refer the
spanner, loosen and remove the turbo Adjustment Procedure 1 & 2 below.
charger oil inlet pipe routing bracket
mounting bolt.
9. Tappet setting values (in Cold condition)

• Inlet Valve: 0.4 - 0.45 mm (16-18 thou).
6. Using a 13 mm deep spanner, loosen
and remove the cam cover mounting nuts. • Exhaust Valve: 0.5 - 0.55 mm (20- 22
thou).
7. Detach cam cover.
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8.1.2 Tappet Clearance Adjustment Procedure 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.
GOLD
4. Adjustment procedure : 5. Using 22 mm ring spanner rotates the
• Insert feeler gauge and check valve tappet damper pulley to 360° further in the direction
clearance. of engine rotation.
• If found variation from recommended

value, hold valve lever adjusting screw
with the help of an Screw Driver and then
loosen valve lever adjusting screw nut
using a 14 mm ring spanner.
6. Conditions to bring no. 4 piston at TDC,

match the pointer to Damper pulley white
marking and Ensure no 1 cylinder rockers at
dancing /rocking position.
• Choose correct size on feeler gauge leaf

and insert the leaf in the gap between
rocker arm and valve top surface.
• Hold the adjusting screw nut using a 14

mm ring spanner and rotate adjusting
screw using screw driver to vary the
tappet clearance.
• Once desired tappet clearance is
achieved, hold adjusting screw with screw
driver and tighten the adjustment screw
nut to specified torque value.
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7. Adjust the tappet clearance of 3rd /5th /
7th / 8th valve as per adjustment procedure
above.
Ensure tightening rocker adjusting screw

nut to 20 ± 2 Nm.
• 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.
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8.1.3 Tappet Clearance Adjustment Procedure 2
1. Bring no. 1 piston at TDC. 3. Adjust the tappet clearance of 1st

cylinder both inlet & exhaust valves as per
2. For Bring no. 1 piston at TDC, match the procedure mentioned below:
pointer to Damper pulley white marking and • Insert feeler gauge and check inlet and
Ensure no 4 cylinder rockers at dancing exhaust tappet clearance.
/rocking position.
• If found variation from recommended
value, hold valve lever adjusting screw
with the help of an Screw Driver and then
loosen valve lever adjusting screw nut
using a 15 mm ring spanner.
• Choose correct size on feeler gauge leaf

and insert the leaf in the gap between
rocker arm and valve top surface.
• Hold the adjusting screw nut using a 14

mm ring spanner and rotate adjusting
screw using screw driver to vary the
tappet clearance.
• Once desired tappet clearance is
achieved, hold adjusting screw with screw
driver and tighten the adjustment screw
nut to specified torque value.
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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.
5. Rotate the damper pulley to 180° further

in the direction of engine rotation (1st
cylinder rockers at dancing / rocking Ensure tightening rocker adjusting screw
position). Adjust tappet of 4th cylinder valves nut to 20 ± 2 Nm.
as per specifications.
Always do the tappet setting when

engine is cold.
6. Ensure and match the pointer to Damper

pulley white marking.
GOLD
9 780-MAT-0050 / Accessory Drive Belts - Inspect / 0.05 HRS
• Position the vehicle on a 2 post/ 4 post lift.
• Open the bonnet.
Drive Belt (Alternator/Water Pump) - Inspect
GOLD
9.1 Accessory Drive Belt Inspection
Rotate the crank pulley 360⁰ till belt

completes one full rotation to check belt
condition and confirm following belt
appearances if any.
1. Random Cracking Across the Ribs

Appearance:
Small yet visible cracks along the length of a
rib or ribs.
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.
GOLD
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).
5. Damaged Outermost Ribs

Appearance:
Sidewalls of the belt may appear glazed or
the edge-cord may become frayed and ribs
removed. A noticeable noise may result.
Causes:
Pulley misalignment is a common cause of
premature belt failure. Misalignment forces
the belt to twist while running, causing
premature wear.
GOLD
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.
GOLD
9. Uneven Rib Wear

Appearance:
Wear that is more severe on one rib than on
the others or one rib that exhibits a different
wear pattern than the others. A thumping or
grinding noise may also be heard.
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.
10. Broken Belt

Appearance:
The belt is broken.
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.
11. Belt Noise

Inspection:
Run the engine and inspect for Chirping,
squealing. tapping, ticking or grinding noise
coming from the belt.
GOLD
12. MATERIAL LOSS - EPDM BELTS

Appearance:
Belts made from a material known as
chloroprene show traditional signs of wear
(cracks. chunk outs, rib separation, etc)
EPDM belts don’t necessarily exhibit these
symptoms even through they might be at or
near failures as much of the rubber material
has worn away.
Causes:
EPDM is stringer, is suitable for a wider
range of extreme temperatures and it is more
durable. EPDM belts gradually lose rubber
material — Similar to the way tyres wear out.
It is recommended to remove & check the drive belts thoroughly if any abnormality
noticed.
GOLD
9.2 Belt Tension Checking Procedure
Check belt tension as per procedure mentioned

below:
Do not touch the probe to the belt, this can

damage the probe.
a. Turn ON belt tension gauge.
b. Select reading mode in hertz (Hz) and hold
the probe approximately 5mm distance in front
of the belt.
c. Tap on the belt near the probe.
d. Belt Tension 4PK (ALT/D. Pulley) Installed
Belt tension needs to be checked at (cold Condition) 140-146 HZ
the green point shown in illustration.
e. Belt Tension 4PK (ALT/D. Pulley) Stabilized
(cold Condition) 113-119 HZ
e. Belt Tension 4PK (ALT/D. Pulley) Retension
(cold Condition) 84-88 HZ
e. Belt Tension (AC Compressor 900 mm Belt)
Stabilized 145-165 HZ
GOLD
9.3 Drive Belt (Power Steering) - Inspect
Drive Belt (Power Steering) - Inspect
GOLD
9.3.1 Accessory Drive Belt Inspection

appearances if any.

Appearance:
rib or ribs.
Causes:
leads to cracking.
should be replaced.
2. Chunk-Out
Appearance:
Causes:
contributors.
GOLD
3. Pilling
Appearance:
Causes:
Appearance:
Causes:
(s).

Appearance:
Causes:
premature wear.
GOLD
Appearance:
Causes:
and fail.
7. Abrasion
Appearance:
damaged.
Causes:
two pulleys.
8. Rib Separation
Appearance:
from the belt base.
Causes:
GOLD
9. Uneven Rib Wear

Appearance:
Causes:
10. Broken Belt

Appearance:
The belt is broken.
Causes:
11. Belt Noise

Inspection:
GOLD

Appearance:
has worn away.
Causes:
noticed.
GOLD
9.3.2 Belt Tension Checking Procedure
Check belt tension as per procedure

mentioned below:

damage the probe.
of the belt.
d. Note the reading, if the reading is within
Belt tension needs to be checked at the 175 – 180 Hz, belt tension is OK.
green point shown in illustration.
e. If the reading is less than 175 Hz. Adjust
the belt tension to 175 – 180 Hz.
f. Run the engine for 5 minutes (or) after test
drive the vehicle, repeat the steps (a-c).
d. Note the reading, if the reading is within
175 – 180 Hz, belt tension is OK.
h. If the value is less than 175 Hz, adjust the
tension again and check as per above
procedure.
For New Belt, The belt tension value should be
210 – 215 Hz
GOLD
9.4 Drive Belt (AC Compressor) - Inspect
Drive Belt (Power Steering) - Inspect
GOLD
9.4.1 Accessory Drive Belt Inspection

appearances if any.

Appearance:
rib or ribs.
Causes:
leads to cracking.
should be replaced.
2. Chunk-Out
Appearance:
Causes:
contributors.
GOLD
3. Pilling
Appearance:
Causes:
Appearance:
Causes:
(s).

Appearance:
Causes:
premature wear.
GOLD
Appearance:
Causes:
and fail.
7. Abrasion
Appearance:
damaged.
Causes:
two pulleys.
8. Rib Separation
Appearance:
from the belt base.
Causes:
GOLD
9. Uneven Rib Wear

Appearance:
Causes:
10. Broken Belt

Appearance:
The belt is broken.
Causes:
11. Belt Noise

Inspection:
GOLD

Appearance:
has worn away.
Causes:
noticed.
GOLD
9.4.2 Belt Tension Checking Procedure
Check belt tension as per procedure

mentioned below:

damage the probe.
of the belt.
d. Belt Tension (AC Compressor 1010 mm
Belt tension needs to be checked at the Belt) Installed 130-140 HZ
green point shown in illustration.
e. Belt Tension (AC Compressor 1010 mm
Belt ) Stabilized 105-120 HZ
e. Belt Tension (AC Compressor 900 mm Belt
) Installed 185-195 HZ
e. Belt Tension (AC Compressor 900 mm
Belt) Stabilized 145-165 HZ
GOLD
10 780-MAT-0070 / Accessory Drive Belts - Replace / 0.2 HRS
10.1 Accessory Drive Belt (Alternator/Water Pump) Replace
Tools Required
Size Type Quantity
22 mm Socket spanner / Ring Each 01

Spanner
- MST- Belt Removal Tool 01

- MST- Belt Installation Tool 01
• Position the Vehicle on a 2/4 post lift.
Accessory Drive Belt (Alternator/Water Pump) Replace
GOLD
10.1.1 Removal
1. Place and position the special tool over

the damper pulley.
2. Using a 22 mm socket spanner, rotate

the damper pulley in clockwise direction and
remove the special tool.
3. Remove the belt from the vehicle.
GOLD
10.1.2 Installation
1. Refit the alternator belt in place. 3. Using a 22 mm socket spanner, rotate

remove the tool after belt installation.
2. Place and Position the special tool to the

damper pulley.
GOLD
10.2 Accessory drive Belt (Power Steering) Replace
Tools Required
Size Type Quantity

Spanner

• Position the Vehicle on a 2/4 post lift.
• Remove alternator belt.
Accessory drive Belt (Power Steering) Replace
GOLD
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.
2. Place and Position the special tool Part

over the power steering pump pulley.

remove the special tool from steering pump
pulley.
GOLD
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.
2. Place and Position the special tool over

the power steering pump pulley.

GOLD
10.3 Accessory drive Belt (AC Compressor) Replace
Tools Required
Size Type Quantity

Spanner

• Position the Vehicle on a flat level surface.
• Remove alternator belt.
Accessory drive Belt (AC Compressor) Replace
GOLD
10.3.1 Removal
1. Remove Accessory Drive Belt 4. Remove AC compressor belt from the

(Alternator/Water Pump). For additional vehicle.
information refer to Accessory Drive Belt
(Alternator/Water Pump) R&R section.
2. Fit the special tool Part over the damper

pulley.

remove the special tool from damper pulley.
GOLD
10.3.2 Installation
1. Refit the AC compressor 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.
2. Insert the special tool over the power

steering pump pulley.

GOLD
11 780-MAT-0090 / Coolant - Inspect / 0.03 HRS
11.1 Coolant Level & Leak - Inspect
Coolant – MAHINDRA "MAXIMILE ULTRA COOL"

Capacity – 8 Litres.
GOLD
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.
5. Inspect the radiator inlet hose connection

Escaping steam can cause burns. Never on radiator for coolant leakage. Also check
remove the pressure cap while the the mounting hose clamp for any damage,
engine is warm or hot. Always allow the replace the spring band clamp if found
engine to cool before removing the damaged or loose.
pressure cap.
2. Use a rag to cover the radiator pressure

cap, push down then slowly turn the cap
counter clockwise. Check the coolant level in
the recovery tank when the fluid is cool, it
should be between MAX and MIN marks.
3. If found below MIN mark then top it up by

using funnel with recommended coolant.
GOLD
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.
9. Inspect for coolant leakage at thermostat

7. Inspect for coolant leakage at water housing outlet to EGR cooler inlet. Also
pump inlet from radiator and EGR cooler. check the mounting spring band clamp for
Also check the mounting spring band clamp any damage, replace the spring band clamp
and hose clamp for any damage, replace the if found damaged or loose.
clamps if found damaged or loose.
GOLD
10. Inspect for coolant leakage at EGR
cooler inlet and outlet. Also check the
mounting spring band clamp for any damage,
replace the spring band clamp if found
damaged or loose.
• 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.
GOLD
12 780-MAT-0100 / Coolant - Replace / 0.42 HRS
12.1 Coolant - Replace
Coolant – MAHINDRA "MAXIMILE ULTRA COOL"

Capacity – ~8 Liters.
GOLD
12.1.1 Engine Coolant Draining Procedure:
1. Position the Vehicle on 2 post lift/ 4 post 5. Refit the radiator drain plug back and
lift. tight it properly.
2. Open the hood.
3. Slowly open the radiator pressure cap.
6. Using a 13 mm socket and ring spanner

loosen and remove the water recovery tank
mounting bolt and nut and detach the tank
from the vehicle and pour out the coolant
from the tank.
Escaping steam can cause burns. Never

remove the pressure cap while the
engine is warm or hot. Always allow the
engine to cool before removing the
pressure cap.
4. Remove the drain plug and allow the

entire coolant to get drained.
Place a tray beneath the drain plug to

collect coolant drained.
GOLD
12.1.2 Engine Coolant Filling & De-aeration Procedure:
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.
4. Refit the radiator pressure cap.

2. Start the engine and run at approx. 2500
RPM for about 5 to 7 min. (So that the
thermostat valve will open).
5. Inspect the coolant circuit for any

leakages. For additional information refer to
Coolant level & leak inspection section.
GOLD
• 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.
GOLD
13 780-MAT-0110 / Air Filter Element - Clean / 0.15 HRS
13.1 Air Filter Element - Clean
Preliminary Activities/ Conditions

1. Park the vehicle on level bay.
2. Open the bonnet and lock it in open position using bonnet stay rod.
Air Filter Element – Clean
GOLD
13.1.1 Air Filter Element Removal Procedure:
Before starting of the procedure, always switch off the ignition.
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.
1. Open the bonnet. 3. Using a star screwdriver, loosen and

remove the airfilter mounting screws.
2. Disconnect the HFM sensor electrical

connector. 4. Remove the air filter element gently from
the air cleaner housing.
GOLD
13.1.2 Air Filter Element Cleaning Procedure:
1. Clean the inner side of the air cleaner

housing using a lint free cloth.
2. Blow the compress air from the top clean

side of filter element.
While cleaning, ensure the air pressure

should be less than 2 bar.
• Do not tap or hit the filter element.

• Ensure dust should not fall inside the clean hose area while fitting the back cover.
• Do not blow the air from bottom dirty side.
GOLD
13.1.3 Air Filter Element Installation Procedure:
1. Refit the air filter element gently inside 4. Close the bonnet.
2. Refit the air filter housing mounting

screws. • Always use recommended genuine air
filter element.
• Do not tap or hit the new filter element.
3. Connect the HFM sensor electrical

connector.
GOLD
14 780-MAT-0120 / Air Filter Element - Replace / 0.1 HRS
14.1 Air Filter Element - Replace

1. Park the vehicle on level bay.
2. Open the bonnet and lock it in open position using bonnet stay rod.
Air Filter Element – Replace
GOLD
14.1.1 Air Filter Element Removal Procedure:
Before starting of the procedure, always switch off the ignition.
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.
1. Open the bonnet. 3. Using a star screwdriver, loosen and

remove the airfilter mounting screws.
2. Disconnect the HFM sensor electrical

connector. 4. Remove the air filter element gently from
GOLD
14.1.2 Air Filter Element Installation Procedure:
1. Refit the air filter element gently inside 4. Close the bonnet.
2. Refit the air filter housing mounting

screws. • Always use recommended genuine air
filter element.
• Do not tap or hit the filter element.
3. Connect the HFM sensor electrical

connector.
GOLD
15 780-MAT-0140 / Fuel Filter Element - Replace / 0.2 HRS
Tools Required
Size Type Quantity
32 mm / 12 mm Socket spanner 01 each
- Bench vice 01
2–3 inch M12 Bolts & nuts 02
• Position the vehicle on a flat surface.
Fuel Filter Element — Replace
GOLD
15.1 Fuel Filter Element Removal Procedure
• 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.
GOLD
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.
6. Remove the bottom cover of fuel filter

assembly.
7. Remove the O-ring from the fuel filter

housing.
GOLD
15.2 Fuel Filter Element Installation Procedure:
1. Insert the filter element correctly into the 3. Tighten the filter body using 36 mm
housing. socket spanner to specified torque value.
• Do not over tighten beyond 25 ±5 Nm.

This may cause damage to the bowl
and Head.
• Is it recommended to tight the fuel
filter using torque wrench.
2. Assemble the new O-ring back on to filter

housing. Ensure little oil is smeared on to the
surface of O-ring before assembly on to
head.
• Assemble filter element on to head in

the direction shown. Ensure open end
of filter element goes inside first. 4. Refit the fuel filter assembly with the help
of mounting bolts. Torque tighten the bolts to
• Press the filter element by gentle push specified value.
into the head.
GOLD
5. Connect the fuel filter electrical
connector.
6. Connect fuel filter assembly inlet and

outlet fuel lines.
• Check and ensure proper fitment of

fuel lines, any leakage can lead to fire.
• Always use recommended filter
element only.
• Before removing the fuel filter, open
the fuel tank cap to release the
pressure from the tank and fuel lines.
• Fuel filter cartridge needs to be
replaced earlier in case of repeat water
in fuel warning in cluster even after the
water is drained from the system.
GOLD
16 780-MAT-0150 / Water In Fuel Filter - Clean / 0.05 HRS
• Position the vehicle on a flat surface.
Water In Fuel Filter - Clean
GOLD
16.1 Water Sediment Draining Procedure
1. Connect the transparent pipe to the drain 4. Start the engine and check for any leaks.
plug outlet of the fuel filter assembly.
2. Rotate drain plug anti clockwise till the

water starts flowing from the tube. Clean fuel spilled on exposed surfaces
with a clean cloth.
• Wear protective gloves and OSHA

approved eye protection when
performing this procedure to help
prevent injury.
• Drain plug requires hand tight only; do
not use any tool and avoid over
tightening.
• Water sediments to be drain from fuel
filter
3. Rotate drain plug in clockwise direction • Do not over tight the drain plug.
to stop the flow as soon as water gets over
and fuel flow starts then tighten the drain
plug.
GOLD
17 780-MAT-0230 / Exhaust Pipe Mountings & Damage / Leakage
- Inspect / 0.05 HRS
Tools Required
Size Type Quantity
10 mm Ring Spanner / Socket Spanner 01

1. Position the vehicle on a 2 post lift/ 4 post lift.
Exhaust pipe mountings and damage/ leakage - Inspect
GOLD
17.1 Exhaust Pipe Mountings And Damage/Leakage-Inspect
Procedure:
1. Lift the vehicle. 3. Check the Center muffler rubber isolator

for elongation, replace if found elongated.
2. Check the rubber isolator of the muffler, Also check the flange joint for any leakage, if
replace if found elongated or damaged. Also found replace the gasket and torque tighten
check the flange joint for leakage, replace the the nuts to specified value.
gasket if found and torque tighten the nut to
specified value.
GOLD
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.
GOLD
18 780-MAT-0260 / Transmission Oil - Replace / 0.18 HRS
Tools Required
Size Type Quantity
8 mm Square bit 01
• Position the vehicle on a 2/4 post lift.
Transmission Oil Level & Leak Inspection & Replacement
Transmission Oil MAHINDRA "MAXIMILE SYNTEC F2"

Capacity – 2 liters.
GOLD
18.1 Transmission Oil Replacement –Draining Procedure
1. Remove the oil level plug using 8 mm

square bit.
• Do not use an impact wrench to

remove the oil level plug. This may
damage the threads in the
transmission .
2. Remove the drain plug using 8 mm

square bit & allow the oil to drain out
completely.
GOLD
18.2 Transmission Oil Replacement – Filling Procedure
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.
• Always replace the drain plug washer

with a new one.
Torque: 47 ± 7 Nm
• Recommend to use only MAHINDRA

"MAXIMILE SYNTEC F2" Transmission
fluid.
Torque: 47 ± 7 Nm
• Never mix two different oils.
3. Add specified oil to bring it to the level
when it starts dripping out.
GOLD
19 780-MAT-0290 / Transfer Case Oil - Replace / 0.18 HRS
Tools Required
Size Type Quantity
15 mm Open end spanner 1
8 mm Square Socket 1
• Place the vehicle on a 2/4 post lift.
Transfer Case Oil Level & Leak Inspection & Replacement
Transfer Case Oil MAHINDRA "MAXIMILE SYNCHRO UV2"

Capacity –1.6 Liters.
GOLD
19.1 Transfer Case Oil Replacement – Draining Procedure
1. Using a 15 mm Open end spanner,

remove the oil level plug from the transfer
case.
• Do not use an impact wrench to

remove the oil level plug. This may
damage the threads in the transfer
case.
2. Remove the drain plug by using 8 mm

Square Socket and drain the transfer case
fluid into a suitable container.
GOLD
19.2 Transfer Case Oil Replacement – Filling Procedure
1. Clean the oil level & drain plug and

surrounding area.
2. Refit the drain plug. Torque tighten the

drain plug to specified value.

4. Tighten the oil level plug in the transfer

case, Torque tighten the plug to specified
value.
• Recommend to use MAHINDRA

"MAXIMILE SYNCHRO UV2" Transfer
Case Fluid.
GOLD
20 780-MAT-0300 / Propeller Shaft Sliding Joint And Universel
Joint -Lubricate / 0.1 HRS
Tools Required
Size Type Quantity
— Grease Gun 01
Drive Shaft (Propeller Shaft) Lubrication
1. Clean the propeller shaft sliding yoke 3. Clean the propeller shaft sliding yoke
lubrication nipple and surrounding area (Dirt, lubrication nipple and surrounding area to
rust, paint & anti rust coating etc.,). avoid dust accumulation after greasing.
2. Apply greasing (Lithium Complex

Grease) on sliding yoke lubrication nipple by
using greasing gun.
• Use Grease Grade as LC Grease
(Lithium Complex Grease).
GOLD
21 780-MAT-0320 / Front Axle Oil - Replace / 0.18 HRS
Tools Required
Size Type Quantity
10 mm Allen Key 01
Front Differential Oil Level & Leak Inspection & Replacement
Front Differential Oil – MAHINDRA “MAXIMILE ELITE”

Capacity – 1.25 Liters.
GOLD
21.1 Front Differential Oil Replacement – Draining Procedure:
1. Remove front differential oil level plug

using 10 mm allen key.
2. Remove front differential drain plug using

10 mm allen key and drain the entire oil
completely.
• Place a tray beneath the drain plug for

collecting the oil while draining.
• Ensure entire oil is drained before
filling the new oil.
GOLD
21.2 Front Differential Oil Replacement – Filling Procedure:
1. Clean the oil level plug & drain plug and

surrounding area.
2. Refit the drain plug and torque tighten to

specified value.
Torque: 47 ± 7 Nm

4. Refit the oil level plug back and torque

tighten to specified value.
Torque: 47 ± 7 Nm
• Recommend to use only MAHINDRA “MAXIMILE ELITE” Differential Oil.

• Never reuse drained oil.
• Never mix different types of oil and use.
GOLD
22 777-MAT-0340 / Rear Axle Oil - REPLACE / 0.18 HRS
Tools Required
Size Type Quantity
10 mm Allen Key 01
Rear Differential Oil Level & Leak Inspection
Rear Differential Oil – MAHINDRA “MAXIMILE ELITE”

GOLD
22.1 Rear Differential Oil Replacement – Draining Procedure:
1. Remove rear differential oil level plug

using 10 mm allen key.
2. Remove rear differential drain plug using

10 mm allen key and drain the entire oil
completely.
• Place a tray beneath the drain plug for collecting the oil while draining.
• Ensure entire oil is drained before filling the new oil.
GOLD
22.2 Rear Differential Oil Replacement – Filling Procedure:
1. Clean the oil level plug & drain plug and

surrounding area.
2. Refit the drain plug and torque tighten to

specified value.
Torque: 47 ± 7 Nm

4. Refit the oil level plug back and torque

tighten to specified value.
Torque: 47 ± 7 Nm
• Recommend to use only MAHINDRA “MAXIMILE ELITE” Differential Oil.

• Never reuse drained oil.
• Never mix different types of oil and use.
GOLD
23 780-MAT-0350 / Rear Wheel Bearings - Lubricate / 0.8 HRS
Tools Required
Size Type Quantity

- Flat end screw driver 01
- Nose plier 01
- MST-Special Hub spanner 01
11 mm/ 14 mm Open end spanner 01
• Position the vehicle on a 2 post lift.
• Remove the Rear Back Plate.
Rear Wheel Bearings Inspection
GOLD
23.1 Removal:
1. Remove the rear axle shaft and brake 4. Remove the axle shaft with wheel hub
drum from the wheel hub. from axle assembly and separate the wheel
hub from axle shaft.
2. Using a wheel bearing adjusting nut
special tool, loosen and remove the wheel
bearing outer nut and washer.
5. Separately take out the axle shaft

bearing outer race from the wheel hub.
3. Mount the axle shaft puller on wheel hub,

pull out and remove the axle shaft by hitting
the sliding hammer outwards.
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6. Remove the wheel bearing from the
wheel hub by using hydraulic press.
7. Follow the Steps 1 to 6 for other side

wheel bearing removal.
23.2 Inspection:
1. Check rear wheel bearings for any damage.
2. Check rear wheel bearings for wear & tear.
• Clean bearing & outer race with metal cleaning solvent before Inspection.
• Clean bearing bore in the housing.
• Bearing should not be ‘Spin dried’ with compressed air. Air should be directed so
that it goes through the bearing.
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23.3 Installation:
1. Using hydraulic press refit the wheel 2. Insert the axle shaft bearing outer race
bearing on axle shaft. on shaft bearing.
Apply grease by hand evenly on both sides

of the bearing.
• Ensure that the axle shaft bearing is

properly seated in its position.
• Apply the sufficient quantity of LC
grease (Lithium Complex Grease) on
rear axle shaft bearing in axle housing.
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3. Position the wheel hub with bearing on
rear axle tube and torque tighten the locking
nut with washer.
It is strongly recommended to properly

grease (LCG — Lithium Complex Grease)
the wheel bearing seating area on axle
tube before inserting the shaft.
Ensure to properly seat the axle shaft

bearing outer race on axle tube.
4. Refit the Rear brake drum and axle shaft.
5. Follow the Steps 1 to 4 for other side

wheel bearing Refitment.
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24 780-MAT-0370 / Brake & Clutch Fluid Level And Leak - Inspect
/ 0.05 HRS
1. Position the vehicle on level ground/ 2 post lift /4 post lift.
Brake/ Clutch Fluid – Level & Leak Inspect
Brake & Clutch Fluid – “Maximile DOT 3”

Brake & Clutch System Capacity – 1 liter.
1. Check Brake/clutch reservoir fluid level,

if found less than MIN mark, top up to
MAX mark.
2. Check the reservoir for leakage and
check the level of fluid, if found less top
up till MAX mark
3. Always maintain fluid level at MAX
mark on reservoir
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24.1 Check for Brake Fluid leakages at :
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).
2. Check for brake fluid leakage at master

cylinder outlet pipes.
5. Check for brake fluid leakage at front

caliper inlet and bleeding nipple (Both RH &
LH).
3. Check for brake fluid leakage at front
three way tee connection.
6. Check for brake fluid leakage at rear

flexible hose inlet & rear 3 way tee
connection.
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7. Check for brake fluid leakage at rear
wheel cylinder inlet and bleeding nipple (Both
LH & RH side).
• 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.
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24.2 Check for leakage in Clutch system at:
1. Clutch bundy tube connection to master 4. Flexible hose joint on slave cylinder.
cylinder.
5. Check clutch master cylinder for any

2. Clutch bundy tube connection to flexible leakage.
hose joint.
3. Clutch slave cylinder bleed screw.
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• Use recommended fluid & do not mix different brand fluids.

• Use the same brand fluid for top up; do not top up with used and unsealed clutch
fluid container.
• The clutch fluid reservoir cap/ container should not be opened with dirty hands.
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25 780-MAT-0390 / Brake & Clutch Fluid - Replace / 0.6 HRS
Tools Required
Size Type Quantity

- Transparent tube & 01
container
1. Position the vehicle on a 2 post lift /4 post lift.
2. Open the bonnet.
Brake & Clutch Fluid - Replace
Brake & Clutch Fluid – “Maximile DOT 3”

Brake & Clutch System Capacity – 1 liter.
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• Entire bleeding operation should be done with engine ON condition.

• In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is
required.
• 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.
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25.1 Brake Fluid Draining Procedure :
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.
• Press the brake pedal gently to drain

the fluid completely.
2. Pull-out the bleeding nipple dust cap

from both front RH and LH bleeding nipple.
3. Pull-out the bleeding nipple dust cap

from both rear RH and LH bleeding nipple.
5. Hand tighten all bleeding nipples.
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25.2 Clutch Fluid Draining Procedure:
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.
3. Open the clutch reservoir cap by rotating

it in anti-clockwise direction.
• Press the clutch pedal gently for

draining the complete clutch fluid.
4. Remove the dust cap of the bleeder
screw. • Collect the fluid drained in a tray.
Avoid spilling on floor.
5. Connect a transparent tube to bleeding
screw on slave cylinder and insert the other
end of tube in to an empty container.
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25.3 Brake Fluid Refilling Procedure
1. Fill recommended brake fluid up to

“MAX” mark on the brake fluid reservoir.
2. Press and release brake pedal gently, so

that brake fluid will get circulated throughout
the circuit.
3. Open each bleeding nipple one by one in

the order of bleeding sequence given below,
pump the brake pedal gently and close
bleeding nipple as soon as the constant flow
of fluid starts without air bubbles.
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25.4 Brake Fluid Air Bleeding Procedure:
• 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 CAMPER / CAMPER GOLD
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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.
• Rear right wheel.

• Front left wheel.
• Front right wheel. • Ensure proper quantity of brake fluid
in the reservoir throughout the
2. Connect a transparent tube into rear LH bleeding procedure.
bleeding nipple and insert the other end of
tube in a transparent container with brake
fluid.
• Ensure other end of tube is

submerged in liquid, else chances for
air entry is high.
• Always use transparent tube for better
visibility of air bubbles.
4. Open the rear LH bleeding screw, allow

the fluid to flow through the transparent pipe
into the container.
• Air bubbles will escape from brake

circuit to container through
transparent pipe and the bubbles will
be clearly visible.
5. Tighten the bleeder screw as soon as

there is no air bubbles visible in the
transparent tube.
6. Continue steps 2-4 till there is no air

bubbles visible in the transparent tube.
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7. Remove the transparent tube. 13. Maintain recommended brake fluid up
to MAX mark on the brake fluid reservoir.
8. Tighten the bleeding screw firmly.
9. Follow steps from 2-8 for Rear RH side

brake.
10. Follow steps from 2-8 for Front LH side

brake.
11. Follow steps from 2-8 for front RH side

brake.
12. Refit the dust cap back on all the

bleeding nipples (both front and rear).
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25.5 Clutch Fluid Re-Filling and Bleeding Procedure
1. Connect a transparent tube to bleeding 4. Holding the clutch in depressed condition

screw on slave cylinder. loosen the bleeding screw till fluid starts
flowing through the transparent tube in to the
2. Ensure that the other end of the tube is bottle.
fully immersed in the bottle having clean
clutch fluid.
• If the bleeding operation is done

without connecting a tube and in the
open air then the chance of air
remaining trapped is high.
During this operation ensure fluid level in

reservoir.
5. Continue steps 4 & 5 till all the air escape

in to the container bottle [no more air bubbles
visible in transparent tube].
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.
8. Check the fluid level in reservoir and top

up to the ‘MAX’ level if required.
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9. Close the Brake/clutch fluid reservoir cap
by rotating it in clockwise direction.
10. Check and ensure proper working of

clutch.
11. If pedal sponginess is present do the

entire bleeding procedure again.
• 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.
• Always use “Maximile DOT 3” brake fluid.
• During the bleeding operation ensure the container and pipe used is of transparent
for better visual.
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26 780-MAT-0430 / Front Brake Pads/ Calipers - Inspect / 0.38
HRS
Tools Required
Size Type Quantity
21 mm Wheel Spanner 01
12 mm Socket spanner 01
Brake Pads / Caliper Inspect
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26.1 Brake Pad Removal
1. Using 21 mm wheel spanner remove the 4. Remove the brake pads.

mounting nuts and remove the respective
side front wheel.
5. Remove the anti-rattle clips.
2. Remove front caliper lower mounting bolt

using a 12 mm socket spanner.
3. Lift the caliper upwards as shown in the

illustration.
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26.2 Brake Pad / Caliper Inspection
Brake Pad Inspection:

• Clean and Inspect the pads for wear,
damage and looseness.
Measure the pad lining thickness if it is found
to be 1 mm or less, it has to be replaced.
Limits:
• New pad thickness: 9.5 mm.
• Useful PAD Thickness: 8.5 mm.
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.
• Inspect the front brake caliper piston seal

condition for any leakage.
• Inspect the front brake caliper piston
proper fitment.
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26.3 Brake Pad Installation
• 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.
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1. Fix both the anti-rattle clips back in its 3. Move the caliper downwards and bring
position. back to its original position.
• Replace anti-rattle shims with a new

one if found any damage or crack.
• Always replace the anti-rattle shims
with a new one during brake pad
replacement.
• For easy movement, pull the caliper

outwards a bit and move it down.
• Chances for piston seal damage is
high, so take adequate precaution
while moving the caliper downwards.
• If the pads are changed with a new
2. Refit the brake pads. one, push both the pistons inside
before moving the caliper downwards.
4. Refit the caliper bottom mounting bolt

Ensure both the brake pads are fitted and torque tighten to specified torque value.
properly.
Ensure the sliding pins are greased well,

whenever removed or replaced.
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5. Refit the front wheel with the help of
mounting nuts and torque tighten it to
specified torque value in recommended
sequence.
6. Follow the same procedure for other side

of front brake pad and caliper inspection.
• 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.
GOLD
27 780-MAT-0440 / Rear Brake Drum And Lining - Inspect / 0.38
HRS
Tools Required
Size Type Quantity
21 mm Wheel Spanner 01
— Star Screwdriver 01
Rear Brake Drum And Lining - Inspect
GOLD
27.1 Brake Drum Removal Procedure:
1. Remove the rear wheel assembly.
2. Using a star screw driver, remove drum

mounting screw and then slightly hammer
drum using a mallet and remove.
3. Clean and Inspect the brake drums for

signs of cracks, excessive wear or corrosion,
warping or other damage.
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27.2 Brake Drum/Lining Inspection Procedure:
1. Clean the brakes by blowing

compressed air.
2. Check the wheel cylinder for oil leakage.

(It is recommended to check the oil
seepage from wheel cylinder by lifting the
dust boots.)
3. Check the brake lining for wear/cracks or

damage.
4. The minimum usable thickness of the

rear brake liner is 1.65 mm.
• The brake shoe must be replaced

before the rib starts touching the
drum.
• Measure the wear of the brake lining at
the maximum worn out place.
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28 780-MAT-0450 / Parking Brake Operation - Inspect / 0.13 HRS
Tools Required
Size Type Quantity
10 mm, 12 mm Open End Spanner 01
28.1 Parking Brake adjustment
1. Apply and release the parking brake 5

times to condition the cables for normal use.
2. Equalizer is located under the vehicle

next to the Rear propeller shaft.
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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.
Hold the cable while loosening the

adjusting nut.
6. Pull the parking brake lever up slightly,

press the release button on the lever tip and
lower the parking brake lever completely.
4. Position the parking brake lever at 2nd

notch position.
7. Check both the rear wheels for free

rotation, if not, loosen the lock nut and then
loosen the adjusting nut gradually until the
wheels can turn freely.
• Inspect parking brake for excess play, adjust or replace as needed.
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29 780-MAT-0470 / Suspension Bushes / Arms & Links - Inspect /
0.1 HRS
29.1 Suspension Bushes inspect
1. Position the Vehicle on 4 post lift.
29.1.1 Front Suspension Bushes Inspection procedure
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.
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29.1.2 Rear Suspension Bushes Inspection Procedure
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.
29.2 Suspension Links Inspect

29.2.1 Front Suspension Lower Control Arm
Inspect front suspension lower control arm

for any bend, damage or crack.
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29.2.2 Front Suspension Upper Control Arm
Inspect front suspension upper control arm

for any bend, damage or crack.
29.2.3 Front Suspension Stabilizer Bar
Inspect front suspension stabilizer bar for

any bend, twisting, damage or crack.
29.2.4 Front Strut Bar
Inspect front strut bar for any bend, twisting,

damage or crack.
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29.2.5 Front Suspension Coil Spring
Inspect front suspension coil spring for any

bend, twisting, damage or crack.
29.2.6 Front Stabilizer Bar Links
Inspect front suspension stabilizer bar link for

any bend, twisting, damage or crack..
29.2.7 Front Suspension Stabilizer
Inspect front suspension stabilizer bar for

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29.2.8 Front Suspension Shock Absorber
Inspect front suspension shock absorber, for

any bend, leakage, damage or crack.
29.2.9 Front Suspension Spring
Inspect front suspension spring for any bend,

twisting, damage or crack.
29.2.9.1 Front Stabilizer Bar Link
Inspect front suspension stabilizer bar link for

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29.2.10 Rear Suspension Shock Absorber
Inspect rear suspension shock absorber, for

any bend, leakage, damage or crack.
29.2.11 Rear Suspension Spring
Inspect rear suspension spring for any bend,

twisting, damage or crack.
• 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.
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30 780-MAT-0500 / Power Steering Fluid Level - Inspect / 0.03
HRS
30.1 Power Steering Fluid Level & Leak — Inspect
Power Steering Oil - MAHINDRA "MAXIMILE POWER STEERING FLUID" GENUINE

POWER STEERING FLUID
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30.1.1 Power Steering Fluid Leak Checking Procedure
• 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.
• Recommend to use MAHINDRA "MAXIMILE POWER STEERING FLUID" GENUINE

POWER STEERING FLUID.
• In case of non-availability of Genuine fluid, SHELL MAKE "SPIRAX S3 ATF MD3" /
CALTEX MAKE "TEXAMATIC 1888" can be used. NO OTHER BRANDS
RECOMMENDED
• Driving a vehicle with power steering fluid below the minimum mark will damage
steering system.
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31 780-MAT-0510 / Wheel Alignment / 0.4 HRS
31.1 Wheel Alignment procedure

Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile
maintenance that consists of adjusting the angles of the wheels so that they are set to the
specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that
vehicle travel is straight and true (without "pulling" to one side).
Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular
to the ground and parallel to each other. The purpose of these adjustments is maximum tyre
life and a vehicle that tracks straight and true when driving along a straight and level road. The
symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or
drifting away from a straight line, Wandering on a straight level road, Spokes of the steering
wheel off to one side while driving on a straight and level road.
Tools Required
Size Type Quantity
• 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:
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Wheel Alignment Sequence- (Rigid Front Suspension)
Wheel Alignment Sequence- (Independent Front Suspension)
• If above sequence is not followed, it will lead to incorrect wheel alignment even
though individual adjustments are done correctly.
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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.
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Wheel Alignment - Check & Adjust
Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to
each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and
true tracking along a straight and level road.
Specification for Wheel Alignment
Front Rigid Suspension:
Bolero Values in Degree-Minutes Values in Degree-Decimal

Camp-
er
Re-
fresh Remark
Nomi- Nomi-
2WD/ Min Max Min Max
nal nal
4WD
(Rigid)
Not
Camber 0⁰ 00’ (-) 0⁰ 30’ 0⁰ 30’ 0⁰ (-) 0.5⁰ 0.5⁰ adjusta-
ble
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
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Front Independent Suspension:
Bolero Values in Degree-Minutes Values in Degree-Decimal

Camp-
er
Gold
VX/ZX Remark
Nomi- Nomi-
Re- Min Max Min Max
nal nal
fresh
(IFS)
(-) 0⁰ 00’ (-) 0⁰ Adjusta-

Camber 0⁰ 30’ 1⁰ 00’ 0.5⁰ 1⁰
ble
Not
Caster 4° 00’ 3⁰ 00’ 5⁰ 00’ 4° 3⁰ 5⁰ adjusta-
ble
Not
KPI
11⁰ 30’ 10⁰ 30’ 12⁰ 30’ 11.5⁰ 10.5⁰ 12.5⁰ adjusta-
/SAI
ble
Toe-In
(Individ- (+) 0⁰ 15’ (+) 0⁰ 12’ (+) 0⁰ 18’ (+) 0⁰ 25’ (+) 0.2⁰ (+) 0.3⁰ Adjusta-
ual) ble
Toe-In Adjusta-
(Total) 3 to 5 mm
ble
Steering setting angle – (Toe-out on turns) :
Left Wheel Right Wheel
Left Lock 46° 38°
Right Lock 38° 46°
• Wheel alignment procedure to be done in vehicle unladen condition only.

• Do wheel alignment only according to manufacturer's specifications.
• 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.
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31.1.1 Camber Adjustment Procedure
Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front.
• While adjusting camber angle vehicle should be unladen and nobody should sit
inside.
• The camber values for independent front Suspension should be within: (-) 0⁰ to 1⁰.
• The difference between two wheels should be within: 0.5°.
1. Using a 18 mm socket spanner loosen

the upper control arm and chassis bracket
locking nuts.
While loosening hold the bolt with the

help of a 16 mm ring spanner.
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2. The camber angle is adjusted by
adjusting shims.
• To increase the camber, add shims in

between upper control arm and
chassis bracket.
• To decrease the camber, remove
shims from upper control arm and
chassis bracket.
• Difference between left and right
camber value should be within < 20’.
• By interchanging 1 mm of shim
camber will vary approximately 8’.
3. Tighten the upper control arm and

chassis locking nuts to specific torque. Then
recheck the camber angle.
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31.1.2 Toe-in Adjustment Procedure (IFS)
Toe is the difference of measured distances between the front ends of the tyres (A) and the
rear ends of the tyres (B) along the same axle when viewed the wheels from the top.
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1. Hold tie rod end using a 21 mm open end 3. After adjusting the length of tie rods,
spanner first and then loosen tie rod end lock recheck toe in and then hold tie rod end with
nut with the help of 19 mm open end 19 mm open end spanner and then tightening
spanner. locknut with 19 mm open end spanner.
2. Toe-in is adjusted by varying the length

of tie rods with the help of 14 mm open end
spanner. • Front Toe In to be adjusted individually
on LH and RH side tie rod ends.
• The Front Total Toe In values should
be within: 3 to 5 mm.
While adjusting toe-in, adjust the length

of both the tie rods by rotating them in
the same direction such that their
lengths remain equal at all times.
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31.1.3 Toe-in Adjustment Procedure (Rigid Suspension)
Toe is the difference of measured distances between the front ends of the tyres (A) and the
rear ends of the tyres (B) along the same axle when viewed the wheels from the top.
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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.
2. Toe-in is adjusted by varying the length

of master tie rod with the help of pipe wrench.
• The Front Total Toe In values should

be within: (+) 0.13⁰ to (+) 0.27⁰ each
side.
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32 780-MAT-0520 / Tyre Rotation / 0.25 HRS
32.1 Tire Rotation
• 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.
Nut/ Bolt Description Torque value - Nm
Wheel nut (Steel/Alloy) 88±17
Spare Wheel Nut 88±17
GOLD
33 780-MAT-0550 / Battery Health Checkup / 0.1 HRS
Tools Required
Size Type Quantity
10 mm Open end or Ring spanner or socket spanner 01
MDX - 650P Midtronics Battery Tester 01

1. Park the vehicle on a level ground.
2. Open the bonnet.
Battery Health - Inspect
GOLD
33.1 Battery Health Testing:
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.
3. Open the driver door and get inside the

vehicle.
4. Press the Enter button and confirm the

BATTERY LOCATION by selecting the “IN
VEHICLE” in the tester using navigation
button Up or Down.

BATTERY TYPE by selecting the
“REGULAR FLOODED” in the tester using
navigation button Up or Down.

POST TYPE by selecting the “TOP POST” in
the tester using navigation button Up or
Down.
GOLD
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
Exide 85D26RMF 85D26RMF
Without ESS
Exide 65D26RMF 65D23
Amaron 65D26R 65D26R
GOLD
10. Press the Enter button and perform the
TESTING.
11. Once the TESTING done, the initial

battery result will be display.
12. Press the PRINT button to get the hard

copy print out.
13. Close the bonnet.
GOLD
Follow the below table for Battery Testing test results condition and remedial action:
Testing Test Result Remedial Action
GOOD BATTERY Battery in good condition.
GOOD-RECHARGE Fully charge the battery.
• Fully charge the battery

and retest. Failure to fully
charge the battery before
retesting may cause
inaccurate results. If
CHARGE & RETEST
appears again.
CHARGE & RETEST • Check the electrolyte level.
If electrolyte level is low fill
it to the level and fully
charge the battery.
• If “CHARGE & RETEST”
appears again, then
replace the battery.
Battery
• A REPLACE BATTERY
result may also mean a
poor connection between
the battery cables and the
battery. After disconnecting
the battery cables, retest
the battery using the out of-
vehicle test.
REPLACE BATTERY
• Check the electrolyte level.
If electrolyte level is low fill
it to the level and fully
charge the battery.
• If “REPLACE BATTERY”
appears again, then
replace the battery.
BAD CELL-REPLACE Replace the battery.
GOLD
34 780-MAT-0560 / All Lights, Horns, Wipers And Washers -
Check / 0.03 HRS
34.1 Lighting Control Stalk

The lighting control stalk is located on the right hand side of the steering wheel and is a part of
the combination switch. It controls operations of parking lamps, head lamps, head lamp beam
selection, high beam flashing and turn signals.
34.2 Turn Signals
Taking a Right Turn

• Push the lighting control stalk clockwise
(to stop position B) to indicate a right turn.
The instrument cluster arrow lamp
pointing towards the right flashes along
with the right side turn signal lamps with
chime indicating your intention of turning
towards right
• After you have completed your right turn,
the stalk will automatically return to the
neutral position. Both the right turn lamp
and the right turn signal lamp switch OFF
Taking a Left Turn
Turn Signal - Turn Signal -
A B Push the lighting control stalk anti-clockwise
Left Right
(to stop position A) to indicate a left turn. The
instrument cluster arrow lamp pointing
towards the left flashes along with the left
side turn signal lamps with chime indicating
your intention of turning towards left
After you have completed your left turn, the
stalk will automatically return to the neutral
position. Both the left arrow lamp and the left
turn signal lamp switch OFF
Lane Changing
You can signal a lane change by moving the
lighting control stalk clockwise or anti-
clockwise to the limit point of free movement
of the lever and releasing it once you change
the lane.
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.
GOLD
34.3 Lamps OFF
Rotate the outer rotary switch on the lighting

control stalk aligning the “dot” on the switch
to “OFF” on the stalk to switch OFF all lamps.
34.4 Parking Lamps ON

to the “1st detente” position on the stalk to
switch ON the parking lamps.
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.
GOLD
34.5 Head Lamp ON

to the “2nd detente” position on the stalk to
switch ON the head lamps.
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.
34.6 Head Lamp High Beam
With the head lamp low beam ON, push the

lighting control stalk down (away) from
steering wheel to switch ON the head lamp
high beam. The head lamp high beam telltale
lamp in the instrument cluster illuminates
indicating high beam option selected.
A Low Beam B High Beam
34.7 Head Lamp Low Beam

With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel
to switch ON the head lamp low beam.
GOLD
34.8 Head Lamp Flash
Pull the lighting control stalk (from the head

lamp low beam position) towards the steering
wheel to instantaneously flash the head lamp
high beam. The head lamp flash works even
when the head lamp is OFF.
34.9 Head Lamp Leveling System
When the vehicle is either fully or partially

loaded, it may have an upward inclination
disturbing the head lamp aiming. A correct
head lamp setting provides good visibility to
the driver with minimum inconvenience to
other road users.
To properly aim the head lamp beam, use the
head lamp leveling switch. This switch is
located on the left side of the steering column
shroud in the instrument panel center bezel.
This switch has 2 positions marked as 0,1.
Switch Position Vehicle Loading Condition
0 Driver only or Driver with Front Passenger
1 Driver + Front passenger + Cargo Loaded
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.
GOLD
34.10 Roof Lamp
A. The Roof lamp remains permanently OFF

in this position
B. The Roof lamp remains in AUTO mode (if
equipped) in this position. The lamp remains
ON as long as the driver door is open and
switches OFF when door is closed properly
C. The Roof lamp remains permanently ON in
this position
Do not leave the Roof lamp in permanent ON mode. This will drain your vehicle battery.
34.11 Hazard Warning Lamp
The hazard warning lamp switch is located on

the instrument panel center bezel as shown in
the figure.
To turn the hazard warning lamp ON, pull the
switch up. All the turn signal lamps flash. The
instrument cluster lamps also flash when the
hazard warning lamp is switched ON. To turn
OFF, push the switch down.
Use the hazard warning lamp when your
vehicle is stationary or to warn other road
users to be cautious while passing your
vehicle.
The turn lamps do not work when the hazard warning lamps are operational.
GOLD
34.12 Horn
Press the pad on the steering wheel to blow/

sound the horn. The horn functions even
when the ignition has been switched OFF.
34.13 Wiper Control Stalk

The wipe/wash function can be activated only when the ignition is in “ACC” or “ON” position.
A Flick Wipe (MIST)

B Off
C Intermittent (INT)
D Low Speed (LO)
E High Speed (HI)
34.14 Wiper Off

The wipe function is OFF when the wipe control stalk is in neutral position (A).
GOLD
34.15 Flick-Wipe (Mist)
Push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously
(simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk
automatically comes back to position B when released.
34.16 Intermittent (INT) Mode

Intermittent (INT) wiping is selected when the wipe control stalk is pushed down to position C.
In the INT mode, the wiper operates on preset intervals.
34.17 Low Speed Wiping

Push the wipe control stalk down to the position D to operate the wiper at a fixed low speed.
34.18 High Speed Wiping

Push the wiper control stalk down to position E to operate the wiper at a fixed high speed.
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.
Using a windshield washer in freezing temperatures could be dangerous. The washer

fluid could freeze on the windshield, and block your vision resulting in an accident. If
you operate your vehicle in temperatures below 4°C, use washer fluid with antifreeze
protection.
• 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
GOLD
35 780-MAT-0570 / Head Lamp Aiming - Check & Adjust / 0.2
HRS
Tools Required:
Size Type Quantity

- Star screw driver 01

1. Vehicle & black screen/ board both are placed on the same Level surface.
2. Check and ensure all four tyre pressures as per specification.
3. head lamp levelling switch position is on zero (0).
Head Lamp Alignment In The Dark Room.
GOLD
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
Switch Position Vehicle Loading Condition
0 Driver / Driver With Front Passenger
1 Driver + Front Passenger + Cargo Loaded
• If head lamp centre height in BOLERO CAMPER/CAMPER GOLD 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.
GOLD
36 780-MAT-0610 / Tyre Pressure - Check And Adjust / 0.15 HRS
36.1 Tire Pressure Inspection

Proper tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle.
Three primary areas are affected by improper tyre pressure;
1. Safety.
2. Economy
3. Ride Comfort and Vehicle Stability
Proper tyre inflation contributes to a comfortable and safe ride. Overinflating produces a jarring
and uncomfortable ride. Both underinflation and overinflation affect the stability of the vehicle
and can produce a feeling of sluggish response or over responsiveness in the steering.
Unequal tyre pressures can cause erratic and unpredictable steering response or may cause
the vehicle to drift left or right.
Improper inflation pressures can cause uneven wear patterns to develop across the tyre tread.
These abnormal wear patterns will reduce tread life resulting in a need for earlier tyre
replacement. Under inflation also increases tyre rolling resistance and results in higher fuel
consumption.
• The proper cold tyre inflation pressure is listed in the Tyre Label (Vehicle Placard),
located on the driver's door corner.
BOLERO CAMPER TIRE INFLATION PRESSURE KG/CM2
6.0 J R15
Front 2.0
UNLADEN
Rear 2.0
Front 2.0
LADEN 2.5
Rear 3.1 (For Cash Van)
MAHINDRA BOLERO CAMPER Gold TYRE INFLATION PRESSURE KG/CM2

P 235/ 75 R 15
Front 2.0
UNLADEN
Rear 2.0
Front 2.0
LADEN 2.5
Rear 3.1 (For Cash Van)
• 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.
GOLD
• 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.
GOLD
37 780-MAT-0630-MAT-0060 / Underbody Nuts & Bolts For
Tightness - Inspect / 0.3 HRS

1. Park the vehicle in inspection pit /2 post lift/ 4 post lift.
2. Check and tight all the body mounts at every service interval.
Cabin / Cargo Mounting Bolts - Tighten
Nut / Bolt description Torque Value – Nm
Body mtg. bolts 36-50 Nm
Cargo mtg. bolts 36-50 Nm
Refer below sketch for Cabin mounts and its locations on chassis –
GOLD
Refer below sketch for Cargo mounts on chassis
GOLD
38 780-MAT-0680 / Oil Leakage - Inspection / 0.05 HRS
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.
Torque for Oil sump mounting bolts:

25 ± 3 Nm
Torque for Differential cover bolts: Torque for Oil sump drain bolt:
29 ± 5 Nm 22.5 ± 2.5 Nm
Torque for Filler and drain plugs:
47 ± 7 Nm
GOLD
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
specified value.
Torque: 76.5 ± 11.5 Nm
5. Check the flanging areas of transmission

housing for any leakage, if found leakage
refit the transmission center cover and apply 7. Check the rear differential oil cover for
sealant on the mating areas. Then, torque any leakage, if found leakage refit the
tighten the bolts to the specified value. differential cover and apply sealant on the
mating areas. Then, torque tighten the bolts
to the specified value.
Check for leakages at the oil filler and drain
specified value.
Torque: 30 ± 5 Nm
Torque for Differential cover bolts:

29 ± 5 Nm
Torque for Filler and drain plugs:
47 ± 7 Nm
GOLD
39 780-MAT-0690 / Diagnostic Trouble Code — Check / 0.1 HRS

1. Position the vehicle on 2 post lift/ 4 post lift.
2. Turn the ignition OFF.
39.1 DTC — Check Procedure using i-Smart diagnostic tester
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.
6. All ECUs will be analyzed and if screen

3. Select Dearborn Electronics India Pvt showing the registered DTC’s in the following
Ltd. — Garuda and then click START. window, then take the Snap shots for
recording DTC Codes history of that vehicle
for future reference and click “Clear All
DTC”.
4. Select "PIKUP" from the list of vehicles

displayed as in following window.
GOLD
7. Once clicking “Clear All DTC” a pop up
window appear and then click “Yes” on the
window.
8. After clearing DTC, If Screen showing “

No trouble code found” then click “ Finish “
and close the iSmart.
9. Even after clearing DTC, If Screen still

showing any DTC then Refer Diagnostic
manual for more information.
GOLD
39.2 DTC — Check Procedure using miniSMART ANDROID
1. Connect the miniSMART ANDROID VCI 3. From the list, select “DTC Fetch”.
on DLC and turn the ignition ON.
2. Connect the miniSMART Android and

select each “ECU” from the list of controllers.
GOLD
4. The ECU will be analysed and the
registered DTCs will be displayed as in the
following screen, then click “Clear DTC”.
If any DTC is not getting cleared or

healed, refer to Diagnostic manual for
more information.
5. Repeat the above steps 3 to 5 on other

ECU.
GOLD
40 Maintenance Check Sheet
• 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.
GOLD
40.1 Maintenance Check Sheet @10000 Kms
WORK NATURE ACTION WORK STATUS Time

Allotted
Com- Incom- (Man-hours)
plete plete
ENGINE OIL Replace 0.23
ENGINE OIL FILTER Replace 0.08
VALVE CLEARANCE Adjust 0.5
COOLANT Inspect 0.03
AIR FILTER ELEMENT Clean 0.15
WATER IN FUEL FILTER Clean 0.05
EXHAUST PIPE MOUNTINGS & Inspect

0.05
DAMAGE / LEAKAGE
PROP SHAFT SLIDING JOINT Lubricate

0.1
AND UJ
FRONT DIFFERENTIAL OIL (ONLY Replace

FOR 4WD) 0.18
REAR DIFFERENTIAL OIL Replace 0.18
BRAKE & CLUTCH FLUID LEVEL Inspect

0.05
& LEAK
FRONT BRAKE PAD / CALIPERS Inspect 0.38
PARKING BRAKE OPERATION Adjust 0.13
SUSPENSION BUSHES / ARMS & Inspect

0.1
LINKS
POWER STEERING FLUID LEVEL Inspect 0.03
TYRE ROTATION Rotation 0.25
BATTERY HEALTH CHECKUP Checkup 0.1
ALL LAMPS, HORNS, WIPERS Inspect

0.03
AND WASHERS
HEAD LIGHT AIMING Inspect 0.2
GOLD
TYRE PRESSURE Inspect 0.15
UNDERBODY NUTS & BOLTS Inspect

0.3
FOR TIGHTNESS
OIL LEAKAGE Inspect 0.05
DTC CHECK Inspect 0.10
Additional Repair Work carried out, if any -
1)
2)
3)
4)
5)
Observations, Notes if any -
1)
2)
3)
4)
5)
Above Services Performed by – Job Start Time:
Name of the Technician –
Date of Service – Job End Time:
Repair order No –
Repair order date - Standard Time: Camper 3.40

man-hrs, ,Camper Gold-3.24man-
hrs
GOLD
40.2 Maintenance Check Sheet @20,000 Kms
WORK NATURE ACTION WORK STATUS Time Allotted

(Man-hours)
Complete Incomplete
ENGINE OIL Inspect 0.02
AIR FILTER
Clean 0.15
ELEMENT
WATER IN FUEL
Clean 0.05
FILTER
EXHAUST PIPE
MOUNTINGS & Inspect 0.05
DAMAGE / LEAKAGE
TRANSMISSION OIL Replace 0.18
PROP SHAFT
SLIDING JOINT and Lubricate 0.1
UJ
BRAKE & CLUTCH Inspect 0.05

FLUID LEVEL & LEAK
FRONT BRAKE Inspect 0.38

PADS/ CALIPERS
REAR BRAKE DRUM Inspect 0.38

AND LINING
PARKING BRAKE Inspect 0.13

OPERATION
SUSPENSION
BUSHES / ARMS & Inspect 0.1
LINKS
POWER STEERING Inspect 0.03

FLUID LEVEL
TYRE ROTATION Inspect 0.25
BATTERY HEALTH Checkup 0.1

CHECKUP
ALL LAMPS, HORNS,

WIPERS AND Check 0.03
WASHERS
GOLD
Check and
TYRE PRESSURE Adjust 0.15
UNDERBODY NUTS
& BOLTS FOR Inspect 0.3
TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper 2.61 man-hrs, ,Camper Gold-
2.63 man-hrs
GOLD

(Man-hours)
Complete Incomplete
VALVE CLEARANCE Check &

Adjust 0.5
AIR FILTER ELEMENT Replace 0.1
FUEL FILTER Replace

0.2
ELEMENT
EXHAUST PIPE Inspect

MOUNTINGS & 0.05
DAMAGE / LEAKAGE
PROP SHAFT Lubricate

SLIDING JOINT and 0.10
UJ
BRAKE & CLUTCH Replace

0.60
FLUID
FRONT BRAKE PADS/ Inspect

0.38
CALIPERS
PARKING BRAKE Inspect

0.13
OPERATION
SUSPENSION Inspect
BUSHES / ARMS & 0.1
LINKS
POWER STEERING Inspect

0.03
FLUID LEVEL
BATTERY HEALTH Inspect

0.10
CHECKUP
ALL LIGHTS, HORNS, Inspect

WIPERS AND 0.03
WASHERS
GOLD

(Man-hours)
Complete Incomplete
TYRE PRESSURE Check and

Adjust 0.15
UNDERBODY NUTS & Inspect

BOLTS FOR 0.3
TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper 3.51 man-hrs, Camper

Gold-3.51 man-hrs
GOLD
40.4 Maintenance Check Sheet @ 40,000 Kms

(Man-hours)
Complete Incomplete
ENGINE OIL LEVEL Inspect 0.02
EXHAUST PIPE
MOUNTINGS & Inspect 0.05
DAMAGE/LEAKAGE
PROP SHAFT SLIDING

Lubricate 0.05
JOINT and UJ
BRAKE & CLUTCH Inspect 0.05

FLUID LEVEL & LEAK
FRONT BRAKE PADS/ Inspect 0.38

CALIPERS
REAR BRAKE DRUM Inspect 0.38

AND LINING

OPERATION
SUSPENSION BUSHES / Inspect 0.10

ARMS & LINKS
POWER STEERING Inspect 0.03

FLUID LEVEL
Check &
WHEEL ALIGNMENT Adjust 0.40
BATTERY HEALTH Check up

0.10
CHECK UP
ALL LAMPS, HORNS,

Check 0.03
WIPERS & WASHERS
GOLD

(Man-hours)
Complete Incomplete

BOLTS FOR TIGHTNESS 0.3
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper 2.83 man-hrs, Camper

Gold-2.85 man-hrs
GOLD

(Man-hours)
Complete Incomplete

Adjust 0.5
WATER IN FUEL Clean

0.05
FILTER

MOUNTINGS & 0.05
DAMAGE / LEAKAGE
TRANSFER CASE OIL Replace 0.18
PROP SHAFT Lubricate

SLIDING JOINT and 0.1
UJ
REAR WHEEL Lubricate

0.8
BEARINGS
BRAKE & CLUTCH Inspect

0.05
FLUID-LEVEL & LEAK
FRONT AND REAR Inspect

BRAKE PADS / 0.38
CALIPER

0.13
OPERATION
SUSPENSION Inspect
BUSHES / ARMS & 0.1
LINKS

0.03
FLUID LEVEL
GOLD

0.10
CHECK UP
ALL LAMPS, HORNS, Inspect

0.03
WIPERS & WASHERS

BOLTS FOR 0.3
TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper – 3.82 man-hrs, , Camper

Gold- 3.84 man-hrs
GOLD

(Man-hours)
Complete Incom-
plete
ACCESSORY DRIVE Inspect 0.05

BELTS
COOLANT Replace 0.42
FUEL FILTER ELEMENT Replace 0.2
EXHAUST PIPE
MOUNTINGS & DAMAGE/ Inspect 0.05
LEAKAGE
PROP SHAFT SLIDING

Lubricate 0.1
JOINT and UJ
BRAKE & CLUTCH FLUID Inspect 0.05

LEVEL & LEAK
FRONT BRAKE PADS / Inspect 0.38

CALIPERS
REAR BRAKE DRUM AND Inspect 0.38

LINING

OPERATION
SUSPENSION BUSHES / Inspect 0.1

ARMS & LINKS
POWER STEERING FLUID Inspect 0.03

LEVEL

0.10
CHECK UP
ALL LAMPS, HORNS, Inspect 0.03

WIPERS & WASHERS
GOLD

(Man-hours)
Complete Incom-
plete

0.3
BOLTS FOR TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper – 3.12 man-hrs,

Camper Gold- 3.24 man-hrs
GOLD

(Man-hours)
Complete Incomplete

Adjust 0.5
EXHAUST PIPE MOUNTINGS Inspect

0.05
& DAMAGE / LEAKAGE
PROP SHAFT SLIDING Lubricate

0.1
JOINT and UJ
FRONT AXLE OIL Replace 0.18
REAR AXLE OIL Replace 0.18
BRAKE & CLUTCH FLUID Replace 0.6

0.38
CALIPERS

0.13
OPERATION
SUSPENSION BUSHES / Inspect

0.1
ARMS & LINKS
POWER STEERING FLUID Inspect

0.03
LEVEL
BATTERY HEALTH CHECK Inspect

0.10
UP

0.03
WIPERS & WASHERS
GOLD

0.3
BOLTS FOR TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper– 3.77 man-hrs,

Camper Gold- 3.59 man-hrs
GOLD

Allotted
Complete Incom- (Man-hours)
plete
ACCESSORY DRIVE BELTS Replace 0.20

0.05
& DAMAGE/LEAKAGE

0.10
JOINT and UJ
BRAKE & CLUTCH FLUID Inspect

0.05
LEVEL & LEAK

0.38
CALIPERS
REAR BRAKE DRUM AND Inspect

0.38
LINING

0.13
OPERATION

0.1
ARMS & LINKS

0.03
LEVEL

0.10
UP

0.03
WIPERS & WASHERS
GOLD

Allotted
Complete Incom- (Man-hours)
plete

0.3
BOLTS FOR TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper – 2.63 man-hrs, ,

Camper Gold — 2.70 man-hrs
GOLD

(Man-hours)
Complete Incomplete

Adjust 0.5
FUEL FILTER ELEMENT Replace 0.2

0.05
& DAMAGE / LEAKAGE

0.1
JOINT and UJ
BRAKE & CLUTCH FLUID- Inspect

0.05
LEVEL CHECK

0.38
CALIPERS

0.13
OPERATION

0.1
ARMS & LINKS

0.03
LEVEL

0.10
UP

0.03
WIPERS & WASHERS

0.3
BOLTS FOR TIGHTNESS
GOLD
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper – 2.96 man-hrs, ,

Camper Gold - 2.96 man-hrs
GOLD

(Man-hours)
Complete Incom-
plete

MOUNTINGS & DAMAGE/ 0.05
LEAKAGE
TRANSFER CASE OIL Replace 0.18

0.1
JOINT and UJ
REAR WHEEL BEARINGS Lubricate 0.8
BRAKE & CLUTCH FLUID Inspect

0.05
LEVEL & LEAK

0.38
CALIPERS
REAR BRAKE DRUM AND Inspect

0.38
LINING
PARKING BRAKE Adjust

0.13
OPERATION

0.1
ARMS & LINKS

0.03
FLUID LEVEL
BATTERY HEALTH Checkup

0.10
CHECK UP

0.03
WIPERS & WASHERS
GOLD

(Man-hours)
Complete Incom-
plete

0.3
BOLTS FOR TIGHTNESS
1)
2)
3)
4)
5)
1)
2)
3)
4)
5)
Repair order No –
Repair order date - Standard Time: Camper – 3.41 man-hrs,

Camper Gold - 3.43 man-hrs

Mahindra Bolero Camper Camper Gold BS 6

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Mahindra Bolero Camper Camper Gold BS 6

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Maintenance Manual

1.1 Maintenance Schedule

1.2 Standard Operating Procedures (SOP)

1.3 Check Sheets

1.4 Explanation on Colour Codes used in Illustrations

1.5.2 Vehicle Protection

1.5.4 Parts and Tools

1.5.5 Removed Parts

Term/ Symbol Denotation

DANGER indicates an imminently hazardous

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

NOTICE Indicates important information

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

Dis - assembly Sequence

Lubrication Symbol (Semi solid)

DESCRIPTION CHANGE INTERVAL 10 20 30 40 50 60 70 80 90 100

Replace at first 10000 then at

Engine Oil Change engine oil in 10000km or 12 months(whichever is earlier), if

Valve Clearance Adjust First 10000, then every 20000 km A A A A A

Air, Fuel and Exhaust

Fuel Filter element Replace at every 30000 km R R R

Brakes and Clutch

DESCRIPTION CHANGE INTERVAL 10 20 30 40 50 60 70 80 90 100

• Always use "MAXIMILE ULTRA"

Brand specific. Use of other brand coolants /

If Syntec F2 is used, oil change has

For other than maximile brand, the

For other than maximile brand, the

If Maximile DOT 3 brake fluid is not used and in

Advise to use only the Genuine grease for better

We do not recommend any supplementary fuel

Sl No Part No Description Quantity

1 0311AAC00260N Cu non asbestos washer dia 16 01

2 0313AAB03061N Air filter element 01

3 S0305D020021N Element - fuel filter 01

4 S0305D020011N O ring - filter bowl 01

5 0306DAB00301N Belt alternator 01

6 0306CAB00161N Belt power steering 01

7 0306AAB00551N Belt compressor 01

5.1 Engine Oil Level Checking Procedure

3. Insert the dip stick gauge into the dip

5. Insert the dip stick back and fix properly,

• Maintain the oil level in the safe range. Do not overfill.

Size Type Quantity

Engine Oil – MAHINDRA "MAXMILE ULTRA"

1. Clean the area around the drain plug.

2. Place a drain pan beneath the engine

• Hot oil can cause burns to skin. Do not

3. Loosen and remove engine oil drain plug

4. Allow the entire engine oil to get drained.

2. Verify the sealing washer is on the drain

6. Fill recommended quantity of engine

Torque : 22.5 ± 2.5 Nm

3. Torque tighten the drain plug to specified

4. Pull-out the dip stick completely, so that

7. Refit the oil fill cap.

9. Start the engine and check for Oil

3. Insert the dip stick gauge into the dip

5. Insert the dip stick back and fix properly,

• Maintain the oil level in the safe range. Do not overfill.

Size Type Quantity