🏷️ Basic Information

Make:

Mahindra

Model:

Bolero

Variant Codes:

SC (Single Cab), DC (Double Cab), NEF (Nasser Engine Family)

Generation Designation:

First Generation (MUV/SUV platform, evolved from the Armada Grand)

Engine Code Family:

NEF (Nasser Engine Family)

👋 Introduction

Segment:

Compact SUV/MUV and Light Commercial Vehicle (LCV) segment, known for its ruggedness, utility, and affordability.

Competitors:

Traditionally competed against vehicles like the Tata Sumo, Force Motors Trax, and other utility vehicles in its segment, often positioned as a workhorse and reliable people/goods mover.

Bolero Strengths:

Robust body-on-frame construction, capable off-road (in some configurations), simple mechanicals, utilitarian design, high ground clearance, strong torque for hauling.

Professional Standard:

Designed for professional mechanics and technicians, ensuring accuracy and thoroughness for complex repairs and maintenance.

Visual Aid Quality:

Contains detailed photos and diagrams to illustrate procedures, enhancing clarity for both novice and experienced users.

📋 Manual Details

Coverage Scope:

Comprehensive service, repair, and troubleshooting for all systems and components of the Mahindra Bolero SC and DC models equipped with NEF engines.

Estimated Page Count:

Hundreds of pages (specific number not provided, but described as extensive).

Type:

Factory Service Repair Workshop Manual

Language:

English (Assumed based on typical workshop manual conventions for export/international markets)

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Engine mechanical, cooling system, lubrication system, fuel system (including injection), ignition system (if applicable), emission control systems, turbocharger system (if applicable).

Transmission:

Clutch, manual gearbox (gear shifting mechanisms, internal components), transmission fluid, drive shafts, differentials.

Brakes:

Hydraulic system, brake lines, master cylinder, brake boosters, brake calipers, brake pads, brake discs/drums, parking brake system, ABS (if equipped).

Suspension:

Front suspension (e.g., torsion bar, independent), rear suspension (e.g., leaf springs, solid axle), shock absorbers, coil springs, control arms, bushings, steering knuckle.

Steering:

Steering column, steering gear/rack and pinion, power steering system (pump, fluid, hoses, steering rack), tie rods, ball joints.

Electrical:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting system (headlights, taillights, interior lights), wiring harnesses, fuses, relays, ignition system components, instrumentation and gauges, body control modules (BCM) if applicable.

Body:

Body shell structure, doors, hood, tailgate, bumpers, exterior trim, interior trim, seats, upholstery, glass, seals, chassis components, frame, welding procedures.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, evaporator, condenser, compressor, blower motor, controls, refrigerant system.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication points, brake checks, tire rotation.

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, electrical diagnostic charts, fault code interpretation (if applicable).

Repair:

Step-by-step repair instructions for all major and minor components, engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical component repair and replacement.

Diagnostics:

Detailed diagnostic information, circuit diagrams, testing procedures for sensors, actuators, and control modules.

Depth:

Professional level, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely searchable text (as is standard for professional PDF manuals).

Printability:

Yes, printable by page or entire manual.

Binding:

N/A (Digital download - PDF)

Paper Quality:

N/A (Digital download - PDF)

Usage Rights:

Unlimited use on multiple devices, lifelong access, no expiry or renewal fees.

⚙️ Engine Specifications

Engine Family:

Mahindra NEF (Nasser Engine Family)

Engine Type:

Typically a 2.5L or 2.6L Inline-4 Diesel engine, often turbocharged.

Displacement:

Commonly around 2523 cc (2.5 Liters) or 2609 cc (2.6 Liters), depending on specific sub-variant and market.

Bore X Stroke:

Specific figures vary but common for this class of engine.

Compression Ratio:

Typically in the range of 18:1 to 20:1 for naturally aspirated/turbocharged diesel engines.

Horsepower Range:

Approximately 60 HP to 80 HP, with turbocharged variants offering more.

Torque Range:

Around 160 Nm to 200 Nm, optimized for low-end torque for utility.

Fuel Type:

Diesel

Injection Type:

Commonly indirect injection (IDI) or direct injection (DI) with rotary or common rail fuel pumps, depending on the specific NEF engine variant.

Turbocharging:

Many NEF variants feature turbocharging for improved performance and efficiency.

Emission Standards:

Varies by model year and market; may include Euro II, III, or IV compliance features. Manual will cover associated components.

🔧 Transmission

Type:

5-speed manual transmission is typically standard.

Type:

Automatic transmissions are generally not a common option for the Bolero during this generation.

Drivetrain:

Rear-wheel drive (RWD) is standard; some variants may offer selectable four-wheel drive (4WD).

Gear Ratios:

Specific gear ratios will be detailed in the manual, optimized for torque delivery and fuel economy.

Clutch Type:

Typically a single-plate dry type clutch.

📐 Dimensions

Length:

Varies significantly between SC (Single Cab) and DC (Double Cab) variants, generally in the 4.5m - 4.9m range.

Width:

Typically around 1.7m - 1.8m.

Height:

Generally around 1.9m - 2.0m, offering good headroom and commanding view.

Ground Clearance:

Excellent, often exceeding 180mm, suitable for rough terrain.

Gross Vehicle Weight Rating:

Typically in the 2500 kg - 3000 kg range, allowing for substantial payload.

Curb Weight:

Ranges from approximately 1600 kg to 1800 kg depending on configuration.

Payload Capacity:

Designed for significant payload, often exceeding 800 kg for SC variants and slightly less for DC variants.

🛡️ Safety Features

Crash Test Results:

Typically not subjected to rigorous global NCAP or equivalent testing for this segment and era; basic structural integrity is emphasized for utility.

ABS:

Optional on some variants, likely not standard on all.

E Brake Warning:

Standard parking brake indicator light.

Airbags:

Driver airbag may be standard on later models, passenger airbags less common.

Seatbelts:

Three-point seatbelts for front occupants, lap belts for rear/bench seats depending on configuration.

Roll Over Protection:

Reinforced chassis and cabin structure for basic rollover resistance due to its robust construction.

💡 Technology Features

Audio System:

Basic AM/FM radio, CD player, or MP3 player depending on trim level and year. Likely analog or basic digital displays.

Parking Aids:

Reverse parking sensors may be optional on later models.

Bluetooth:

Unlikely on early models; may be present on later, higher-spec variants.

Dashboard Layout:

Functional and utilitarian, with essential gauges like speedometer, tachometer (if equipped), fuel gauge, temperature gauge, and warning lights.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 10,000 km or 6 months, whichever comes first (detailed in manual).

Air Filter Replacement:

Every 10,000 - 20,000 km or as needed based on operating conditions.

Fuel Filter Replacement:

Every 15,000 - 30,000 km, critical for diesel engine longevity.

Coolant Change:

Every 2 years or a specified mileage (e.g., 40,000 km).

Engine Oil Spec:

API CF or higher, SAE 15W-40 or 10W-30 diesel engine oil (specific viscosity depends on climate, refer to manual).

Engine Oil Capacity:

Approximately 5.5 - 6.5 liters, depending on filter and engine variant.

Coolant Type:

Ethylene glycol-based coolant with anti-corrosion inhibitors (typically a 50/50 mix with distilled water).

Transmission Oil Spec:

GL-4 or GL-5 gear oil, typically 75W-90 or 80W-90 viscosity (refer to manual for exact type and grade).

Differential Oil Spec:

GL-5 gear oil, typically 85W-140 for rear axle.

Brake Fluid Spec:

DOT 3 or DOT 4 hydraulic brake fluid.

Common Faults And Fixes:

Front suspension wear (bushings, ball joints), clutch wear, turbocharger issues (if applicable), electrical gremlins (older models), injector pump maintenance for diesel engine. Manual provides detailed diagnostic and repair procedures.

📚 Vehicle History

Mahindra Legacy:

Mahindra & Mahindra is a major Indian conglomerate with a long history in manufacturing utility vehicles, tractors, and defense equipment, known for ruggedness and reliability.

Bolero Lineage:

Evolved from the Mahindra Armada Grand, the Bolero was launched in 1999 and has been continuously updated, maintaining its core utilitarian identity. It's one of Mahindra's longest-running and most successful models.

Manufacturing Location:

Primarily manufactured in India by Mahindra & Mahindra.

Introduction Year:

1999

🏆 Awards & Recognition

Market Success:

Consistently one of India's best-selling UVs, recognized for its durability, reliability in tough conditions, and value for money.

Customer Satisfaction:

High customer satisfaction in its segment due to its workhorse nature and low maintenance costs.