Bolero Pikup FB SC RHD Mdi TC 3200 Bsii Bsiii PS 2WD - Ver 1 - Sept 2007

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

Kandivali
GENERAL INFORMATION

) THIS PARTS CATALOGUE COVERS SERVICEABLE COMPONENTS OF PIK-UP


RANGE OF VEHICLES. IT SHOWS ALL 'BOLERO PIKUP FB PS' VEHICLES FITTED
WITH ''MDI TC BS II & BS III DIESEL ENGINE'.

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

) THE VEHICLE SERIAL NUMBER AND ENGINE SERIAL NUMBER ARE LOCATED
ON THE MANUFACTURER'S PLATE
LOCATED ON RIGHT SIDE TOP
CORNER OF DASH CORNER OF
DASH PANEL ABOVE THE BATTERY
TRAY. ENGINE SERIAL NUMBER IS
ALSO PUNCHED ON CYLINDER
BLOCK ON FRONT PAD
DIESEL BS II & BS III
(NEAR WATER PUMP)
(RHD 2WD) ) THE VEHICLE CHASSIS NUMBER
IS STAMPED ON THE RIGHT SIDE
CHASSIS 'SIDE MEMBER' BELOW
THE FRONT FENDER.

) ADDITIONAL PART NUMBERS GIVEN IN THE BRACKETS ARE OPTIONAL ONCE


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

FIRST EDITION : SEPTEMBER 2007 - VERSION: 1


) THE ASSEMBLIES AND SUB ASSEMBLIES ARE SHOWN EXPLODED VIEW FOR
EASE OF UNDERSTANDING ONLY. THEREFORE ALL THE PARTS SHOWN IN THE
EXPLODED VIEW ARE NOT ESSENTIALLY SERVICEABLE.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE S C S O S O S
MARKED 'NS' ARE NOT SEPARATELY SERVICEABLE.
MAHINDRA & MAHINDRA LTD.
MUMBAI - INDIA ) THE ASSEMBLIES AND SUB ASSEMBLIES ARE SHOWN EXPLODED VIEW FOR
EASE OF UNDERSTANDING ONLY. THEREFORE ALL THE PARTS SHOWN IN THE
EXPLODED VIEW ARE NOT ESSENTIALLY SERVICEABLE.

2
INDEX SHEET
S. NO. GROUP DESCRIPTION PAGE NO.
1 GENINFO GENERAL INFORMATION 3
2 INDEX INDEX 4
3 M11A01 ENGINE ASSEMBLY M11A01.1
MODEL CODE DETAILS 4 M11A02 LUBRICANTS M11A02.1
5 M11B01 CYLINDER BLOCK M11B01.1
NAME DESCRIPTION 6 M11B02 CYLINDER HEAD M11B02.1
BM4210SCNXFTC2PS BOLERO CAMPER SC XL 128.5" MDI TC 2WD BS2 PS KMT90 FB 7 M11B03 CRANKSHAFT M11B03.1
BM4210SCNXFTC3PS BOLERO CAMPER SC XL 128.5" MDI TC 2WD BS3 PS NGT520 FB 8 M11B04 CRANKSHAFT BEARING M11B04.1
9 M11B05 CRANKSHAFT PULLEY M11B05.1
10 M11B06 CONNECTING ROD M11B06.1
11 M11B07 CONNECTING ROD BEARING M11B07.1
12 M11B09 OIL PAN M11B09.1
13 M11B11 FRONT CASE M11B11.1
14 M11B12 ROCKER COVER M11B12.1
15 M11B13 BREATHER M11B13.1
16 M11B14 CYLINDER HEAD GASKET M11B14.1
17 M11B15 PISTON M11B15.1
18 M11B16 FLYWHEEL M11B16.1
19 M11B19 CAMSHAFT M11B19.1
20 M11B20 IDLER GEAR M11B20.1
21 M11B21 VALVE GEAR TRAIN M11B21.1
22 M11B22 INLET MANIFOLD M11B22.1
23 M11B23 EXHAUST MANIFOLD M11B23.1
24 M11B25 OIL FILLER & OIL LEVEL GAUGE M11B25.1
26 M11C01 OIL PUMP AND GEAR TRAIN M11C01.1
27 M11C02 OIL FILTER M11C02.1
28 M11C04 OIL STRAINER AND PIPE M11C04.1
29 M11C05 WATER PUMP M11C05.1
30 M11C07 THERMOSTAT M11C07.1
31 M11C08 FAN AND PULLEY M11C08.1
32 M11C09 DRIVE BELT M11C09.1
33 M11C11 OIL PRESSURE SWITCH OR GAUGE M11C11.1
34 M11C12 OIL LINES - ENGINE M11C12.1
35 M11D01 FUEL INJECTION PUMP (ROTARY) M11D01.1
36 M11D02 FUEL INJECTION PIPE (ROTARY) M11D02.1
37 M11D04 FUEL INJECTION NOZZLE M11D04.1
38 M11E01 ALTERNATOR M11E01.1
39 M11E02 STARTER MOTOR M11E02.1
40 M11F02 EMISSION CONTROL SYSTEM M11F02.1
41 M25A01 ENGINE MOUNTING M25A01.1
42 1101 CLUTCH 1101.1
43 1102 CLUTCH HOUSING 1102.1
44 1103 CLUTCH LINKAGE 1103.1
45 1104 CLUTCH CYLINDER 1104.1
46 1201 FUEL TANK GAUGES AND LINES 1201.1
47 1202 AIR CLEANER 1202.1
48 1203 ACCELERATOR LINKAGE 1203.1

3
INDEX SHEET INDEX SHEET
S. NO. GROUP DESCRIPTION PAGE NO. S. NO. GROUP DESCRIPTION PAGE NO.
49 1301 RADIATOR AND HOSES 1301.1 95 2606 ASSEMBLY INSTRUMENT PANEL 2606.1
50 1401 EXHAUST SYSTEM 1401.1 96 2607A BODY SHELL ASSEMBLY 2607A.1
51 1503 HEAD LIGHT 1503.1 97 2607B CARGO BOX 2607B.1
52 1504 INDICATING LAMP 1504.1 98 2608 DOORS AND FITTINGS (FRONT) 2608.1
53 1505 TAIL, STOP, TURN SIGNAL AND REVERSE LIGHT 1505.1 99 2610A TAIL GATE & FITTINGS 2610A.1
54 1507 BATTERY HOLD DOWN & CABLE 1507.1 100 2610B PLUGS 2610B.1
55 1508 HORN 1508.1 101 2611 BODY TRIMMING 2611.1
56 1509 WINDSHIELD WIPER MOTOR 1509.1 102 2612 PLATES AND COVERS 2612.1
57 1510 WIRING HARNESS 1510.1 103 2613 DRIVER SEAT 2613.1
58 1601 INSTRUMENTS 1601.1 104 2614 FRONT PASSENGER SEAT 2614.1
59 1602 WINDSHIELD WASHER 1602.1 105 2617 FRONT BUMPER 2617.1
60 1700 TRANSMISSION ASSEMBLY - NGT 520 1700.1 106 2618 FENDER EXTENSION & MUD FLAP 2618.1
61 1701A TRANSMISSION HOUSING & ATTACHING - NGT 520 1701A.1 107 2619 TOOLS 2619.1
62 1702 SELECTION BIASING - NGT 520 1702.1 108 2620 FLOOR TRIMMING 2620.1
63 1703 SHAFT RAIL & FORKS - NGT 520 1703.1 109 2621 SEAT BELT 2621.1
64 1704 DRIVE SHAFT - NGT 520 1704.1
65 1705 MAIN SHAFT DRIVE GEAR & SYNCHRONIZER - NGT 520 1705.1
66 1706 COUNTER LAY SHAFTGEAR & SYNCRONYZER - NGT 520 1706.1
67 1707 TRANSMISSION SHAFT LEVER - NGT 520 1707.1
68 1701A TRANSMISSION HOUSING & ATTACHING - KMT 90 1701A.1
69 1702A TRANSMISSION CASE, GEARS & COMPONENTS KMT-90 1702A.1
70 1703A TRANSMISSION CONTROLS KMT-90 1703A.1
71 1704A REAR BEARING & RETAINER & ATTACHING PARTS KMT-90 1704A.1
72 1901 PROPELLER SHAFT 1901.1
73 2001 FRONT AXLE (2WD) 2001.1
74 2002 REAR AXLE 2002.1
75 2101 STEERING GEAR & MOUNTINGS 2101.1
76 2103 STEERING TIE ROD 2103.1
77 2104 STABILIZER BAR 2104.1
78 2201 HAND BRAKE 2201.1
79 2202A DISC BRAKE 2202.1
80 2202B WHEEL BRAKE 2202B.1
81 2204 BRAKE MASTER CYLINDER & RESERVOIR 2204.1
82 2205 BRAKE PEDAL 2205.1
83 2206 BRAKE TUBES 2206.1
84 2301 WHEEL AND ATTACHING PARTS 2301.1
85 2401A FRAME 2401A.1
86 2401C SPARE WHEEL MOUNTING 2401C.1
87 2501 FRONT SPRING AND SHOCK ABSORBER 2501.1
88 2502 REAR SPRING AND SHOCK ABSORBER 2502.1
89 2601 HOOD 2601.1
90 2602A FENDER RIGHT 2602A.1
91 2602B FENDER LEFT 2602B.1
92 2603 RADIATOR GUARD AND GRILL 2603.1
93 2604 FOOT STEPS 2604.1
94 2605 BODY MOUNTINGS 2605.1

4 5
GROUP M11A01 - ENGINE ASSEMBLY GROUP M11A02 - LUBRICANTS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
0301BB0960N ENGINE ASSY MDI TC GD BS2 HUBER 1 1 0022678 MAHINDRA MAXIMILE 10 K OIL - 7.5 LIT NS
0301BB0980N ENGINE ASSY MDI TC GD BS3 HUBER 1

M11A01.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11A02.1
GROUP M11B01 - CYLINDER BLOCK GROUP M11B01 - CYLINDER BLOCK

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


PART NO.
0302AB0310N CRANKCASE ASSEMBLY - BS2 1
CONSIST OF :
1 0302AB0300N 1 - CRANKCASE - BS2
2 0050930 4 - CAP CRANKSHAFT BRG FRONT NS
3 0024607 1 - CAP CRANKSHAFT BRG REAR NS
4 0302AB0220N 10 - BOLT CRANKSHAFT MAIN BRG CAP NS
5 0051322 1 - BEARING FRONT CAM SHAFT NS
6 0051323 1 - BEARING CENTER CAM SHAFT NS
7 0050028 1 - BEARING REAR CAMSHAFT NS
8 0024721 CYLINDER LINER 4
9 0302AB0060N 'O' RING 8
10 0302AB0210N BRIDGE LADDER FRAME 2
11 0024503 FLANGED BOLT M8 x 1.25 - 30 4
12 9420000232 WATER DRAIN PLUG M12 x 1.5 1
13 7903062026 COPPER WASHER 2
14 7903067028 SPRING PIN 20 x 20 N/S 1
15 0311BB0030N EXPANSION PLUG 1
16 7932561906 PLUG M13 x 1.5 3
17 0024739 TAPER PLUG M10 x 1 3
18 0303EB0480N STUD OIL FILTER 1
19 G141287 PIN DOWEL CYLINDER BLOCK REAR 1

M11B01.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B01.2
GROUP M11B02 - CYLINDER HEAD GROUP M11B02 - CYLINDER HEAD

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


PART NO.
0302BB0070N CYLINDER HEAD ASSEMBLY 1
CONSIST OF :
1 0302BB0080N 1 - CYLINDER HEAD 17mm NS
2 0022611 6 - EXPANSION PLUG 30-DIN 470
3 0311BB0030N 1 - EXPANSION PLUG
4 0051342 8 - GUIDE VALVE STEM
5 0060810 4 - VALVE SEAT INTAKE
6 0060811 4 - VALVE SEAT EXHAUST
7 0051349 4 - PLUG WATER JET
8 0024609 BOLT CYLINDER HEAD SHORT 16
9 0304GB0010N TEMP SENSOR UNIT M12 - PRICOL 1
10 0071566 COPPER WASHER 14 x 20 1
11 0091043 STUD ROCKER ARM BRACKET 4
12 G141244 PIN DOWEL CYLINDER BLOCK FRONT 2
13 0094040 ENGINE LIFTING HOOK - MDI 1
14 0302FB0010N BRAKET ENGINE LIFTING FRONT 1
15 0024501 FLANGE BOLT M8 x 1.25 - 15 4

M11B02.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B02.2
GROUP M11B03 - CRANK SHAFT GROUP M11B04 - CRANKSHAFT BEARING

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0051967 CRANKSHAFT 1 1 7932580560 THRUST WASHER (UPPER) 2
2 0306HB0100N WOODRUFF KEY 2 2 7932580561 THRUST WASHER (LOWER) 2
3 0310BB0350N PINION CRANKSHAFT 1 3 0051412 BEARING FRT & CNTR - BYMETAL 5
3 0051432 BEARING FRT & CNTR - GABRIEL 5
3 0084091 BEARING FRT & CNTR - KIRLOSKAR * 5
(* OPTIONAL)
3 0051413 BRG FRT & CNTR LWR - BYMETAL 5
3 0051433 BRG FRT & CNTR LWR - GABRIEL 5
3 0084092 BRG FRT & CNTR LWR - KIRLOSKAR * 5
(* OPTIONAL)

M11B03.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B04.1
GROUP M11B05 - CRANKSHAFT PULLEY GROUP M11B06 - CONNECTING ROD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0306HB0070N PULLEY FAN DRIVE 1 1 0091002 CONNECTING ROD ASSEMBLY 4
1 0306HB0131N PULLEY FAN DRIVE (OPT) 1 CONSIST OF:
1 0306HB0132N PULLEY FAN DRIVE (OPT) 1 2 0051976 4 - CONNECTING ROD NS
2 0084136 SPACER DAMPER PULLEY 1 3 0051977 4 - CAP CONNECTING ROD NS
3 9350208280 SCREW M14 x 1.50 - 45 N/S 1 4 0312BB0410N 4 - BUSH CON ROD (SMALL END)
5 0084440 8 - SCREW CONNECTING ROD
6 0312BB0150N 8 - NUT CONNECTING ROD

M11B05.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B06.1
GROUP M11B07 - CONNECTING ROD BEARING GROUP M11B09 - OIL PAN

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0051979 CONNECTING ROD BEARING - HALF 8 1 0303CB0100N OIL PAN ASSY - NVH - BS2 1
1 0084256 CONNECTING ROD BEARING - HALF 8 2 0311AB0090N GASKET OIL PAN 1
1 0084268 CONNECTING ROD BEARING - HALF * 8 3 0024501 BOLT FLANGED M8 x 1.25 - 15 14
1 0084291 CONNECTING ROD BEARING - HALF 8 4 7903062003 SEAL 16 1
(* OPTIONAL) 5 0303CB0050N MAGNETIC DRAIN PLUG ASSEMBLY 1

M11B07.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B09.1
GROUP M11B11 - FRONT CASE GROUP M11B12 - ROCKER COVER

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0311DB0050N COVER ENGINE FRONT 1 0310BB0510N ROCKER ARM COVER ASSY WITH BRKT 1
2 0305BB0820N TIMING INDICATOR 1 2 0024735 GASKET ROCKER ARM COVER 1
3 0311AB0070N GASKET FRONT COVER 1 3 5308202 4 - NYLOC NUT M8 x 1.25 NS
4 0311DB0091N OIL SEAL ENGINE FRONT COVER 1 4 0091041 WASHER SEAL ROCKER COVER 4
5 0024628 FLANGE BOLT M8 x 1.25 - 50 10
6 0024626 BOLT FLANGED M8 x 1.25 - 20 3
7 0024614 FLANGE BOLT M8 x 1.25 - 28 9
8 0311DB0110N INJECTION PUMP GEAR COVER 1
9 0084142 'O' RING, INJECTION PUMP GEAR COVER 1
10 0024615 FLANGE BOLT M6 x 1.0 - 12 2
11 0024623 RETAINER CRANKSHAFT REAR OIL SEAL 1
12 0311AB0040N GASKET C/CASE REAR OIL SEAL 1
13 0060952 CRANKSHAFT REAR SEAL 1

M11B11.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B12.1
GROUP M11B13 - BREATHER GROUP M11B14 - CYLINDER HEAD GASKET

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
0303BB0070N OIL FILLER ASSEMBLY 1 1 0302BB0131N CYLINDER HEAD GASKET 1
CONSIST OF :
1 9420000345 1 - OIL FILLER CAP 11 DEG OUTLET T
2 9420000104 2 - SEAL - OIL FILLER CAP
3 0303BB0080N 1 - OIL ENAMATION TUBE
4 03110B0010N CLIP CLOSED 1

M11B13.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B14.1
GROUP M11B15 - PISTON GROUP M11B16 - FLYWHEEL

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0060871 PISTON (IPL) 4 1 0312CB0020N FLYWHEEL ASSEMBLY BS2 1
2 0060873 PISTON PIN 4 1 0312CB0120N FLYWHEEL ASSEMBLY BS3 - LCT 1
3 0051463 8 - CIRCLIP PISTON PIN 2 0050116 GEAR FLYWHEEL RING 1
4 0060861 RING PISTON - OIL 4 3 9420000528 FLYWHEEL DOWEL PIN 2
4 0060862 PISTON RING - TOP COMPRESSION 4 4 0050231 BOLT FLYWHEEL (KMT 90) BS2 6
4 0060863 PISTON RING - COMPRESSSION 4 4 0312CB0110N BOLT FLYWHEEL BS3 6
4 0312BB0120N RING PISTON OIL CONTROL 4 5 SF0400005 WASHER SPECIAL PLAIN M12 6
4 0312BB0130N RING PISTON COMPRESSION TOP 4 6 9420000007 FLYWHEEL BUSHING 1
4 0312BB0140N RING PISTON COMPRESSION MIDDLE 4 7 9420000528 CYLINDRICAL COTTER PIN 3

M11B15.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B16.1
GROUP M11B19 - CAMSHAFT GROUP M11B20 - IDLER GEAR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0091072 CAMSHAFT 1 1 0310BB0430N IDLER GEAR ASSEMBLY 1
2 G218217 WOODRUFF KEY 4.76mm x 15.88mm 1 CONSIST OF :-
(3/16" x 5/8") 0310BB0330N 1 - GEAR IDLER NS
3 0024605 THRUST PLATE, CAMSHAFT 1 2 0310BB0401N 1 - BUSH IDLER GEAR 1
4 0084144 FLANGED SCREW M10 x 1.5 - 25 2 3 0310BB0640N THRUST PLATE 1
4 0024630 FLANGED BOLT M10 x 1.5 - 25 (OPT) 2 4 7932560855 PLUG M9 x 1.0 1
5 0310BB0320N GEAR CAMSHAFT 1 5 0310BB0360N SHAFT IDLER GEAR 1
6 0310BB0410N GROOVED PIN 1
7 7932564136 SPACER WASHER 1
8 SF0601040 EXTERNAL RETAINING RING 28 1
9 0024501 FLANGE BOLT M8 x 1.25 - 15 3

M11B19.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B20.1
GROUP M11B21 - VALVE GEAR TRAIN

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


PART NO.
1 0310BB0080N VALVE TAPPET 8
2 0051503 VALVE PUSH ROD 8
3 0091048 VALVE INTAKE 4
0091058 VALVE INTAKE (SRIRAM) OPT 4
4 0091049 VALVE EXHAUST 4
0091059 VALVE EXHAUST (SRIRAM) OPT 4
3 0310DB0040N VALVE INTAKE (PATTERN HARD) 4
4 0310DB0030N VALVE EXHAUST(PATTERN HARD) 4
5 0051345 VALVE STEM SEAL 8
6 0310BB0310N RETAINER VALVE SPRING LOWER 8
7 03100B0010N VALVE SPRING 8
8 03100B0020N RETAINER VALVE SPRING UPPER 8
9 0310DB0010N CONE HALF VALVE LOCK 16
GROUP M11B21 - VALVE GEAR TRAIN

10 0091027 ROCKER ARM SHAFT ASSY COMPLETE 1


CONSIST OF :
11 0091029 1 - ROCKER ARM SHAFT
12 G117918 2 - PLUG EXPANSION 14.29mm (9/16")
13 0091031 1 - OILER BRACKET
14 0072048 1 - PLUG CORE 8 DIA
15 7910016442 1 - GASKET INTERNAL BEARING N/S
16 7903057013 1 - ELASTIC WASHER M6
17 0091033 1 - POSITIONING SCR VALVE ROCKER
18 0051332 4 - BRKT VALVE LEVER SH FRT & RR
19 0084156 8 - ROCKER ARM ASSY
20 0050226 8 - SCREW VALVE LEVER ADJ
21 0050227 8 - NUT VALVE LEVER ADJ SCREW
22 0051327 2 - SPRING VALVE LEVER SHAFT
23 0051325 6 - WASHER ROCKER ARM SHAFT
24 0051326 2 - RET RING VALVE LEVER SHAFT
25 9420000177 1 - PLAIN WASHER M8
26 6110214 4 - WASHER M10 NS
27 7903032023 4 - NUT M10
0091028 SHAFT VALVE LEVER WITH PLUG 1
CONSIST OF :
11 0091029 1 - ROCKER ARM SHAFT NS
12 G117918 2 - PLUG EXPANSION 14.29mm (9/16")
0091030 ASSEMBLY OILER BRACKET 1
CONSIST OF :
13 0091031 1 - OILER BRACKET NS
14 0072048 1 - PLUG CORE 8 DIA

M11B21.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B21.2
GROUP M11B22 - INLET MANIFOLD GROUP M11B23 - EXHAUST MANIFOLD

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0024756 AIR INTAKE MANIFOLD 1 1 0302DB0030N EXHAUST MANIFOLD 1
2 0302CB0020N GASKET AIR INTAKE MANIFOLD 1 2 0302BB0010N STUD EXHAUST MANIFOLD 4
3 0084143 FLANGE BOLT M8 x 1.25 - 40 11 3 0302DB0130N GASKET EXHAUST MANIFOLD (MLS) 2
4 SF0400002 WASHER PLAIN SS M10 x 2 - 21 4
5 SF0300001 NUT SPECIAL CLINCH M10 x 1.5 x 10 4
6 0024014 EXHAUST MANIFOLD STUD 31 x 8 5
7 0024018 GASKET EXHAUST FLANGE 1
8 0305GB0021N TURBOCHARGER ASSY K03 - 1875ECA4.82 1
9 0024033 STUD PIPE TURBOCHARGER OUTLET 2
10 03010G0010N STUD PIPE TURBO OUTLET - SHORT 3
11 0302DB0070N GASKET TURBO OUTLET FLANGE 1
12 0302DB0060N PIPE TURBO CHARGER OUTLET 1
13 57080A0050N FLANGED CLINCH NUT M8 x 1.25 8
14 0091083 STUD M8 x 1.25 3

M11B22.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11B23.1
GROUP M11B25 - OIL FILLER & OIL LEVEL GAUGE GROUP M11C01 - OIL PUMP & GEAR TRAIN

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0303BB0110N ASSEMBLY DIPSTICK GUIDE 1 1 0084157 OIL PUMP ASSEMBLY 1
2 0303BB0290N OIL LEVEL DIPSTICK ASSEMBLY 1 2 0024630 BOLT FLANGED M10 x 1.5 - 25 1
3 0303BB0260N BRACKET ASSY DIPSTICK 1
4 0024617 ADAPTOR DIPSTICK 1
5 0024743 COPPER WASHER M10 1
6 0024501 BOLT FLANGE M8 x 1.25 - 15 1

M11B25.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11C01.1
GROUP M11C02 - OIL FILTER GROUP M11C04 - OIL STRAINER & PIPE

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0303BC0071N OIL FILTER CARTRIDGE (OE) 1 1 0303AB0150N STRAINER ASSEMBLY 1
2 0904AA0310N HEAT SHIELD OIL COOLER 1 2 3106226 2 - SCREW HEX HD M6 x 1 - 16 NS
3 0024615 FLANGE BOLT M6 x 1.0 - 12 2 3 6506208 SPRING LOCK WASHER M6 2

M11C02.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11C04.1
GROUP M11C05 - WATER PUMP GROUP M11C07 - THERMOSTAT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0304EB0410N WATER PUMP ASSY WITH BY PASS 1 1 0304EB0740N ASSY THERMOSTAT HOUSING 1
2 0304EB0190N GASKET WATER PUMP 1 2 0311AB0050N GASKET THERMOSTAT HSG 1
3 0024521 FLANGED BOLT M10 x 1.5 - 45 4 3 0304EB0491N THERMOSTAT 1
4 0304EB0210N CAP THERMOSTATE HSG 1
5 0311AB0080N GASKET WATER OUTLET FITTING 1
6 0024626 BOLT FLANGED M8 x 1.25 - 25 6
7 9420001104 TEMP SENSOR 1
8 0024743 COPPER WASHER M10 1

M11C05.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11C07.1
GROUP M11C08 - FAN & PULLEY GROUP M11C09 - DRIVE BELT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 7910007436 COOLING FAN ASSEMBLY (8 BLADES) 1 1 0306GB0022N ALTERNATOR BELT AV 1
2 0024517 FLANGED BOLT M6 x 1 - 20 3

M11C08.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11C09.1
GROUP M11C11 - OIL PRESSURE SWITCH OR GAUGE

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


PART NO.
1 0083780 SWITCH OIL PRESS SIG INDICATOR 1
2 0303EB0340N ADAPTOR OIL PRESSURE SWITCH 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11C11.1
GROUP M11C12 - OIL LINES - ENGINE

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


PART NO.
1 03030B0040N PIPE OIL VAC PUMP INLET - MICO BS2 1
1 03030B0030N PIPE OIL VAC PUMP INLET - LUCAS BS3 1
2 0303EB0180N OIL LINE TURBO INLET 1
3 0303EB0250N BANJO BOLT SPECIAL M12 x 1.5 2
4 9420000194 COPPER WASHER 4
5 0303EB0060N ASSEMBLY PIPE TURBO OIL RETURN 1
CONSISTS OF:
0303EB0070N 1 - PIPE TURBO OIL RETURN
0303EB0080N 1 - HOSE TURBO OIL RETURN
6 0023825 GASKET TURBO OIL DRAIN PIPE 1
7 0024517 FLANGE BOLT M6 x 1.00 - 20 2
8 0062147 CLAMP HOSE 2
9 SF0705022 CLIP SPRING BAND 19 x 12 x 0.90 2
GROUP M11C12 - OIL LINES - ENGINE

10 03130C0020N NIPPLE TURBOCHARGER RETURN 1


11 7903062003 COPPER WASHER 16 N/S OIL SUMP 1
12 0024743 COPPER WASHER M10 5
13 0056882 BANJO BOLT M10 (VACUUM PUMP END) 1
14 0050336 BANJO BOLT 1
15 0303EB0170N OIL DRAIN HOSE ALT VACUUM PUMP 1
16 0303EB0090N ADAPTER OIL RETURN 1

M11C12.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11C12.2
GROUP M11D01 - FUEL INJECTION PUMP (ROTARY) GROUP M11D02 - FUEL INJECTION PIPE (ROTARY)

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0305BB0671N ASSY FUEL INJ PUMP MDI TC - GD - BS2 1 1 0305BB0230N SET ASSY HIGH PRESSURE PIPE - BS II 1
1 0305BB0621N ASSY FUEL INJ PUMP MDI TC - GD - BS3 1 CONSISTS OF :
2 0091061 GASKET VE PUMP 1 0305BB0240N 1 - ASSY HIGH PRESSURE PIPE 1 & 2 NS
3 0310BB0340N GEAR INJECTION PUMP (FORGE) 1 0305BB0250N 1 - ASSY HIGH PRESSURE PIPE 3 & 4 NS
4 0305BB0740N BRACKET FIP 1 2 0305DB0030N LEAK OFF PIPE ASSY - MICO 1
5 7932566524 PLATE 3
6 7903055003 LOCK WASHER SPRING M8 4
7 7903232005 NUT HEX M8 x 1.25 4
8 0024626 FLANGE BOLT M8 x 1.25 - 20 1
9 9420000193 BOLT BANJO M12 x 1.5 1
10 9420000194 WASHER COPPER M12 2
11 0091083 STUD INJECTION PUMP 3
12 0024501 BOLT FLANGE M8 x 1.25 - 15 1

M11D01.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11D02.1
GROUP M11D04 - FUEL INJECTION NOZZLE GROUP M11E01 - ALTERNATOR

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0305BB0781N INJECTOR ASSEMBLY BS2 4 1 1402AA2880N ALTERNATOR 55 AMP 1
1 0305BB0731N INJECTOR ASSEMBLY BS3 4 1 1402AA2881N ALTERNATOR 55 AMP - MICO (OPT) 1
1 1402AA2882N ALTERNATOR 55 AMP - LUCAS (OPT) 1
2 0306DB0050N STUD ALTERNATOR 1
3 0024822 PIVOT ALTERNATOR 1
4 7903032023 NUT HEX M10 x 150 4
5 6510214 LOCKWASHER SPRING M10 4
6 6110214 4 - PLAIN WASHER M10 NS
7 0024626 SCREW HEX HD M8 x 1.25 - 20 1
8 7903057005 ELASTIC WASHER M8 1
9 G120393 1 - PLAIN WASHER G7.93mm (5/16") NS
10 0056887 BOLT M10 x 1.5 - 130mm 1
11 0306DB0030N SPACER ALTERNATOR 1
12 0306DB0010N SPACER ALTERNATOR BRACE 1

M11D04.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E01.1
GROUP M11E01A - SERVICEABLE COMPONENTS OF ALTERNATOR (MICO)

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


PART NO.
1402AA2881N ALTERNATOR 55 AMP - MICO 1
1 1402AA2721N DRIVE END SHIELD 1
2 1402AA1131N DEEP GROOVE BALL BEARING 1
3 1402AA1141N COVER PLATE 1
5 1402AA1151N FLAT HEAD SCREW 4
GROUP M11E01A - SERVICEABLE COMPONENTS OF ALTERNATOR (MICO)

6 1402AA2981N ROTOR 1
9 1402AA1171N SPACER RING 1
10 1402AA1181N DEEP GROOVE BALL BEARING 1
11 1402AA2741N COLLECTOR RING END 1
12 1402AA2751N RECTIFIER 1
13 1402AA1211N 'O' RING 1
17 1402AA2991N TRANSISTOR REGULATOR 1
18 1402AA2761N STATOR 1
20 1402AA1251N CHEESE HEAD SCREW 1
21 1402AA1251N CHEESE HEAD SCREW 3
24 1402AA1252N CHEESE HEAD SCREW 2
26 1402AA1281N SPRING WASHER 2
27 1402AA1291N HEXAGON NUT 2
32 1402AA2771N INSULATING WASHER 1
34 1402AA2781N WASHER 1
35 1402AA2791N SPRING WASHER 1
37 1402AA2801N HEXAGON NUT 1
38 1402AA2811N INSULATING PART 1
41 1402AA1341N INSULATING WASHER 1
42 1402AA1351N INSULATING WASHER 1
42 1402AA1351N WASHER 1
43 1402AA1361N HEXAGON NUT 2
44 1402AA3001N CONNECTOR HOUSING 1
45 1402AA1381N SPRING WASHER 2
46 1402AA1391N INSULATING WASHER 1
47 1402AA1401N SPRING WASHER 2
48 1402AA1411N WASHER 1
49 1402AA2821N HEXAGON NUT 1
51 1402AA1421N SPRING WASHER 1
52 1402AA1431N HEXAGON NUT 1
53 1402AA3011N FAN 1
54 1402AA3021N PULLEY 1
56 1402AA1461N SEAL 1
57 1402AA1481N VACUUM PUMP ASSEMBLY 1
57/005 1402AA3061N NON RETURN VALVE (VACUUM PUMP) 1
1

CONTINUE …

M11E01A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E01A.2
GROUP M11E01A - SERVICEABLE COMPONENTS OF ALTERNATOR (MICO)

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


PART NO.
58 1402AA1511N VACUUM PUMP END COVER 1
59 1402AA1521N VANE (FOR VACUUM PUMP) 3
61 1402AA1531N HEXAGON SCREW 3
62 1402AA2831N SPRING WASHER 3
63 1402AA1551N WASHER 3
GROUP M11E01A - SERVICEABLE COMPONENTS OF ALTERNATOR (MICO)

64 1402AA1561N 'O' RING 1


65 1402AA1571N 'O' RING 1
68 1402AA2841N BANJO 1
70 1402AA1591N FLAT SEAL RING 2
71 1402AA1601N VACUUM PUMP ROTOR 1
75 1402AA3031N BANJO ASSEMBLY 1
80 1402AA1621N CLAMP 1
99 1402AA1631N SPRING WASHER 2
100 1402AA1641N WASHER 2
106 1402AA3041N SUPPRESSION CAPACITOR 1
110 1402AA3051N FUSE 2
112 1402AA1631N SPRING WASHER 1
113 1402AA1671N CHEESE HEAD SCREW 1
114 1402AA1681N HEXAGON NUT 1
117 1402AA1691N WASHER 1
118 1402AA1701N SPRING WASHER 1
119 1402AA1711N HEXAGON NUT 1
801 1402AA1721N CARBON BRUSH SET
807 1402AA1731N COLLECTOR RING

M11E01A.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E01A.4
GROUP M11E02 - STARTER MOTOR

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


PART NO.
1 0091970 STARTER MOTOR - MICO 1
1 0091971 STARTER MOTOR - LUCAS 1
1 0307CB0471N STARTER MOTOR - GEAR REDUCTION
- MICO 1
2 0024630 FLANGED BOLT M10 x 1.5 - 25 3
3 7903055007 SPRING LOCKWASHER M10 3

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E02.1
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (MICO)

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


PART NO.
0091970 STARTER MOTOR - MICO 1
1 0307CB0501N ARMATURE 1
2 0307CB0511N INTERMIDIATE BEARING 1
3 0307CB0521N CLUTCH DRIVE 1
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (MICO)

4 0307CB0531N SPRING RING 1


5 0307CB0541N STOP RING 1
7 0307CB0551N SINTERED BUSH 1
9 0307CB0561N SCREW COUNTERSUNK 1
10 0307CB0571N WASHER 1
11 0307CB0581N HEXAGONAL NUT 1
14 0307CB0591N THREADED PIN 2
17 0307CB0601N COUNTERSUNK SCREW 3
18 0307CB0611N 'O' RING 2
19 0307CB0621N 'O' RING 2
23 0307CB0631N EXCITATION WINDING 1
25 0307CB0641N COUNTERSUNK SCREW 4
27 0307CB0651N MOUNTING FLANGE 1
28 0307CB0661N BRUSH HOLDER 1
29 0307CB0671N SPRING RING 4
30 0307CB0681N COMMUTATOR END COVER 1
30/2 0307CB0691N SINTERED BUSH 1
31 0307CB0701N SPACING WASHER 2
32 0307CB0711N HEXAGONAL NUT 2
34 0307CB0721N COMPENSATING WASHER 0.5mm A/R
34 0307CB0731N COMPENSATING WASHER 0.7mm A/R
34 0307CB0751N COMPENSATING WASHER 0.9mm A/R
34 0307CB0741N COMPENSATING WASHER 1.1mm A/R
34 0307CB0761N COMPENSATING WASHER 1.3mm A/R
35 0307CB0771N LOCKING WASHER 1
36 0307CB0781N SEALING RING 1
37 0307CB0791N CAP 1
38 0307CB0801N HEXAGONAL HEAD SCREW 2
39 0307CB0811N SPRING WASHER 1
40 0307CB0821N HEXAGONAL NUT 1
41 0307CB0831N HEXAGONAL NUT 1
42 0307CB0841N SPRING WASHER 1
43 0307CB0851N HEXAGONAL NUT 1
45 0307CB0861N SPRING WASHER 1
67 0307CB0871N 'O' RING 2
68 0307CB0881N WASHER 2
800 0307CB0891N CARBON BRUSH SET 1
803 0307CB0901N FORK LEAVER 1
804 0307CB0911N SOLENOID SWITCH 1
805 0307CB0921N DRIVE END FLANGE 1

M11E02A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E02A.2
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (LUCAS)

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


PART NO.
0091971 STARTER MOTOR - LUCAS 1
1 0307CG0011N MAIN TERMINAL 1
1A 0307CG0021N MAIN TERMINAL 1
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (LUCAS)

2 0307CG0031N TERMINAL BASE ASSEMBLY 1


3 0307CG0041N SPINDLE ASSEMBLY 1
4 0307CG0051N PLUNGER RETURN SPRING 1
5 0307CG0061N SEALING REING (SOL) 1
6 0307CG0071N SOLENOID SWITCH 1
7 0307CG0081N PLUNGER ASSEMBLY 1
7A 0307CG0091N SHROUD 1
8 0307CG0101N SCREW SOL FIXING 3
9 0307CG0111N CONNECTOR 1
10 0307CG0121N SEAL 1
11 0307CG0131N SEALING RING (C E & D E) 2
12 0307CG0141N INTER BRACKET ASSEMBLY 1
13 0307CG0151N OIL SEAL 1
14 0307CG0161N ENGAGING LEVER ASSEMBLY 1
15 0307CG0171N JUMP RING - PINION 1
16 0307CG0181N SPRING - PINION 1
17 0307CG0191N GROMMET 1
18 0307CG0201N NUT PIVOT 1
19 0307CG0211N PIVOT PIN 1
20 0307CB0481N FIXING BRACKET ASSEMBLY 1
21 0307CG0231N BEARING BUSH (FIXING BRACKET) 1
22 0307CG0241N BEARING BUSH (INTER BRACKET) 1
23 0307CG0251N OPERATING PLATE (PINION) 1
24 0307CB0491N DRIVE ASSEMBLY 1
25 0307CG0271N THRUST COLLAR 1
26 0307CG0281N JUMP RING 1
27 0307CG0291N END COVER 1
28 0307CG0301N SEAL (END COVER) 1
29 0307CG0311N 'C' WASHER 1
31 0307CG0321N SPRING (END COVER) 1
32 0307CG0331N C E BRACKET ASSEMBLY 1
33 0307CG0341N BRUSH SET 1
34 0307CG0351N BRUSH CARRIER ASSEMBLY 1
35 0307CG0361N LEAD ASSEMBLY 1

CONTINUE…

M11E02A.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E02A.4
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (LUCAS)

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


PART NO.
36 0307CG0371N GROMMET 1
37 0307CG0381N FIELD COIL ASSEMBLY 1
38 0307CG0391N ARMATURE ASSEMBLY 1
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (LUCAS)

39 0307CG0401N NUT (FIXING STUD) 2


40 0307CG0411N FIXING STUD 2
41 0307CG0421N BEARING BUSH (C R BRACKET) 1
42 0307CG0431N BRUSH SPRING 4
43 0307CG0441N STOP WASHER 1
44 0307CG0451N INSULATOR YOKE 1
45 0307CG0461N POLE SHOE 4
47 0307CG0471N SCREW (B G FIXING) 2

M11E02A.5 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E02A.6
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (MICO)

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


PART NO.
0307CB0471N STARTER MOTOR - GEAR REDUCTION
1 0307CB1220N EPICYCLOIDAL GEAR 1
2 0307CB1230N OVERRUNNING CLUTCH 1
3 0307CB0951N RETAINER 1
GROUP M11E02A - SERVICEABLE COMPONENTS OF STARTER MOTOR (MICO)

4 0307CB0961N STOP RING 1


5 0307CB0971N DRIVE END FLANGE 1
6 0307CB0981N NEEDLE BUSHING 1
7 0307CB0991N FORK LEVER 1
8 0307CB1240N BEARING PEDESTAL 1
9 0307CB1011N RUBBER SEAL 1
10 0307CB1250N SOLENOID SWITCH 1
11 0307CB1031N COUNTERSUNK HEAD SCREW 3
12 0307CB1041N ARMATURE 1
13 0307CB1051N COMMUTATOR END SHIELD 1
14 0307CB1061N SINTERED METAL BUSH 1
15 0307CB1071N HEXAGONAL SCREW 2
16 0307CB1081N SHIM 1
17 0307CB1091N RETAINING WASHER 1
18 0307CB1101N CLOSURE CAP 1
19 0307CB1111N OVER - HEAD SCREW 2
20 0307CB1270N FLANGED NUT 1
21 0307CB1131N SPRING LOCK WASHER 1
22 0307CB1280N HEXAGONAL NUT 1
23 0307CB1151N SPRING LOCK WASHER 1
24 0307CB1161N HEXAGONAL NUT 1
25 0307CB1171N BRUSH HOLDER 1
26 0307CB1181N STATOR FRAME 1
27 0307CB1260N SEAL RING 1

M11E02A.7 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11E02A.8
GROUP M11F02 - EMISSION CONTROL SYSTEM GROUP M11F02 - EMISSION CONTROL SYSTEM

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


PART NO.
1 0309DB0020N EGR PIPE ASSEMBLY 1
2 0022672 GASKET EGR PIPE FLANGE 2
3 0309DB0121N EGR VALVE DIA 13.5/ 90 - PADMINI (A) 1
(4 SPEED GEAR BOX)
3 0309DB0121N EGR VALVE DIA 12.8/ 90 - PADMINI (B) 1
(5 SPEED GEAR BOX)
3 0023231 EGR VALVE BS III
4 57080A0050N FLANGE CLINCH NUT M8 x 1.25 2
5 0022673 GASKET EGR VALVE 1
6 7903009053 SCREW CHS M8 x 1.25 - 25 4
7 0062138 CLAMP HOSE 55 - 75 NO 75A 1
8 0313AB0170N PIPE AIR INTAKE ASSEMBLY - BS2 1
9 0313AB0150N HOSE AIR TURBOCHARGER SIDE 1
10 0313AB0160N HOSE AIR MANIFOLD SIDE - BS2 1
11 0062139 CLAMP HOSE 45 - 60 NO.2X 3
12 0313AB1140N BRACKET AIR INTAKE UPPER 1
13 0313AB1150N BRACKET AIR INTAKE LOWER 1
14 0024501 BOLT FLANGED M8 x 1.25 - 15 3
15 0091041 WASHER SEAL ROCKER COVER 2
16 0309DA0050N VACUUM RESERVOIR 1
17 18050A0010N VACUUM MODULATOR 1
18 3106226 4 - SCREW HEX M6 x 1 - 16 NS
19 6506208 WASHER SPRING M6 4
20 6106206 PLAIN WASHER M6 4
0309DA0040N KIT VACUUM TUBES 1
CONSISTS OF :
21 16000A0070N 1 - HOSE VACUUM MODLTR /AIR CLEAN
22 0309DA0010N 1 - TUBE VACUUM
23 0309DA0020N 1 - TUBE VACUUM
24 0309DA0060N 1 - TUBE VACUUM

M11F02.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 M11F02.2
GROUP M25A01 - ENGINE MOUNTING GROUP 1101 - CLUTCH

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 099828 INSULATOR FRONT 2 1 0801CA0030N CLUTCH COVER ASSY 1
2 G120396 PLAIN WASHER 2 1 0801CA0031N CLUTCH COVER ASSY (OPT) 1
3 5312204 NYLOC NUT M12 - 1.25 2 1 0801CA0032N CLUTCH COVER ASSY (OPT) 1
4 0099105 SPECIAL BOLT HEX HD M10 x 1.5 - 25 4 2 0801BA0161N CLUTCH DRIVEN PLATE ASSEMBLY 1
5 7903055007 SPRING LOCKWASHER M10 10 2 0801BA0162N CLUTCH DRIVEN PLATE (F491) (OPT) 1
6 804373 WASHER SPECIAL 6 2 0801BA0285N CLUTCH DRIVEN PLATE (F491) (OPT) 1
7 0302AB0360N BRKT ENGINE FRONT SUPPORT - RH 1 3 SF0201060 SCREW HEX M8 x 1.25 - 20 6
8 094025 BRKT ENGINE FRONT SUPPORT - LH 1 4 6508212 6 - LOCK WASHER SPRING M8 NS
9 024720 SPECIAL BOLT M12 x 1.25 7
10 052385 LOCKWASHER SPRING M12 7
11 069895 INSULATOR ENGINE REAR SUPPORT 1
12 052064 BOLT M10 x 1.25 - 17mm 4
13 6110214 2 - PLAIN WASHER M10 NS
14 5110206 NUT HEX M10 x 1.25 2

M25A01.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1101.1
GROUP 1102 - CLUTCH HOUSING BS II GROUP 1102 - CLUTCH HOUSING BS III

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 08010A0200N CLUTCH HOUSING 1 1 0801AA0280N CLUTCH HOUSING 1
2 0024632 BOLT CL HOUSING M12 x 1.5 - 35 2 2 0024632 BOLT CL HOUSING M12 x 1.5 - 35 2
3 6512216 5 - LOCKWASHER SPRG M12 NS 3 6512216 5 - LOCKWASHER SPRG M12 NS
4 0024635 BOLT CL HOUSING M12 x 1.5 - 80 1 4 0024635 BOLT CL HOUSING M12 x 1.5 - 80 1
5 0024633 BOLT SPECIAL 1 5 0024633 BOLT SPECIAL 1
6 0802CA0020N CLUTCH RELEASE THRUST BEARING 1 6 0802CA0020N CLUTCH RELEASE THRUST BRG. 1
7 0802CA0050N CLUTCH RELEASE FORK 1 7 0802CA0050N CLUTCH RELEASE FORK 1
8 0802CA0030N PROP SPRING CLUTCH RELEASE 1 8 0802CA0030N PROP SPRING CLUTCH RELEASE 1
9 0802CA0710N CLIP CLUTCH RELEASE FORK 2 9 0802CA0710N CLIP CLUTCH RELEASE FORK 2
10 0801AA0240N GROMMET CLUTCH RELEASE FORK 1 10 0801AA0240N GROMMET CLUTCH RELEASE FORK 1
11 0802CA0890N BALL STUD 1 11 0802CA0890N BALL STUD 1
12 0801AA0300N VENTILATION CAP 1 12 0801AA0300N VENTILATION CAP 1
13 0024601 COVER PLATE CLUTCH HSG BOTTOM 1 13 57100A0040N FLANGE NUT M10 x 1.5 (A/C - 16) 2
14 0024603 COVER PLATE TOP BELL HOUSING 1 14 0024601 COVER PLATE CLUTCH HSG BOTTOM 1
15 0024615 FLANGE BOLT M6 x 1.0 - 12 5 15 0024603 COVER PLATE TOP BELL HOUSING 1
16 0024615 FLANGE BOLT M6 x 1.0 - 12 3
17 0110FG0090N COMBI BOLT M10 x 1.5 6

1102.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1102.2
GROUP 1103 - CLUTCH LINKAGE

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


PART NO.
0802CA1410N SUSPENDED PEDAL ASSEMBLY COMP 1
1 0802CA1420N BRACKET ASSEMBLY PEDAL SUPPORT 1
2 0802CA1400N PEDAL ASSEMBLY CLUTCH 1
3 0036422 BUSH 2
4 0099269 PEDAL SHAFT 1
5 G131016 PLAIN WASHER(ID 21/32) 1
6 7032208 PIN COTTER 3.2 x 25 1
7 0062452 SPRG RETRACTING 1
8 3108208 SCR HEX HD M8 x 1.25 - 25 9
9 5108206 1 - NUT HEX M8 x 1.25 NS
10 01050N0030N STAY TUBE SUSP PEDAL HORZ 1
11 0081805 PEDAL PAD COVER 1
12 0101CK0930N PLATE REINF OUTER ASSEMBLY 1
13 01050N0020N STAY TUBE SUSP PEDAL VERTICAL 1
GROUP 1103 - CLUTCH LINKAGE

14 6108212 14 - WASHER PLAIN M8 NS


15 SF0402034 WASHER SPRING L M8 5
16 3106208 SCREW HEX M6 x 1 - 20 4
17 6106208 PLAIN WASHER M6 6
18 SF0402033 WASHER SPRING L M6 7
19 SF0301025 NUT HEX M6 x 1 2
20 0099275 RUBBER STOPPER SUS PEDAL 1
21 SF0301026 NUT HEX M8 x 1.25 6

1103.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1103.2
GROUP 1104 - CLUTCH CYLINDER GROUP 1104 - CLUTCH CYLINDER

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


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

1104.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1104.2
GROUP 1201 - FUEL TANK GAUGES AND LINES

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


PART NO.
1 1001AA0400N FUEL TANK ASSEMBLY 1
2 1001BA0340N BRACKET ASSEMBLY FUEL TANK 2
3 SF0101103 BOLT HEX HD M8 x 1.25 - 65 6
4 6108212 20 - WASHER PLAIN M8 NS
5 SF0301026 NUT HEX M8 x 1.25 8
6 2108230 BOLT HEX HD M8 x 1.25 - 30 2
7 SF0402034 WASHER SPRING L M8 10
8 0029791 REST BUTTON FUEL TANK 4
9 0087698 FERRULE FUEL LINE 7
10 10000A0450N STRAP ASSEMBLY FUEL TANK 2
11 0067147 COPPER WASHER 16 MM 2
GROUP 1201 - FUEL TANK GAUGES AND LINES

12 0098010 SKID PLATE FUEL TANK 1


13 3108220 SCREW HEX HD M8 x 1.25 - 12 4
14 10000A0200N TANK UNIT 1
14 0097846 TANK UNIT (OPT) 1
14 13000A0160N TANK UNIT (60 LTR V3) (OPT) 1
15 0011594 GASKET FUEL TANK 1
16 6204204 LOCK WASHER EXT TOOTH M4 6
17 3304206 SCREW PAN HD M4 x 0.7 - 12 6
18 1001CA2420N HOSE ASSY FUEL TANK TO NECK 1
19 0062140 CLIP WORM TYPE NO - 2 (42-55) 2
20 1001DA0680N HOSE ASSY VENT TUBE FUEL TANK 1
21 1001DA0200N FUEL FILLER NECK ASSEMBLY 1
22 3106206 SCREW HEX HD M6 x 1 - 16 3
23 6106208 PLAIN WASHER M6 5
24 SF0301025 NUT HEX M6 x 1 - 5 2
25 1001DA0260N CAP FUEL FILLER NECK 1
26 1001CA2280N FUEL LINE TANK TO FILTER 1
27 0050331 BANJO BOLT 3
28 0050332 COPPER WASHER 14 MM 6
29 10010A0540N FUEL RETURN LINE INJ PUMP TO F/TANK 1
30 1001CA2690N FUEL LINE FILTER TO FIP 1
31 0067148 BANJO BOLT 16 MM 1
32 10000A0320N BRKT EXTN FUEL FILTER 1
33 9420000319 FUEL FILTER ASSY TWIN MICO (OPT) 1
34 028582 ASSY BRKT FUEL FILTER & STG RES MTG 1
35 SF0201062 SCR HEX HD M8 x 1.25 - 30 H 3
36 3108212 SCR HEX HD M8 x 1.25 - 35 S 2
37 0097888 CLIP FUEL LINE 3
37 1001DA0950N CLIP FUEL LINE 2
38 6508212 5 - LOCK WASHER SPRING M8 NS
39 5108206 3 - NUT HEX M8 x 1.25 NS

1201.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1201.2
GROUP 1202 - AIR CLEANER GROUP 1202 - AIR CLEANER

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


PART NO.
1 0313AB0311N AIR FILTER ASSEMBLY 1
2 0313AC1710N HOSE ASSEMBLY AIR CLEANER 1
CONSISTS OF :-
0313AB0420N 1 - CONNECTOR HOSE AIR CLEANER
0313AC1720N 1 - HOSE AIR CLEANER UPPER
0313AC1730N 1 - HOSE AIR CLEANER LOWER
3 0313AC1900N 2 - CLAMP HOSE (WIRE TYPE)
4 0313AB0940N AIR INTAKE PIPE ASSEMBLY 1
CONSISTS OF :-
0313AB0330N 1 - ELBOW AIR INTAKE PIPE
0313AB0910N 1 - PIPE AIR INTAKE REAR
0313AB0920N 1 - PIPE AIR INTAKE FRONT
0313AB0930N 1 - MESH AIR INTAKE
5 0313AC0820N WIRE CLAMP - AIR CLEANER END 1
6 0313AC0840N WIRE CLAMP - TC END 1
7 0062136 CLIP WORM TYPE 70 - 90 NO 4 1
8 0313AB1480N CLAMP AIR CLEANER TOP 1
9 0313AB1470N CLAMP AIR CLEANER SUPPORT 1
10 0010218 RUBBER PACKING 1
11 2108232 BOLT HEX HD M8 x 1.25 - 35 1
12 3106226 1 - SCREW HEX M6 x 1 - 16 NS
13 6506208 WASHER SPRING L M6 x 1.6 - 11.6 1
14 6106208 PLAIN WASHER M6 1
15 0313AG0230N SERVICE INDICATOR 1
16 0313AC0280N AIR ELEMENT 1
17 0102DN1630N EDGING STRIP PANEL AIR DEFLECTOR 2

1202.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1202.2
GROUP 1203 - ACCELERATOR LINKAGE

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


PART NO.
1 10020A0790N ACCELERATOR PEDAL ASSY COMP 1
2 0084206 BRACKET ACCELATOR 1
3 SF0402033 WASHER SPRING L M6 2
4 SF0201075 SCREW HEX HD M6 x 1 - 16 2
5 10020A0160N BUSH ACCELERATOR PEDAL 1
6 10020A0180N SPRING RETURN ACCELERATOR PEDAL 1
7 6110114 PLAIN WASHER M10 1
8 7032204 COTTER PIN 3.2 x 20mm 1
9 10020A0810N LEVER ASSY ACCELERATOR PEDAL 1
10 10020A0270N PIVOT ACCELERATOR FOOT PLATE 1
11 10020A0290N SPRING RETURN FOOT PLATE 1
12 10020A0330N BUSH FOOT PLATE 1
GROUP 1203 - ACCELERATOR LINKAGE

13 10020A0300N SLEEVE 1
14 6106208 PLAIN WASHER M6 2
15 7025202 PIN COTTER 2.5 x 14 1
16 10020A0280N FOOT PLATE ASSY ACCELERATOR PEDAL 1
17 10020A0310N RUBBER PAD FOOT PLATE 1
18 0036623 PIN CLEVIS 1
19 6105206 WASHER PLAIN M5 1
20 7002210 PIN COTTER 2 x 20 1
21 10020A0230N ASSY ACCELERATOR CABLE (BALL END) 1
22 0089897 BALL END ASSY 1
23 0A11775 PLAIN WASHER G7.94mm (5/16") 2
24 5108206 2 - NUT HEX M8 x 1.25 NS
25 0035963 RUBBER STOPPER 2
26 5306202 NUT NYLOC M6 x 1 (P TYPE) 1
27 SF0301025 NUT HEX M6 x 1 2

1203.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1203.2
GROUP 1301 - RADIATOR AND HOSES

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


PART NO.
1 0304AB0131N RADIATOR ASSY 1
1 0304AB0132N RADIATOR ASSY (OPT) 1
2 2108232 BOLT HEX HD M8 x 1.25 - 35 1
3 0028552 WASHER PLAIN 2
4 0028550 COLLAR INSULATOR 1
5 0028551 CUSHION RADIATOR SUPPORT 2
6 6508212 1 - LOCK WASHER SPRING M8 NS
7 5108206 1 - NUT HEX M8 x 1.25 NS
8 0304BG0010N INSULATOR RADIATOR MTG BOTTOM 2
9 0028761 SPACER RADIATOR RET CUP ASSY 2
10 A006360 PEDAL SHANK DRAFT PAD WASHER 2
11 5110208 NUT HEX M10 x 1.5 2
12 0304FB0040N SHROUD RADIATOR 1
GROUP 1301 - RADIATOR AND HOSES

12 0304FB0110N SHROUD RADIATOR (OPT) 1


13 3106208 SCREW HEX M6 x 1 - 20 4
14 G120380 LOCK WASHER SPRING G6.35mm (1/4") 4
15 G120392 PLAIN WASHER G6.35mm (1/4") 4
16 0304DB0300N HOSE RADIATOR OUTLET 1
17 0304DB0290N HOSE RADIATOR INLET 1
18 0062140 CLIP WORM TYPE NO 2 (42 - 55) 4
19 0304DB0460N WATER RECOVERY TANK ASSY 1
20 3108206 1 - SCR HEX HD M8 x 1.25 - 20 NS
21 6108212 1 - WASHER PLAIN M8 NS
22 5308202 1 - NYLOC NUT M8 x 1.25 NS
23 0304DB0510N HOSE RAD TO WATER RECOVERY TANK 1
24 0304AB0230N PRESSURE CAP RADIATOR 1
25 0304EB0431N DRAIN COCK 1

1301.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1301.2
GROUP 1401 - EXHAUST SYSTEM

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


PART NO.
1 0903AA2440N EXHAUST PIPE ASSY 1
2 0901BA0200N EXPANSION CHAMBER 1
3 0903AA2200N PIPE ASSY INTERMEDIATE 1
4 0901AA1020N MUFFLER ASSY COMP 1
5 0903BA0300N GASKET EXHAUST 1
6 55080A0010N COMBI SCREW M8 x 1.25 - 25 4
7 0903BA0211N GASKET CATALYTIC CONVERTER 2
8 52100A0060N FL SCREW & SP WASHER M10 x 1.5 - 45 4
9 19000A0360N U - CLAMP - TC 1
10 19000A0370N BRKT U - CLAMP - TC 1
11 0028552 WASHER PLAIN 2
12 6508212 5 - LOCK WASHER SPRING M8 NS
13 5108206 5 - NUT HEX M8 x 1.25 NS
14 0077591 RUBBER INSULATOR EXHAUST 5
GROUP 1401 - EXHAUST SYSTEM

1401.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1401.2
GROUP 1503 - HEAD LIGHT

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

1 1701AA0551N ASSEMBLY HEAD LAMP 2


1 1701AA0552N ASSEMBLY HEAD LAMP (OPT) 2
2 6106208 PLAIN WASHER M6 12
3 6506208 WASHER SPRING L M6 12
4 3106226 8 - SCREW HEX M6 x 1 - 16 NS
5 3306206 SCR SLTD PAN HD M6 x 1 - 14 4
17010A0010N KIT SPARE BULBS HALO HEAD LAMP 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1503.1
GROUP 1504 - INDICATING LAMP

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


PART NO.
FRONT TURN SIGNAL LIGHT
1 0028533 FRT TURN SIGNAL LAMP LH 1
1 0028534 FRT TURN SIGNAL LAMP RH 1
2 17000A0011N BULB 12V - 21W 2
3 1701BA0040N FRT. TURN REFLECTOR WITH LENS LH 1
3 1701BA0050N FRT. TURN REFLECTOR WITH LENS RH 1

SIDE MARKER LIGHT


4 0028354 MARKER LAMP LH 1
4 0028355 MARKER LAMP RH 1
5 1701EA0030N BULB 12V - 3.4W CAP LESS 2
6 0059330 SCREW SPECIAL M4 x 0.7 4
7 6505206 SPRING LOCK WASHER M5 4
8 SF0301024 NUT HEX M4 x 0.7 4
GROUP 1504 - INDICATING LAMP

REAR REGISTRATION PLATE


9 0119DF0040N PLATE ASSY RR REGISTRATION LAMP 1
10 3106208 SCREW HEX M6 x 1 - 20 2
11 6106208 PLAIN WASHER M6 2
12 6506208 WASHER SPRING L M6 2

LAMP RESISTRATION PLATE


13 1703HA0121N LAMP REGISTRATION PLATE 1
13 1703HA0131N LAMP REGISTRATION PLATE (OPT) 1

ROOF LIGHT
14 1701FA0011N ROOF LAMP ASSEMBLY 1
15 SF0214001 SCREW RND HD CS REC M6 x 1 - 25 2
16 17000A0041N BULB FESTOON 12V - 5W 2

WARNING TRIANGLE ASSEMBLY


17 19000A3391N WARNING TRIANGLE ASSY 1
17 19000A3392N WARNING TRIANGLE ASSY (OPT) 1
17 19000A3393N WARNING TRIANGLE ASSY (OPT) 1

REFLEX REFLECTOR
18 1701EA0111N REFLEX REFLECTOR FRT 2
19 3305206 SCR PAN HD SLTD M5 x 0.8 - 14 4

1504.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1504.2
GROUP 1505 - TAIL, STOP, TURN SIGNAL AND REVERSE LIGHT

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

1 1703AA0080N LAMP ASSY COMBINATION RR RH 1


1 1703AA0090N LAMP ASSY COMBINATION RR LH 1
2 1703AA0341N HOUSING AND CABLE ASSEMBLY LH 1
2 1703AA0351N HOUSING AND CABLE ASSEMBLY RH 1
3 17000A0011N BULB 12V - 21W 4
4 17000A0021N BULB 12V - 21/5W 2
5 0075340 SCREW PHILIP HD. M5 8
6 1703AA0531N LENS REVERSE 2
7 1703AA0521N LENS BRAKE / STOP LIGHT 2
8 1703AA0511N LENS TURN SIGNAL 2

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1505.1
GROUP 1507 - BATTERY HOLD DOWN & CABLE GROUP 1507 - BATTERY HOLD DOWN & CABLE

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


PART NO.
1 0070650 BATTERY TRAY ASSY AS PURCH 1
2 SF0201060 SCREW HEX M8 x 1.25 - 20 5
3 6508212 6 - LOCKWASHER SPRING M8 NS
4 6108212 6 - WASHER PLAIN M8 NS
5 0070651 SUPPORT BATTERY TRAY BOTTOM 1
6 2108260 BOLT HEX HD M8 x 1.25 - 35 1
7 0029791 REST BUTTON BATTERY TRAY 2
8 0070654 CLAMP BRKT BATTERY H/DOWN
9 1401BA0170N NUT WING 2
10 0083782 ASSEMBLY BATTERY CABLE NEGATIVE 1
11 0071778 ASSEMBLY BATTERY CABLE POSITIVE 1
12 0071777 CAP POSITIVE CABLE 1
13 0098780 EARTH CABLE 1
14 14010A0021N SEPARATOR - BATTERY TRAY 1
15 0029791 REST BUTTON FUEL TANK 8

1507.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1507.2
GROUP 1508 - HORN

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


PART NO.
1 0060805 HORN ASSEMBLY LO TONE 1
2 6508212 1 - LOCK WASHER SPRING M8 NS
3 6108212 1 - WASHER PLAIN M8 NS
4 SF0201061 SCREW HEX M8 x 1.25 - 25 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1508.1
GROUP 1509 - WINDSHIELD WIPER MOTOR

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


PART NO.
1 0069259 WIPER MOTOR ASSLY LINK TYPE 1
1 0116EA0271N WIPER MOTOR LINK TYPE (OPT) 1
2 0029554 SUPPORT BRKT WIPER MOTOR MTG 1
3 3105208 SCREW HEX HD M5 x 0.8 - 14S 3
4 6505206 SPRING LOCK WASHER M5 3
5 6106208 PLAIN WASHER M6 4
6 6506208 SPRING LOCK WASHER M6 4
7 3106228 SCR HEX HD M6 x 1.0 - 20 H 4
8 0028417 WIPER LINKAGE KIT 1
0028417 KIT LINKAGE WIPER MOTOR 1
CONSIST OF :
0074386 1 - LEVER WIPER MOTOR TO LINK NS
GROUP 1509 - WINDSHIELD WIPER MOTOR

0074388 1 - SPRING LOCK WASHER


0074387 1 - HEX NUT
0074389 2 - DUST SEAL WIPER MOTOR LINK
1 - LINK ASSEMBLY WIPER MOTOR NS
LEVER TO WHEEL BOX
1 - ASSY WHEEL BOX & LEVER CENTER
0074392 2 - RUBBER WASHER WHEEL BOX NS
0074393 2 - RETAINER WASHER WHEEL BOX NUT NS
0069261 2 - NUT HEX WHEEL BOX
1 - LINK ASSEMBLY WHEEL BOX TO NS
WHEEL BOX
0074395 2 - DUST SEAL WIPER MOTOR LINK
0074396 1 - ASSEMBLY WHEEL BOX AND LEVER
9 0028419 WIPER ARM ASSEMBLY 2
10 0028418 WIPER BLADE ASSEMBLY 2
0116GN0010N WIND SCREEN WASHER FLUID 100

1509.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1509.2
GROUP 1510 - WIRING HARNESS GROUP 1510 - WIRING HARNESS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0028741 BONNET LEVER MTG BRKT 1 14 029886 MTG BRKT FOR FUSE BOX 1
2 3306208 SCREW SLOTTED PAN HEAD M6 x 1 - 16 1 3 6106208 PLAIN WASHER M6 2
3 6106208 PLAIN WASHER M6 1 10 3106226 2 - SCREW HEX M6 x 1 - 16 NS
4 6506208 WASHER SPRING L M6 1 13 6306208 WASHER INT TOOTH L M6 1
5 0088454 IC BASED FLASHER (ATD TO FUSE BOX) 1 15 1805AA0241N EGR CONTROLLER 1
5 13050A0011N IC BASED FLASHER (OPT) 1 15 1805AA0531N EGR CONTROLLER ECU BS III 1
5 13050A0012N IC BASED FLASHER (OPT) 1 6 3305208 SCR SLOTTED PAN HD M5 x 0.8 - 16 2
6 3305208 SCR SLOTTED PAN HD M5 x 0.8 - 16 2 7 6505206 SPRING LOCK WASHER M5 2
7 6505206 SPRING LOCK WASHER M5 2 8 6105206 PLAIN WASHER M5 2
8 6105206 PLAIN WASHER M5 2
9 0088587 RELAY HEAD LAMP 1
9 18000A0300N RELAY HEAD LAMP (OPT) 1
10 3106226 2 - SCREW HEX M6 x 1 - 16 NS
11 0028750 WIPE & WASH WIPER INTO RELAY 1
12 3306212 SCR PAN HD SLTD M6 x 1 - 25 1
13 6306208 WASHER INT TOOTH L M6 1

1510.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1510.2
GROUP 1510 - WIRING HARNESS

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


PART NO.
16 1702AA0060N SERVICE LAMP ENGINE 1
17 SF0207002 SCREW PAN HD CR M6 x 1 - 16 2
18 0097552 MECH STOP LIGHT SWITCH 1
19 0038525 CLIP CHASSIS WIRING HARNESS 16
20 1105AA0021N COMBINATION SWITCH 1
20 1105AA0011N COMBINATION SWITCH (OPT) 1
21 3305208 SCREW PAN HD SLTD M5 x 0.8 - 16 4
22 6105206 WASHER PLAIN M5 4
23 0099340 COLUMN COVER 1
1705CA0031N SWITCH DOOR LIGHT 2
CONSIST OF :
24 1705CA0041N 1 - DUST COVER
25 1705CA0051N 1 - DOOR SWITCH
26 0114AF0040N KIT - LOCK WITH COMMON KEY 1
GROUP 1510 - WIRING HARNESS

27 0088409 SPACER STRG LOCK 4


28 1705AA0041N SWITCH HEAD LAMP AIMIMG 1
1801BA0040N ROOF LAMP WIRING HARNESS 1
0067497 CABLE ASSY FUEL GAGE TANK UNIT 1
1801CA0790N CHASSIS WIRING HARNESS 1
1801CA3930N BODY WIRING HARNESS 1
1801BA0170N INTRUMENT WIRING HARNESS 1
1805AA0110N BRKT SMS ECU 1
0028164 PIG TAIL HANDE BRAKE 1

1510.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1510.4
GROUP 1601 - INSTRUMENTS

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

1 1301AA0211N INSTRUMENT CLUSTER 1


2 1302AA0750N ASSY SPEEDOMETER CABLE 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1601.1
GROUP 1602 - WINDSHIELD WASHER GROUP 1602 - WINDSHIELD WASHER

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


PART NO.
1 0116CN0020N KIT WINDSHIELD WASHER 1
CONSIST OF :
5 1 - TUBE PVC 75mm 1
6 1 - TEE 3 WAY 1
7 1 - TUBE PVC 780mm 2
8 1 - MOTOR ASSEMBLY 1
9 0116CN0040N 2 - ASSEMBLY NOZZEL SINGLE JET 2
2 3306206 SCR SLTD PAN HD M6 x 1 - 14 2
3 6306208 WASHER INTERNAL TOOTH M6 2
4 6106208 PLAIN WASHER M6 2
10 0074612 FERRULE WINDSHIELD WASHER TUBE 1

1602.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1602.2
GROUP 1700 - TRANSMISSION ASSEMBLY - BS III

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


PART NO.
0703AD1170N TM ASSEMBLY 2WD NGT520 V4 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1700.1
GROUP 1701A - TRANSMISSION HOUSING AND ATTACHING

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


PART NO.
1 0703BD0450N ASSEMBLY FRONT HOUSING INT PLATE 1
2 0024626 FLANGE BOLT M8 x 1.25 - 20 6
3 0703BD0430N REAR HOUSING 2WD 1
4 0703BD0440N BEARING RETAINER PLATE 1
5 0703FD0220N SPEEDO DRIVEN GEAR 16T NGT 520 1
6 0060345 OIL SEAL SPEEDO DRIVEN GEAR 1
7 0071562 SLEEVE SPEEDOMETER 1
8 7910030169 BREATHER 1
GROUP 1701A - TRANSMISSION HOUSING AND ATTACHING

9 0703BD0480N RAIL END SEALING CAP 2


10 0502DA0360N FILLER PLUG 1
11 7903075044 PLUG M12 x 1.25 3
12 0703CD0920N REVERSE LAMP SWITCH NGT 520 1
13 7903062030 SEAL N/S 1
14 0502DA0370N DRAIN PLUG 1
15 0703CA0261N STUD M10 x 1.5 - 60 2
16 0703CA0271N HEX FLANGE BOLT M10 x 1.5 - 55 8
17 0703BD0460N CLUTCH RELEASE BEARING SLEEVE 1
18 3108224 BOLT HEX HD M8 x 1.25 - 20 3
19 7903055003 SPRING LOCK WASHER M8 3

1701A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1701A.2
GROUP 1702 - SELECTION BIASING GROUP 1703 - SHAFT RAIL AND FORKS

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0703CD0980N ADAPTER PIVOT 1 1 0703CD1030N FORK AND RAIL ASSEMBLY 1ST & 2ND 1
2 0703CD1010N PLUNGER RETURN 2 2 0703CD1040N FORK AND RAIL ASSY 3RD & 4TH 1
3 0703CD1230N SELECTION SPRING 5TH REV 1 3 0703CD0970N FORK AND RAIL ASSY 5TH & REV 1
4 0703CD1080N BIASING SPRING 1ST & 2ND 1 4 7903067342 4 - DOWEL PIN SPRING 6 x 25 NS
5 07030D0310N SIDE COVER PLATE 2 5 0052359 STEEL BALL 4
6 3106224 BOLT M6 x 1.0 - 10 4 5 7903090022 STEEL BALL (OPT) 4
7 6106208 PLAIN WASHER M6 4 6 0703CD1060N PIN 4 - 12 1
7 7836174000 FINGER INTERLOCK 1
8 7836279000 SPRING LOCKING 3
9 7903075044 PLUG M12 x 1.25 2
10 0703CD0131N ROLL PIN (6 - 20) 2

1702.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1703.1
GROUP 1704 - DRIVE SHAFT

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


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

0703DD1810N SELECTIVE SHIM MD GEAR 1.50 1


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

1704.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1704.2
GROUP 1705 - MAIN SHAFT DRIVE GEAR & SYNCHRONIZER

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


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

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


10 0703DD1870N SPACER 1ST GEAR 1
11 0703DD1270N ASSY 1ST GEAR OUTPUT SHAFT V4 1
12 0703DD1440N SPACER 1ST GEAR INT BRG 3.0 1
0703DD2830N SPACER 1ST GEAR INT BRG 2.50 1
0703DD2840N SPACER 1ST GEAR INT BRG 2.55 1
0703DD2850N SPACER 1ST GEAR INT BRG 2.60 1
0703DD1950N SPACER 1ST GEAR INT BRG 2.65 1
0703DD1960N SPACER 1ST GEAR INT BRG 2.70 1
0703DD1970N SPACER 1ST GEAR INT BRG 2.75 1
0703DD1980N SPACER 1ST GEAR INT BRG 2.80 1
0703DD1990N SPACER 1ST GEAR INT BRG 2.85 1
0703DD2000N SPACER 1ST GEAR INT BRG 2.90 * 1
0703DD2010N SPACER 1ST GEAR INT BRG 2.95 1
0703DD2020N SPACER 1ST GEAR INT BRG 3.05 1
0703DD2030N SPACER 1ST GEAR INT BRG 3.10 1
0703DD2040N SPACER 1ST GEAR INT BRG 3.15 1
0703DD2050N SPACER 1ST GEAR INT BRG 3.20 1
0703DD2060N SPACER 1ST GEAR INT BRG 3.25 1
0703DD2070N SPACER 1ST GEAR INT BRG 3.30 1
0703DD2080N SPACER 1ST GEAR INT BRG 3.35 1
(* OPTIONAL AS REQUIRED)
13 0703DD1580N MD GEAR BEARING (6307 2RSRN C3 ) 1
14 0703DD1890N SNAP RING MD GEA BEARING SP80 1
15 9603489380 DRIVEN GEAR - REVERSE 1
16 0703DD1390N SLEEVE OUTPUT SHAFT 1
17 9153656880 5TH DRIVEN GEAR 1
18 7903066114 CIRCLIP 68 - 3 (O/P SHAFT RR BRG) 1
19 9159501780 CYLINDRICAL ROLLER BRG 5TH GEAR 1
20 07000D0361N LIP SEAL 40D58E10 1
21 07000A0210A COMPANION FLANGE NUT TYPE (2WD) 1
22 A001028 COMPANION FLANGE NUT WASHER 1
23 0020178 NYLOC NUT G19.05mm - 16 (3/4" - 16) 1
24 51100A0050N BOLT HEX 4

1705.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1705.2
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

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


PART NO.
1 0703DD2260N COUNTER SHAFT V4 NGT520 1
2 0703DD1460N SPACER COUNTER SHAFT FRONT BRG 1
3 0703DD1590N COUNTER SHAFT FRONT BEARING 1
4 0703DD1600N COUNTER SHAFT REAR BEARING 1
5 0703BD0440N BEARING RETAINER PLATE 1
6 0703DD1370N 5TH REV SUB - SHAFT 1
7 SF0601036 CIRCLIP EXT - LUG 52 x 1.5 x PH 1
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

8 0703ED0350N SYNCHRONIZER ASSEMBLY 5TH & REV 1


9 9151433080 NEEDLE CAGE N/S - 5TH DRIVING GEAR 1
10 0703DD0360N ASSY 5TH DRIVE GEAR (2WD) 1
11 0703DD1480N SPACER 5TH INPUT GEAR 1
12 7910029041 ADJ SHIM SUB SHAFT BEARING 1
7910028076 ADJ SHIM SUB SHAFT 1.00 1
7910028077 ADJ SHIM SUB SHAFT 1.05 1
7910028078 ADJ SHIM SUB SHAFT 1.10 1
7910028079 ADJ SHIM SUB SHAFT 1.15 1
7910028080 ADJ SHIM SUB SHAFT 1.20 1
7910028081 ADJ SHIM SUB SHAFT 1.25 1
7910028082 ADJ SHIM SUB SHAFT 1.30 1
7910028083 ADJ SHIM SUB SHAFT 1.35 1
7910028084 ADJ SHIM SUB SHAFT 1.40 1
7910028085 ADJ SHIM SUB SHAFT 1.45 1
7910028086 ADJ SHIM SUB SHAFT 1.50 1
7910028087 ADJ SHIM SUB SHAFT 1.55 1
7910028088 ADJ SHIM SUB SHAFT 1.60 1
7910028089 ADJ SHIM SUB SHAFT 1.65 * 1
7910028090 ADJ SHIM SUB SHAFT 1.70 1
7910028091 ADJ SHIM SUB SHAFT 1.75 1
7910028092 ADJ SHIM SUB SHAFT 1.80 1
7910028093 ADJ SHIM SUB SHAFT 1.85 1
7910028094 ADJ SHIM SUB SHAFT 1.90 1
7910028095 ADJ SHIM SUB SHAFT 1.95 1
7910028096 ADJ SHIM SUB SHAFT 2.00 1
0703DD2650N ADJ SHIM SUB SHAFT 2.05 1
0703DD2660N ADJ SHIM SUB SHAFT 2.10 1
0703DD2670N ADJ SHIM SUB SHAFT 2.15 1
0703DD2680N ADJ SHIM SUB SHAFT 2.20 1
0703DD2690N ADJ SHIM SUB SHAFT 2.25 1
0703DD2700N ADJ SHIM SUB SHAFT 2.30 1
0703DD2710N ADJ SHIM SUB SHAFT 2.35 1
0703DD2720N ADJ SHIM SUB SHAFT 2.40 1
(* OPTIONAL AS REQUAIRED)

CONTINUE…

1706.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1706.2
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

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


PART NO.
13 0703DD1610N SUB SHAFT REAR BEARING 1
14 0703DD1380N IDLER SHAFT 1
15 0703DD1730N IDLER GEAR ASSEMBLY 1
16 0024630 FLANGE BOLT 2
GROUP 1706 - COUNTER LAY SHAFT GEAR & SYNCHRONIZER

1706.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1706.4
GROUP 1707 - TRANSMISSION SHIFT LEVER GROUP 1707 - TRANSMISSION SHIFT LEVER

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


PART NO.
1 0703CD1050N SHIFT LEVER BOTTOM - BOLERO 1
2 0038525 CLIP WIRING HARNESS STRG COLUMN 2
3 0703CD1020N GROMMET BOTTOM LEVER 1
4 0092658 PIVOT PIN 2
5 0703CD1000N PLATE PIVOT SPRING RETENTION 1
6 0703CD1100N SPRING SHIFT LEVER 1
7 0703CD1140N NYLON BUSH 1
8 7903067078 ELASTIC COTTER PIN 8 - 18 1
9 0024626 FLANGE BOLT M8 x 1.25 - 20 3

1707.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1707.2
GROUP 1701A - TRANSMISSION HOUSING AND ATTACHING KMT - 90

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


PART NO.
0703AC0610N TM ASSY 2WD KMT90 HYD CLUTCH 1
0052152 GASKET AND OIL SEAT SET TRANS 1
CONSISTS OF :
0051875 3 - GASKET GEARING RETAINER
0032253 1 - OIL SEAL
0052065 1 - GASKET BELL HOUSING
0052372 1 - GASKET CONTROL HOUSING
0052380 1 - GASKET
0052388 1 - GASKET TRANS TO TRANS CASE
0703BC0010N 1 - OIL SEAL
0060345 1 - OIL SEAL SPEEDOCABLE
0052349 1 - GASKET
7903062003 2 - GASKET

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1701A.1
GROUP 1702A - TRANSMISSION CASE, GEARS & COMPONENTS KMT - 90 GROUP 1702A - TRANSMISSION CASE, GEARS & COMPONENTS KMT - 90

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


PART NO.
1 0703BC0380N TRANSMISSION CASE 1 93901
2 0052098 STUD 10
4 0052324 KNOCK PIN 2
5 0093902 FILLER PLUG 1
6 7830197000 MAGNETIC DRAIN PLUG 1
7 0092561 REVERSE IDLER GEAR ASSEMBLY 1
9 0052326 REVERSE IDLER GEAR SHAFT 1
10 0052327 REVERSE IDLER SHAFT KEY 1
11 0092560 COUNTERSHAFT GEAR 1
12 0052328 BALL BEARING 2
13 0092595 TRANSMISSION MAIN SHAFT 1
14 0052611 3RD SPEED GEAR 1
15 0052612 MAIN SHAFT NEEDLE BEARING 2
16 0070030 WASHER ROLLER BEARING 2
0052486 HUB 3 - 4 & SLEEVE SUB ASSEMBLY 1
CONSISTS OF :
17 0052334 1 - CLUTCH HUB 3 & 4
18 0052335 1 - CLUTCH HUB SLEEVE
19 0052290 KEY SYNC 3 & 4 3
19 0703EC0010N KEY SYNC 3 & 4 (OPTIONAL) 3
20 0052291 SYNCHRONIZER KEY SPRING 3 & 4 2
21 0071582 SNAP RING (1.75 THICK) A/R

22 0703DC0020N 2ND SPEED GEAR 1


23 0052307 SYNCHRONIZER RING 2ND 1
24 0052338 THRUST WASHER 1
0703DC0080N HUB 1 - 2 AND LOW GEAR SUB ASSY 1
CONSISTS OF :
25 0703DC0030N 1 - CLUTCH HUB 1 & 2
26 0703DC0010N 1 - TRANSMISSION LOW GEAR
27 0703EC0020N SYNCHRONIZER KEY 1 & 2 3
27 0052288 SYNCHRONIZER KEY 1 & 2 (OPT) 3
28 0052289 SYNCHRONIZER KEY SPRING 1 & 2 2
29 0052387 SHIM A/R
30 0703CC0020N PROTECTOR 1
30 0052292 PROTECTOR (OPTIONAL) 1
30 0052292 PROTECTOR (OPTIONAL) 1

CONTINUE…

1702A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1702A.2
GROUP 1702A - TRANSMISSION CASE, GEARS & COMPONENTS KMT - 90 GROUP 1702A - TRANSMISSION CASE, GEARS & COMPONENTS KMT - 90

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


PART NO.
31 0071584 SNAP RING (1.75 THICK) A/R
31 0071585 SNAP RING (1.88 THICK) A/R
31 0071586 SNAP RING (2.01 THICK) A/R
32 0052301 BALL BEARING 1
33 0052002 MAIN DRIVE GEAR 1
34 0052303 BALL BEARING MAIN DRIVE GEAR 1
35 0052296 SNAP RING MAIN DRIVE GEAR 1
36 0052279 MAIN SHAFT NEEDLE BEARING 1
37 0052308 SYNCHRONIZER RING 3 & 4 2
38 0052065 GASKET TRANSMISSION CASE 1
39 0032253 OIL SEAL TRANS FRT BEARING RETAINER 1
40 0052003 TRANS MAIN DRIVE GEAR RETAINER 1
41 0051875 GASKET BEARING RETAINER 3
42 3108224 SCREW HEX HD M8 x 1.25 - 20 3
43 7903062003 SEAL 16 2
0703DC0040N TORQUE LOCK KIT FOR KMT 90 1
CONSIST OF :
0703DC0080N 1 - HUB 1 - 2 & LOW GEAR SUB ASSY
0703DC0020N 1 - 2ND SPEED GEAR

1702A.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1702A.4
GROUP 1703A - TRANSMISSION CONTROLS KMT - 90

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


PART NO.
1 0092574 TRANSMISSION CONTROL HOUSING 1
2 6508212 1 - LOCKWASHER M8 NS
3 0052345 SET SCREW 1
4 0082781 AIR BREATHER ASSEMBLY 1
5 0092572 REVERSE LAMP SWITCH 1
6 0092573 SEALING WASHER 1
7 0703CC0710N BALL 3
8 0642769 SHIFT RAIL POPPET SPRING 3
9 0076678 SHIFT RAIL 1 & 2 1
GROUP 1703A - TRANSMISSION CONTROLS KMT - 90

10 0052675 SHIFT RAIL 3 & 4 1


11 0092575 SHIFT RAIL REVERSE 1
12 0052363 INTERLOCK PIN 2
13 0052364 INTERLOCK PIN 1
14 0050928 PLUG PIPE SLOTTED HEADLESS 1/8" 1
15 0083027 SHIFT FORK 1 & 2 1
16 0052672 SHIFT FORK 3 & 4 1
17 0083028 SHIFT FORK REVERSE 1
18 0052763 SPRING PIN 3
19 0083026 PLUNGER RETURN 2
20 0083024 COIL SPRING 1 & 2 1
21 0083025 COIL SPRING REVERSE 1
22 0082778 SLOTTED SPRING PIN 2
23 0052372 GASKET CONTROL HOUSING 1
24 3108226 SCREW HEX HD M8 x 1.25 - 25 8
25 6508212 8 - LOCKWASHER SPRING M8 NS
26 0052371 SEALING CAP 2
27 07060C0010N GEAR SHIFT LEVER 1
28 0052376 BUSH NYLON GEAR SHIFT LEVER 1
29 0082788 LEVER COIL SPRING 1
30 0052380 GASKET GEAR SHIFT LEVER CVR PL 1
31 0082771 PLATE COVER 1
32 3106224 SCREW HEX HD M6 x 1 - 12 3
33 6506208 LOCKWASHER M6 3
34 0052017 DUST BOOT CHANGE LEVER 1
35 5108206 1 - NUT HEX M8 x 1.25 NS
36 0083131 KNOB TRANSMISSION LEVER 1

1703A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1703A.2
GROUP 1704A - REAR BEARING & RETAINER & ATTACHING PARTS KMT - 90

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


PART NO.
1 0052385 LOCKWASHER SPRING 5
2 SF0101080 BOLT HEX HD M12 x 1.5 - 30 5
3 0052388 GASKET TRANS - TRANSFER CASE 1
4 0052387 SHIM A/R
GROUP 1704A - REAR BEARING & RETAINER & ATTACHING PARTS KMT - 90

5 0052024 SPACER 1
6 0036352 SPEEDOMETER DRIVE GEAR (6 -T) 1
7 0076708 TRANSMISSION REAR BRG RETAINER 1
8 A000985 SPEEDOMETER DRIVE GEAR
PINION BUSHING 1
9 0036355 SPEEDOMETER DRIVEN GEAR (18 -T) 1
10 0071562 SPEEDOMETER DRIVE GEAR SLEEVE 1
11 0060345 OIL SEAL SPEEDO DRIVEN GEAR 1
12 0703BC0010N OUTPUT CLUTCH SHAFT OIL SEAL 1
13 0912105 COMPANION FLANGE & OIL SEAL
GUARD ASSEMBLY 1
CONSIST OF:
0912106 1 - COMPANION FLANGE REAR NS
A000979 1 - OIL SEAL GUARD NS
14 A001028 COMPANION FLANGE NUT WASHER 1
15 0020178 NUT NYLOC G19.05mm (3/4") 1
16 51100A0050N BOLT HEX 4
19 0092553 OIL DEFLECTOR 1

1704A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1704A.2
GROUP 1901 - PROPELLER SHAFT

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

1 0501AA0691N PROPELLER SHAFT ASSY REAR 1


2 51100A0050N BOLT HEX 4
3 G103321 LOCK WASHER SPRING
G 9.53 mm (3/8") 8
4 0501EA0040N PROPSHAFT LOCKNUT AXLE END 4
5 0501EA0030N PROPSHAFT LOCKNUT TRANS END 4
0038166 KIT UNIVERSAL JOINT JOURNAL 2
CONSIST OF:
0038148 1 - JOURNAL ASSEMBLY NS
0038167 4 - BEARING ASSEMBLY NS
0038168 4 - SNAP RING NS
G271287 2 - GREASE NIPPLE NS

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 1901.1
GROUP 2001 - FRONT AXLE (2WD)

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


PART NO.
0503AA1730N FRONT AXLE ASSY 2WD 1
1 0027516 TUBE ASSEMBLY FRONT AXLE 2WD 1
2 0027512 SPLIT RING SEAT UPPER BALL JOINT 2
0027534 ASSY STRG KNUCKLE & BALL JOINT LH 1
CONSIST OF:
3 0027505 1 - STEERING KNUCKLE LH
4 0027511 1 - LOWER BALL JOINT
5 0027515 1 - CIRCLIP LOWER BALL JOINT
6 0027510 1 - UPPER BALL JOINT
0027535 ASSY STRG KNUCKLE & BALL JOINT RH 1
CONSIST OF:
3 0027506 1 - STEERING KNUCKLE RH
4 0027511 1 - LOWER BALL JOINT
0027515 1 - CIRCLIP LOWER BALL JOINT
GROUP 2001 - FRONT AXLE (2WD)

5
6 0027510 1 - UPPER BALL JOINT
7 0027513 NUT UPPER BALL JOINT 2
8 0027514 NUT LOWER BALL JOINT 2
9 7032218 COTTER PIN 3.2 x 45 2
10 0038237 WHEEL BEARING SPINDLE 2
11 G181637 BOLT HEX HD G9.52 x 25.4mm (3/8"-24x1") 12
12 G108580 SPRING LOCK WSHR HD G9.53 mm (3/8") 12
13 5110208 NUT HEX M10 x 1.5 2
14 0027533 STOPPER BOLT 2
15 0027522 PLUG FRONT AXLE TUBE 2

2001.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2001.2
GROUP 2002 - REAR AXLE

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


PART NO.
0502AA2360N REAR AXLE ASSEMBLY 4.3R 1
1 0502BA0680N TUBE ASSEMBLY REAR AXLE RH 1
1 0502BA0690N TUBE ASSEMBLY REAR AXLE LH 1
2 0503DA0010N GEAR CARRIER COVER ASSEMBLY 1
3 0602BB1670N BRACKET LSRV AND TEE 1
4 52080A0101N FLANGED SCREW AXLE COVER (14.0mm) 2
5 52080A0111N FLANGED SCREW AXLE COVER (17.0mm) 8
6 0502AA1920N RATIO TAG 4.3R 1
7 0502DA0360N FILLER PLUG 1
8 0502DA1290N DRIVE GEAR & PINION PAIR 4.3R NS
CONSISTS OF:
0502DA0930N 1 - PINION HYPOID DRIVE 10T
0502DA0940N 1 - HYPOID BEVEL DRIVE GEAR 4.3R
0502CA0110N KIT CONE & ROLLER DIFF BRG 2
CONSISTS OF:
GROUP 2002 - REAR AXLE

9 0052961 1 - DIFFERENTIAL BEARING CUP NS


10 0052960 1 - DIFFERENTIAL BEARING CONE NS
11 0502DA0240N DIFF ADJ SHIM 0.076mm (0.003") A/R
11 0502DA0250N DIFF ADJ SHIM 0.127mm (0.005") A/R
11 0502DA0260N DIFF ADJ SHIM 0.254mm (0.010") A/R
11 0502DA0270N DIFF ADJ SHIM 0.762mm (0.030") A/R
11 0502DA0850N DIFF ADJ SHIM 0.1651mm (0.0065") A/R
0502EA2080N DIFFERENTIAL ASSEMBLY 4.3R 1
12 0502EA0050N DIFFERENTIAL CASE RH 1
13 0502EA0040N DIFFERENTIAL CASE LH 1
14 0502DA0390N SIDE GEAR AND PINION MATE ASSY - 4.3R 1
CONSISTS OF:
0502DA0230N 2 - DIFFERENTIAL BEVEL SIDE GEAR NS
0647062 4 - DIFFERENTIAL BEVEL PINION MATE NS
0502DA0380N KIT DIFF GEAR & PINION 1
CONSISTS OF:
15 0502DA0400N 1 - DIFF BEVEL PINION MATE SHAFT NS
16 0502EA1300N 1 - SPIDER BLOCK DIFFERENTIAL NS
17 0090637 2 - DIFF BEVEL PINION MATE PIN NS
18 0090559 4 - WASHER THRUST PINION MATE NS
19 0502EA0400N 3 - PIN SPRING DIFFERENTIAL NS
20 0012109 2 - DIFF BEVEL GEAR THRUST WASHER NS
20 0036394 2 - DIFF BEVEL GEAR THRUST WASHER NS
20 0037709 2 - DIFF BEVEL GEAR THRUST WASHER NS
20 0645789 2 - DIFF BEVEL GEAR THRUST WASHER NS
21 0802561 STRAP LOCK 5
22 0502EA0620N SCREW DRIVE GEAR 10
23 0502DA0370N DRAIN PLUG 1

CONTINUE…

2002.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2002.2
GROUP 2002 - REAR AXLE

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


PART NO.
24 0639969 DRIVE PINION BEARING ADJUSTABLE
SHIM 0.0762mm (0.003") - REAR A/R
24 0639970 DRIVE PINION BEARING ADJUSTABLE
SHIM 0.127mm (0.005") - REAR A/R
24 0639971 DRIVE PINION BEARING ADJUSTABLE
SHIM 0.254mm (0.010") - REAR A/R
0019405 KIT CONE ROLLER & CUP PINION 1
BEARING INNER
CONSISTS OF:
25 0052877 1 - CUP PINION BRG. INNER NS
26 0807266 1 - CONE & ROLLER PINION BRG INNER NS
27 G179890 BOLT HEX HD G12.70 x 57.16mm 4
(1/2" UNC - 2-1/4")
28 0091412 NIPPLE BREATHER 1
29 0502EA0210N SPACER PINION BEARING 3.500T A/R
GROUP 2002 - REAR AXLE

29 0502EA0220N SPACER PINION BEARING 3.550T A/R


29 0502EA0230N SPACER PINION BEARING 3.600T A/R
29 0502EA0240N SPACER PINION BEARING 3.650T A/R
29 0502EA0250N SPACER PINION BEARING 3.700T A/R
29 0502EA0260N SPACER PINION BEARING 3.750T A/R
29 0502EA0270N SPACER PINION BEARING 3.800T A/R
29 0502EA0280N SPACER PINION BEARING 3.850T A/R
29 0502EA0290N SPACER PINION BEARING 3.900T A/R
29 0502EA0300N SPACER PINION BEARING 3.950T A/R
29 0502EA0310N SPACER PINION BEARING 4.000T A/R
29 0502EA1170N SPACER PINION BEARING 3.525T A/R
29 0502EA1180N SPACER PINION BEARING 3.575T A/R
29 0502EA1190N SPACER PINION BEARING 3.625T A/R
29 0502EA1200N SPACER PINION BEARING 3.675T A/R
29 0502EA1210N SPACER PINION BEARING 3.725T A/R
29 0502EA1220N SPACER PINION BEARING 3.755T A/R
29 0502EA1230N SPACER PINION BEARING 3.825T A/R
29 0502EA1240N SPACER PINION BEARING 3.875T A/R
29 0502EA1250N SPACER PINION BEARING 3.925T A/R
29 0502EA1260N SPACER PINION BEARING 3.975T A/R
0019402 KIT CONE ROLLER & CUP PINION 1
BEARING OUTER
CONSISTS OF:
30 0052879 1 - CUP PINION BRG OUTER NS
31 0052878 1 - CONE & ROLLER PINION BRG OUTER NS
32 0075871 DRIVE PINION BRG OIL SLINGER 1
33 0502CA0131N SEAL PINION REAR AXLE 1
35 0502EA1280N COMPANION FLANGE AND DUST SHIELD
ASSEMBLY 1

CONTINUE…

2002.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2002.4
GROUP 2002 - REAR AXLE

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


PART NO.
36 A001028 COMPANION FLANGE NUT WASHER 1
37 0020178 NYLOC NUT G19.05mm (3/4" x 16) 1
AXLE SHAFT SUB ASSEMBLY REAR RH 1
CONSISTS OF:
38 0502FA0390N 1 - AXLE SHAFT REAR RH
39 0097871 5 - WHEEL BOLT
40 0502AA1040N 1 - DUST SHIELD
41 0502AA1110N 6 - BOLT M10 x 1.5
42 0502CA0180N 1 - OIL SEAL AXLE SHAFT OUTER
43 0502BA0320N 1 - BEARING CARRIER
44 0502CA0220N 1 - BEARING
45 0502AA1190N 1 - WASHER
46 0502AA2090N 1 - LOCK WASHER
47 0502AA1210N 1 - LOCK NUT BEARING
0602BA2621N 1 - BRAKE ASSY RH AUTO ADJ
GROUP 2002 - REAR AXLE

AXLE SHAFT SUB ASSEMBLY REAR LH 1


CONSISTS OF:
38 0502FA0400N 1 - AXLE SHAFT REAR LH
39 0097871 5 - WHEEL BOLT
40 0502AA1040N 1 - DUST SHIELD
41 0502AA1110N 6 - BOLT M10 x 1.5
42 0502CA0180N 1 - OIL SEAL AXLE SHAFT OUTER
43 0502BA0320N 1 - BEARING CARRIER
44 0502CA0220N 1 - BEARING
45 0502AA1190N 1 - WASHER
46 0502AA2090N 1 - LOCK WASHER
47 0502AA1210N 1 - LOCK NUT BEARING
0602BA2611N 1 - BRAKE ASSY LH AUTO ADJ
48 0502CA0210N OIL SEAL AXLE SHAFT INNER 2
49 0502AA1400N SHIM 1.000mm THK A/R
49 0502AA1410N SHIM 0.500mm THK A/R
49 0502AA1420N SHIM 0.200mm THK A/R
49 0502AA1430N SHIM 0.125mm THK A/R
49 0502AA1440N SHIM 0.100mm THK A/R
50 6510114 LOCK WASHER SPRING M10 12
51 7903032023 NUT HEX M10 x 1.5 12
(REAR BRAKE BACKING PLATE TO
AXLE TUBE FLANGE)
52 0097872 REAR BRAKE DRUM 2
53 3206206 SCREW M6 x 1 - 16 2

2002.5 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2002.6
GROUP 2101A - STEERING GEAR AND MOUNTINGS (PS) GROUP 2101A - STEERING GEAR AND MOUNTINGS (PS)

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


PART NO.
1 0088535 ASSY STRG WHEEL WITH LEATHER CVR 1
CONSIST OF:
2 0088822 1 - CONTACT PLATE ASSEMBLY
3 0088823 4 - SPRING
4 0088824 4 - SCREW
5 1106AA0381N 1 - HORN PAD
6 0088826 2 - DOWEL PIN
7 0098464 UPPER STEERING COLUMN SUB
ASSEMBLY WITH STEERING LOCK 1
CONSISTS OF :
8 0099221 1 - JACKET TUBE STRG. COLUMN NS
9 0099222 1 - SHAFT STRG COLUMN NS
10 0099223 1 - RUBBER BUSH UPPER NS
11 0099224 1 - RUBBER BUSH LOWER NS
12 0099225 1 - BUSH NS
14 0099280 1 - NUT STRG COLUMN END
15 0080680 ANTI SQUEAK STRG COLUMN 1
16 3108206 SCREW HEX HEAD M8 x 1.25 - 25 4
17 6108212 PLAIN WASHER M8 4
18 6508212 SPRING LOCK WASHER M8 4
19 0039587 STEERING COLUMN CLAMP 1
20 G123798 BOLT HEX HD G7.93 x 44.45mm 1
(5/16" - 24 x 1 - 3/4")
21 G120393 WASHER PLAIN G7.94mm (5/16 " ) 2
22 G120214 LOCK WASHER SPRING G7.94mm (5/16" ) 1
23 G120368 NUT HEX G7.93mm (5/16" - 24 ) 1
24 0098535 BRKT SUPPORT STRG.COLUMN BOTTOM 1
25 0098536 GROMMET STRG COLUMN BOTTOM 1
27 0028290 ASSY RUBBER COUPLING 1
28 0098776 POWER STRG ASSY WITH DROP ARM 1

2101A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2101A.2
GROUP 2101A - STEERING GEAR AND MOUNTINGS (PS)

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


PART NO.
29 0080649 STEERING GEAR ASSEMBLY 1
30 0098999 DROP ARM 1
31 0097930 LOCKING PLATE FOR DROP ARM 1
32 0097949 DROP ARM LOCK NUT 1
33 0099000 STEERING GEAR MOUNTING BRACKET 1
34 0080654 2 - BOLT STRG GEAR MTG NS
35 6512216 6 - SPRING LOCK WASHER M12 NS
36 6112216 6 - PLAIN WASHER M12 NS
37 0098646 2 - BOLT POWER STRG MTG NS
GROUP 2101A - STEERING GEAR AND MOUNTINGS (PS)

38 0080652 2 - BOLT STG GEAR MTG NS


39 1102CA0270N RETURN PIPE 1
40 0080670 2 - COPPER WASHER M14 NS
41 0087624 BANJO BOLT M14 (PRESSURE) 1
42 0080690 2 - CLAMP HYD PIPE NS
43 1102CA0260N PRESSURE FEED PIPE 1
44 0080669 4 - COPPER WASHER M16 NS
45 0087626 BANJO BOLT M16 (RETURN) 1

CONTINUE...

2101A.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2101A.4
GROUP 2101A - STEERING GEAR AND MOUNTINGS (PS)

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


PART NO.
46 0087625 BANJO BOLT M16 1
47 0028728 SUCTION HOSE 1
48 0028590 ASSY RESVR PWR STG PUMP (SMALL) 1
16 3108206 2 - SCR HEX HD M8 x 1.25 - 20 S NS
17 6108212 2 - PLAIN WASHER M8 NS
18 6508212 2 - SPRING LOCK WASHER M8 NS
49 0098832 ASSEMBLY STEERING PUMP 1
50 1102DA3150N BRKT STEERING PUMP MOUNTING 1
51 0306HB0070N PULLEY STEERING PUMP 1
GROUP 2101A - STEERING GEAR AND MOUNTINGS (PS)

52 3106226 3 - SCREW HEX M6 x 1 - 16 NS


53 1102DA0190N SPLIT BUSH 1
54 1102DA0180N BOLT M10 x 1.25 - 28 2
55 0056887 BOLT HEX HD M10 x 1.5 - 130 1
56 7903032023 NUT M10 x 1.5 1
57 1102DA3150N ASSY BRKT POWER STRG PUMP MTG 1
58 6508212 2 - SPRING LOCK WASHER M8 NS
59 0080697 BELT POWER STEERING PUMP 1
60 6110214 2 - SPRING LOCK WASHER M10 NS
61 SF0102033 2 - BOLT M8 x 1.25 - 90 NS
62 5108206 2 - NUT M8 x 1.25 NS
63 6108212 2 - PLAIN WASHER M8 NS
64 1102DA2950N BRACKET ADJUSTER ROD 1
65 SF0102038 1 - FLANGE BOLT M8 x 1.25 - 55 NS
66 1001CA6420N BRKT FUEL FILTER & PS RESERVOIR 1
67 1102DA3440N ADJUSTER ROD STRG PUMP 1
68 1102DA3400N PIVOT BLOCK 1
69 5110206 4 - NUT HEX M10 x 1.25 NS
70 6110210 PLAIN WASHER M10 1
71 7903055007 SPRING LOCK WASHER M10 2
72 6106208C WASHER PLAIN M6 1
73 6506208C SPRING LOCK WASHER M6 1

2101A.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2101A.4
GROUP 2101B - SERVICEABLE COMPONENTS OF STEERING GEAR (PS - W&R) GROUP 2101B - SERVICEABLE COMPONENTS OF STEERING GEAR (PS - W&R)

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


PART NO.
1 0027852 INPUT SHAFT SEAL KIT 1
CONSISTS OF :
- 1 - DOUBLE LIP SEAL NS
- 1 - BACKUP WASHER NS
- 1 - RETAINING RING NS
2 0027853 NEEDLE BEARING (INPUT SHAFT) 1
3 0027854 SHIM SET RACE BEARING 1
CONSISTS OF : NS
- 1 - SHIM - 0.05 mm THICK NS
- 1 - SHIM - 0.10 mm THICK NS
- 1 - SHIM - 0.15 mm THICK NS
- 1 - SHIM - 0.20 mm THICK NS
- 1 - SHIM - 0.25 mm THICK NS
- 1 - SHIM - 0.50 mm THICK NS
4 0027855 RACE BEARING 2
5 0027856 SEAL RING - VALVE 5
6 0027857 WORM & VALVE ASSEMBLY RHD 1
7 0027859 BALL RING ASSEMBLY 1
8 0027860 'O' RING - WORM COVER 1
9 0027861 WORM ADJUSTER COVER 1
10 0027862 LOCKER PIN 1
11 0027863 COVER LOCKER WIRE 1
12 0027864 CYLINDER COVER 1
13 0027865 QUAD RING SEAL 1
15 0027866 PISTON RACK SEAL KIT 1
CONSISTS OF :
- 1 - 'O' RING - PISTON RACK NS
- 1 - PISTON SEAL RING NS
16 0027867 PISTON RACK ASSEMBLY 1
17 0027868 RACK PAD ADJUSTER 1
18 0027869 'O' RING 1
19 0027870 SPRING 1
20 0027871 RACK PAD 1
21 0027872 LOCK SCREW WITH LEAD PAD 1
22 0027873 NUT 1
23 0027874 TAB WASHER 1
24 0027875 ROLLER SHAFT SEAL KIT 1
CONSISTS OF : NS
- 1 - PRESSURE SEAL NS
- 1 - BACKUP WASHER NS
- 1 - RETAINING RING NS
- 1 - DIRT SEAL NS

CONTINUE...

2101B.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2101B.2
GROUP 2101B - SERVICEABLE COMPONENTS OF STEERING GEAR (PS - W&R) GROUP 2101B - SERVICEABLE COMPONENTS OF STEERING GEAR (PS - W&R)

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


PART NO.
25 0027876 NEEDLE BEARING (ROLLER SHAFT) 1
26 0027877 ROLLER SHAFT ASSY - RHD 1
27 0027879 'O' RING - SIDE COVER 1
28 0027880 NEEDLE BEARING (SIDE COVER) 1
29 0027881 SIDE COVER - RHD 1
31 0027883 BOLT M8 x 20 6
32 0027884 SPECIAL WASHER (SEAL NUT) 1
33 0027885 HOUSING SUB ASSY - RHD 1
0027908 SEAL KIT 1
0027909 WORM & VALVE KIT - RHD 1
0027910 PISTON RACK KIT - RHD 1

2101B.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2101B.4
GROUP 2101C - SERVICEABLE COMPONENTS OF STR. PUMP (PS - W&R)

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


PART NO.
0027887 HOUSING ASSEMBLY 1
CONSISTS OF :
18 - 1 - HOUSING SUB ASSEMBLY NS
26 - 1 - CONNECTOR NS
25 - 1 - 'O' RING NS
GROUP 2101C - SERVICEABLE COMPONENTS OF STR. PUMP (PS - W&R)

24 - 1 - 'O' RING NS
23 - 1 - FLOW CONTROL VALVE NS
22 - 1 - FLOW CONTROL SPRING NS
0027888 SHAFT SUB ASSEMBLY 1
CONSISTS OF :
6 - 1 - SHAFT NS
5 - 1 - BALL BEARING NS
4 - 1 - RETAINING RING (EXT) NS
3 - 1- HUB NS
0027889 CARTRIDGE ASSEMBLY 1
CONSISTS OF :
9 - 1 - FRONT BODY NS
12 - 1 - CAM NS
14 - 1 - ROTOR NS
13 - 10 - VANES NS
15 - 1 - PRESSURE PLATE NS
11 - 2 - DOWEL PIN NS
0027890 SEAL KIT 1
CONSISTS OF :
8 - 1 - DOUBLE LIP SEAL NS
10 - 4 - 'O' RING NS
16 - 1 - 'O' RING NS
17 - 1 - 'O' RING NS
25 - 1 - 'O' RING NS
24 - 1 - 'O' RING NS
20 - 1 - 'O' RING NS
21 0027892 CANISTER 1
19 0027893 MAGNET 1
1 0027894 SCREWS 4
2 0027895 RETAINING RING 1
7 0027896 SPACER 1
11 0027897 DOWEL PIN 2
26 0027898 CONNECTOR 1

2101C.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2101C.2
GROUP 2103 - STEERING TIE ROD

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


PART NO.
1 1103AA0141N MASTER TIE ROD ASSY 1
1 1103AA0142N MASTER TIE ROD ASSY(OPT) 1
2 0084852 ASSEMBLY CONNECTING TIE ROD 1
3 0099805 TIE ROD SOCKET ASSEMBLY LEFT M18 1
4 0099806 TIE ROD SOCKET ASSEMBLY RIGHT M18 2
5 0099807 MASTER TIE ROD SOCKET ASSEMBLY 1
6 A000837 SOCKET ASSEMBLY CLAMP 2
7 2108262 2 - BOLT HEX HD M8 x 1.25 - 40 NS
8 6508212 2 - LOCK WASHER SPRING M8 NS
9 5108206 2 - NUT HEX M8 x 1.25 NS
10 0074294 TIE ROD DUST COVER 4
11 0020231 WASHER SPECIAL 4
12 0074298 NUT HEX M12 x 1.5 4
13 7025212 PIN COTTER 2.5 x 25 4
GROUP 2103 - STEERING TIE ROD

14 0099808 TIE ADJUSTING HEX SLEEVE 1


15 0099809 LOCK NUT RH M18 2
16 0099810 LOCK NUT LH M18 1
17 0099998 STEERING DAMPNER 1
18 0020154 NYLOC NUT G11.11mm (7/16'' - 20) T TYPE 1
19 2108260 BOLT HEX HD M8 x 1.25 - 35 4
20 6108212 4 - WASHER PLAIN M8 NS
21 6508212 4 - LOCK WASHER SPRING M8 NS
22 0028262 BRACKET STRG DAMPNER ON CONROD 1
23 0058974 SPECIAL BOLT STEERING DAMPNER 1
24 G120395 WASHER PLAIN ID G11.11mm 2
(7/16" x 15/32")

2103.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2103.2
GROUP 2104 - STABILIZER BAR

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


PART NO.
1 0401EA0300N STABILISER BAR 1
0084842 ASSEMBLY LINK STABILIZER BAR 1
CONSIST OF:
8 0084843 2 - LINK STABILIZER BAR
0060480 4 - STABILIZER BAR FERRULE NS
2 0401BA1550N BUSHING STABILISER BAR 2
3 0060479 STABILIZER CLAMP 2
4 6510214 LOCKWASHER SPRING M10 4
5 0099105 SPECIAL BOLT HEX HD M10 x 1.5 - 25 4
6 6112216 2 - PLAIN WASHER M12 NS
7 0097964 BUSHING 4
9 G131016 PLAIN WASHER ID G16.67mm (21/32") 4
10 G137218 COTTER PIN 3.96 x 31mm (5/32" x 1 - 1/4") 2
11 0097645 STUD STABILIZER BAR 1
GROUP 2104 - STABILIZER BAR

12 SF0302021 NUT NYLOC M12 x 1.25 - 12 2

2104.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2104.2
GROUP 2201 - HAND BRAKE

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


PART NO.
1 06050A0210N LEVER ASSY PARK BRAKE 1
2 0605AA0220N CABLE PARKING BRAKE FRT 1
3 06050A0200N BRKT ROLLER HOLD DOWN 1
4 0068266 ROLLER PARK BRAKE 1
5 0068362 CIRCLIP HAND BRAKE CABLE FRT 1
6 0605BA0381N CABLE PARKING BRAKE RR 1
6 0605BA0382N CABLE PARKING BRAKE RR(OPT) 1
7 0068153 WIRE CLIP 2
8 0069504 CABLE SUPPT PLATE 1
9 0028023 GROMMET PARKING BRAKE FRONT 1
10 3106226 3 - SCR HEX HD M6 x 1.0 - 16 NS
11 6506208 SPRING LOCK WASHER M6 3
12 6106208 PLAIN WASHER M6 3
13 06050A0350N BRKT GUIDE CABLE FRONT 1
14 06050A0360N BRKT GUIDE CABLE REAR 1
GROUP 2201 - HAND BRAKE

15 6110214 1 - PLAIN WASHER M10 NS

2201.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2201.2
GROUP 2202A - DISC BRAKE GROUP 2202A - DISC BRAKE

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


PART NO.
1 0082597 DISC BRAKE 2
2 G123920 LOCKWASHER SPRING G9.53mm (3/8") 12
3 G181361 BOLT HEX. HEAD G9.25 x 47.62mm
(3/8" - 24 x 7/8") * 12
(* DISC BRAKE TO FRONT WHEEL HUB)
4 0603BA0441N CALIPER ASSEMBLY LH 1
4 0603BA0451N CALIPER ASSEMBLY RH 1
5 G120384 LOCKWASHER SPRING G12.7mm (1/2") 4
6 0068099 BOLT M12 x 1.25 - 30 4
(STEERING KNUCKLE TO CALIPERS)
7 0089323 HOUSING 2
0089335 KIT CALIPER (MAJOR) 2
CONSIST OF :
8 0089324 1 - SEALING RING NS
9 0089325 1 - PISTON NS
10 0089326 1 - BOOT - PISTON NS
11 0089329 2 - SLIDING PIN - BOOT NS
0603BA0511N 2 - SHIM NS
0603BA0521N 2 - GASKET NS
- 1 - GREASE SACHET NS
0089336 KIT CALIPER (MINOR) 2
CONSIST OF :
8 0089324 1 - SEALING RING NS
10 0089326 1 - BOOT - PISTON NS
11 0089329 2 - SLIDING PIN - BOOT NS
0603BA0521N 2 - GASKET NS
- 1 - GREASE SACHET NS
0089337 KIT SLIDING PIN 2
CONSIST OF :
11 0089329 2 - SLIDING PIN - BOOT NS
12 0089327 2 - BOLT PIN NS
13 0089328 2 - SLIDING PIN NS
- 1 - GREASE SACHET NS
14 0089333 BLEED SCREW NS
0603BA0461N KIT PAD ASSEMBLY 4
CONSIST OF :
15 - 4 - PAD ASSEMBLY NS
16 0089332 ANTI RATTLE CLIP 4
17 0089330 CARRIER 2
18 0503CA0110N DUST SHIELD DISC BRAKE - LH 1
18 0503CA0120N DUST SHIELD DISC BRAKE - RH 1

2202A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2202A.2
GROUP 2202B - WHEEL BRAKE

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


PART NO.
0602BA2611N REAR BRAKE ASSY LH AUTO ADJUSTER 1
0602BA2621N REAR BRAKE ASSY RH AUTO ADJUSTER 1
1 0602BA3181N BACK PLATE ASSEMBLY REAR - LH 1
1 0602BA3191N BACK PLATE ASSEMBLY REAR - RH 1
2 0602BA3241N SPRING WHEEL CYLINDER END 2
3 0602BA3251N SPRING SHOE RETURN 2
4 0602BA3261N SPRING ADJUSTER 4
5 0031133 WHEEL CYLINDER ASSY RR LH/RH 2
0032284 KIT RR WHEEL CYLINDER MINOR 1
CONSIST OF :
6 - 2 - CUP SEAL NS
7 - 2 - DUST COVER NS
8 - 1 - DUST CAP NS
0602BA2521N KIT RR WHEEL CYLINDER MAJOR 1
GROUP 2202B - WHEEL BRAKE

CONSIST OF :
6 - 2 - CUP SEAL NS
7 - 2 - DUST COVER NS
8 - 1 - DUST CAP NS
9 - 1 - PLUNGER NS
10 - 1 - SPRING ASSEMBLY NS
11 - 1 - SEAL RETAINER NS
0602BA3271N KIT LINED SHOE 2
CONSIST OF :
12 - 1 - LINED SHOE ASSEMBLY - LEADING NS
13 - 1 - LINED SHOE ASSEMBLY - TRAILING NS
- 48 - RIVET NS
0602BA3281N KIT LINING SET (STD) 1
0011919 KIT BRAKE SHOE HOLD DOWN 2
CONSIST OF :
14 - 4 - CUP WASHER NS
15 - 2 - PINS NS
16 - 2 - SPRING NS
0012657 KIT BOLT & WASHER ASSEMBLY 1
CONSIST OF :
17 - 4 - LOCK WASHER NS
18 - 4 - SET SCREW NS
19 0602BA3291N PUSH ROD ASSEMBLY - LH 1
19 0602BA3301N PUSH ROD ASSEMBLY - RH 1

CONTINUE...

2202B.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2202B.2
GROUP 2202B - WHEEL BRAKE

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


PART NO.
0602BA3311N KIT LEVER - PAWL LH 1
CONSIST OF :
20 - 1 - LEVER - PAWL LH NS
21 - 1 - LOCK WASHER LH NS
22 - 1 - WAVE WASHER NS
23 - 1 - DOWEL PIN NS
0602BA3321N KIT LEVER - PAWL RH 1
CONSIST OF :
20 - 1 - LEVER - PAWL RH NS
21 - 1 - LOCK WASHER RH NS
22 - 1 - WAVE WASHER NS
23 - 1 - DOWEL PIN NS
24 0602BA3331N GROMMET COLLAPSING 1
25 0602BA3341N GROMMET 1
GROUP 2202B - WHEEL BRAKE

0602BA3351N KIT, LEVER ASSEMBLY LH 1


CONSIST OF :
26 - 1 - LEVER ASSEMBLY LH NS
27 - 1 - SPRING PLATE NS
28 - 1 - RETAINING PLATE NS
0602BA3361N KIT, LEVER ASSEMBLY RH 1
CONSIST OF :
26 - 1 - LEVER ASSEMBLY RH NS
27 - 1 - SPRING PLATE NS
28 - 1 - RETAINING PLATE NS
29 0012655 BLEED SCREW 2

2202B.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2202B.4
GROUP 2204 - BRAKE MASTER CYLINDER AND RESERVOIR

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


PART NO.
1 0607AA0551N BOOSTER ASSY DIA 228 WITH 23.81 TMC 1
2 0607AA0871N SERVO ASSEMBLY 1
06060A0371N KIT SERVO 1
CONSIST OF :
3 0029634 1 - FILTER
17 0029635 1 - GROMMET - NRV
1 - SEAL ASSY VACUUM
4 1 - DUST COVER
GROUP 2204 - BRAKE MASTER CYLINDER AND RESERVOIR

1 - GREASE SACHET
0606AA1301N KIT MASTER CYLINDER - MAJOR 23.81 1
CONSIST OF :
5 1 - PLUNGER ASSY - PRIMARY NS
6 1 - PLUNGER ASSY - SECONDARY NS
7 1 - CIRCLIP NS
8 1 - WASHER 6.5mm NS
9 1 - STOP PIN NS
10 2 - SEAL FLUID TANK NS
0606AA1321N KIT MASTER CYLINDER - MINOR 1
CONSIST OF :
11 2 - SEAL RECUPERATING NS
12 2 - SHIM SEAL NS
13 2 - SEAL GLAND NS
8 1 - WASHER 6.5mm NS
10 2 - SEAL FLUID TANK NS
7 1 - CIRCLIP NS
14 6508212 LOCK WASHER SPRING M8 6
15 5108206 6 - NUT HEX M8 x 1.25 NS
16 0606AA1271N MASTER CYLINDER ASSEMBLY 23.81 1
0607AA0341N KIT NON RETURN VALVE 1
CONSIST OF:
17 0064334 1 - GROMMET NS
18 0064333 1 - ASSEMBLY NON RETURN VALVE NS
19 0097612 ASSEMBLY FLUID RESERVOIR 1
20 0606CA0350N HOSE VACUUM PUMP TO BOOSTER 1

2204.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2204.2
GROUP 2205 - BRAKE PEDAL

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

1 0606BA1060N PEDAL ASSY BRAKE 1


2 0036422 BUSH 2
3 0606BA1240N SPRING RETRACTING 1
4 0081805 PEDAL PAD COVER 1
5 0035963 RUBBER STOPPER 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2205.1
GROUP 2206 - BRAKE TUBES

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


PART NO.
1 0606CA8710N TUBE COILED FRONT 1
1 0606CA0840N TUBE COILED (STRAIGHT LENGTH) 1
2 0606CA9580N COILED BUNDY MAIN TUBE TO BOOSTER 1

3 0098595 BRAKE TUBE FRONT TEE TO HOSE LH 1


3 0098596 BRAKE TUBE FRONT TEE TO HOSE LH 1
(STRAIGHT LENGTH)
4 0028630 BRAKE HOSE FRT 2
5 0606CA1800N BRAKE TUBE FRONT TEE TO HOSE RT-150m 1
5 0074215 BRAKE TUBE FRT HOSE TO FRT BRK 1
(STRAIGHT LENGTH)
6 0606CB1000N TUBE CHASSIS BRKT TO LCRV INLET 1
7 0011631 BRAKE HOSE ASSY 1
8 0606CA2010N TUBE REAR TEE TO WHEEL LH 1
8 0606CA1430N TUBE REAR TEE TO WHEEL LH 1
GROUP 2206 - BRAKE TUBES

(STRAIGHT LENGTH)
9 0606CA2020N TUBE REAR TEE TO WHEEL RH 1
9 0606CA1440N TUBE REAR TEE TO WHEEL RH 1
(STRAIGHT LENGTH)
10 0011639 TEE REAR 3 WAY 2
11 0075613 BANJO BOLT M10 x 1 2
12 0011642 GASKET BRAKE HOSE 5
13 0011645 NUT LOCK HOSE SECURING 3
14 0011644 LOCKWASHER BRAKE HOSE SECURING 3
15 0020164 UNION INV FLARED TUBE 6.35mm (1/4") 1
16 3106214 BOLT HEX HD M6 x 1 - 35 2
17 6506208 SPRING LOCK WASHER M6 2
18 6106208 PLAIN WASHER M6 2
19 0804201 CLIP AXLE TUBE BRK TUBE HOLD DOWN 2
20 0081528 BRAKE TUBE CLIP 6
21 0606CA1611N CLIP BUNDY TUBE 1
22 0606CB1480N TUBE BRAKE LCRV TO REAR HOSE 1
23 0601BZ0030N LCRV ASSEMBLY 1

2206.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2206.2
GROUP 2301 - WHEEL AND ATTACHING PARTS

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


PART NO.
1 0404AA0561N WHEEL RIM 5.5J x 15 5
1 0404AA0691N WHEEL RIM 5.5J x 15 (OPT) 5
2 0097878 WHEEL HUB BOLT - FRONT 10
2 0097871 WHEEL HUB BOLT - REAR 10
3 0097882 NUT HEX M14 x 1.5 20
4 0082597 DISC BRAKE FRONT 2
4 0097872 BRAKE DRUM REAR 2
5 0097558 FRONT WHEEL HUB 2WD 2
5 0097870 REAR WHEEL HUB 2
6 0502CA0080N OIL SEAL HUB 4
7 0083152 INNER WHEEL BEARING CUP (SKF) 4
GROUP 2301 - WHEEL AND ATTACHING PARTS

7 0090189 INNER WHEEL BEARING CUP (IMP) 4


7 0917773 INNER WHEEL BEARING CUP (NBC) 4
8 0083151 INNER WHEEL BEARING CONE (SKF) 4
8 0090188 INNER WHEEL BEARING CONE (IMP) 4
8 0052880 INNER WHEEL BEARING CONE (NBC) 4
9 0083150 OUTER WHEEL BEARING CUP (SKF) 4
9 0090187 OUTER WHEEL BEARING CUP (IMP) 4
9 0925447 OUTER WHEEL BEARING CUP (NBC) 4
10 0083149 OUTER WHEEL BEARING CONE (SKF) 4
10 0090186 OUTER WHEEL BEARING CONE (IMP) 4
10 0925446 OUTER WHEEL BEARING CONE (NBC) 4
11 A000865 LOCKWASHER WHEEL BRG FRONT 4
12 A000866 NUT RETAINING WHEEL BEARING 8
13 0099825 TOOTHED LOCK WASHER 4
14 0090708 'O' RING BIG 4
15 0090707 HUB COVER (2WD) 2
16 0502AA1040N DUST SHIELD 2
17 0502AA1110N BOLT M10 x 1.5 12
18 6510114 SPRING LOCK WASHER M10 12
19 7903032023 NUT HEX HM10 12
20 G123920 LOCKWASHER SPRING G9.53mm (3/8") 6
21 G122126 BOLT HEX HD G9.52 x 22.22mm
(3/8" -16 x 7/8") 6
22 0029975 SPACER WHEEL BEARING 27.575 A/R
22 0029976 SPACER WHEEL BEARING 27.600 A/R
22 0029979 SPACER WHEEL BEARING 27.625 A/R
22 0502CA0500N SPACER WHEEL BEARING 27.500 A/R
22 0502CA0510N SPACER WHEEL BEARING 27.550 A/R
22 0502CA0520N SPACER WHEEL BEARING 27.650 A/R
22 0502CA0530N SPACER WHEEL BEARING 27.675 A/R

CONTINUE…

2301.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2301.2
GROUP 2301 - WHEEL AND ATTACHING PARTS

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


PART NO.
23 0029978 SHIM 0.075mm A/R
23 0029979 SHIM 0.200mm A/R
23 0029980 SHIM 0.500mm A/R
24 3206206 SCREW CSK SLOTTED M6 x 1 - 16 2
25 0071635 DOWEL PIN 4
26 04040A0031N WEIGHT WHEEL BALANCE (5 GMS) 5
26 04040A0041N WEIGHT WHEEL BALANCE (10 GMS) 5
26 04040A0051N WEIGHT WHEEL BALANCE (15 GMS) 5
26 04040A0061N WEIGHT WHEEL BALANCE (20 GMS) 5
26 04040A0071N WEIGHT WHEEL BALANCE (25 GMS) 5
26 04040A0081N WEIGHT WHEEL BALANCE (30 GMS) 5
GROUP 2301 - WHEEL AND ATTACHING PARTS

26 04040A0091N WEIGHT WHEEL BALANCE (35 GMS) 5


26 04040A0101N WEIGHT WHEEL BALANCE (40 GMS) 5
26 04040A0111N WEIGHT WHEEL BALANCE (45 GMS) 5
26 04040A0121N WEIGHT WHEEL BALANCE (50 GMS) 5
26 04040A0131N WEIGHT WHEEL BALANCE (55 GMS) 5
26 04040A0141N WEIGHT WHEEL BALANCE (60 GMS) 5
26 04040A0151N WEIGHT WHEEL BALANCE (65 GMS) 5
26 04040A0161N WEIGHT WHEEL BALANCE (70 GMS) 5
26 04040A0171N WEIGHT WHEEL BALANCE (75 GMS) 5
26 04040A0181N WEIGHT WHEEL BALANCE (80 GMS) 5
26 04040A0191N WEIGHT WHEEL BALANCE (85 GMS) 5
26 04040A0201N WEIGHT WHEEL BALANCE (90 GMS) 5
26 04040A0211N WEIGHT WHEEL BALANCE (95 GMS) 5
26 04040A0221N WEIGHT WHEEL BALANCE (100 GMS) 5

2301.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2301.4
GROUP 2401A - FRAME

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


PART NO.
0201AN0930N FRAME ASSEMBLY COMP (BS2) 1
0201AN0300N FRAME ASSEMBLY COMP (BS3) 1
1 0201AN0600N CROSSMEMBER ASSY RADIATOR 1
2 0202AA0320N BRKT AXLE BUMPER REAR 2
3 0203BJ0080N CROSSMEMBER ASSY ENG RR SUPPT 1
4 02000A0310N BRKT ASSY RR SHACKLE RH 1
5 0088508 TOWING HOOK REAR 1
6 0201AA0780N BRKT BUMPER SIDE 2
7 0029718 ASSY X - MEMBER F/TANK MTG FRT 1
8 0097513 ASSEMBLY PLATE NUT RETAINER 2
9 02000A0320N BRKT ASSY RR SHACKLE LH 1
10 0201AA2320N PIVOT BRACKET FRT 2
11 0205AA0100N X MBR ASSY SPARE WHEEL 1
12 0204AA0040N TOWING HOOK FRONT 1
13 0097939 ASSY BRKT SPRING SHACKLE FRT 2
14 0097929 ASSEMBLY BRKT MTG STABILIZER BAR 1
GROUP 2401A - FRAME

15 02010D0890N BRACKET ASSEMBLY HORN MTG 1


16 0201AK0610N BRKT ASSY REGISTRATION PLATE 2
17 0201AA0640N BRACKET FRONT BRAKE HOSE 2
18 0097948 ASSY BRKT SHOCK ABSORBER FRONT 2
19 0099105 SPECIAL BOLT HEX HD M10 x 1.5 - 25 4
20 0029777 ASSY BRKT ENGINE MTG RH 1
21 0029776 ASSY BRKT ENG MTG LH 1
22 0201AJ1160N BRKT BUMPER BOTTOM RH 1
23 0200AA0010N BRKT ASSY SHOCK ABSORBER RR 2
24 0084785 BODY OUTRIGGER NO. 0 2
25 0084805 BODY OUTRIGGER NO. 1 2
26 0084809 BODY OUTRIGGER NO. 2 2
27 0202AA0410N REINF OUTRIGGER CARGO 2
28 0202AE0130N BODY OUTRIGGER LH 1
29 0202AE0120N BODY OUTRIGGER RH 1
30 0202AA0130N OUTRIGGER CARGO 2
31 0201AJ1270N BRKT XMBR ENG SUPPT RR LH 1
32 0201AJ1260N BRKT XMBR ENG SUPPT RR RH 1
33 0202AA0310N PLATE OUTRIGGER 4
34 0202AA0150N OUTRIGGER CARGO RH 1
35 0202AA0330N OUTRIGGER CARGO LH 1

2401A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2401A.2
GROUP 2401A - FRAME

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


PART NO.
36 0202AA0790N OUTRIGGER CARGO LH 1
37 6110214 4 - PLAIN WASHER M10 NS
38 6510214 LOCKWASHER SPRING M10 4
39 0202AA0780N OUTRIGGER CARGO RH 1
40 0202AA0180N OUTRIGGER CARGO RH 1
41 0202AA0370N OUTRIGGER CARGO LH 1
42 0202AA0240N OUTRIGGER ASSEMBLY CARGO RH 1
43 0202AA0360N OUTRIGGER ASSEMBLY CARGO LH 1
44 0201AA0300N CROSSMEMBER OUTRIGGER 2
45 0202AA0140N OUTRIGGER CARGO 2
46 0201AJ1170N BRKT BUMPER BOTTOM LH 1
47 0202AA0420N REINF OUTRIGGER CARGO 2
GROUP 2401A - FRAME

2401A.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2401A.4
GROUP 2401C - SPARE WHEEL MOUNTING

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


PART NO.
1 0205AA0090N ASSY SPARE WHEEL CARRIER 1
2 0205AA0040N BRACKET SPARE WHEEL CARRIER 1
3 2108230 BOLT HEX HD M8 x 1.25 - 30 4
4 6108212 4 - WASHER PLAIN M8 NS
5 6508212 4 - LOCK WASHER SPRING M8 NS

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2401C.1
GROUP 2501 - FRONT SPRING AND SHOCK ABSORBER

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


PART NO.
1 0029725 ASSEMBLY FRONT SPRING 2
3 0912593 BUSH PIVOT END 2
7 G191758 GREASE NIPPLE G3.1mm (1/8") NPTF 2
8 0089517 CLIP SPRING 4
10 0080149 NYLOCK NUT G12.70mm (1/2" - 20) 8
13 0401BA1561N ASSY SHOCK ABSORBER FRONT 2
16 SF0302021 NUT NYLOC M12 x 1.25 - 12 4
0401BA1760N KIT SHOCK ABSORBER BUSHING FRONT 1
CONSIST OF:
GROUP 2501 - FRONT SPRING AND SHOCK ABSORBER

14 04030A0050N 4 - BUSHING
15 G120389 4 - WASHER PLAIN G12.7mm (1/2")
0401BA1770N KIT FRONT SUSPENSION BUSHING 1
CONSIST OF:
2 0084777 2 - SILENT BLOCK BUSH
4 0097932 2 - SPRING PIVOT PIN
5 6116220 6 - PLAIN WASHER M16
6 5316202 6 - NUT NYLOC M16 x 1.5
9 0084814 2 - ASSY SPRING CLIP PLATE FRONT
11 2116282 4 - BOLT HEX HD M16 x 1.5 - 110
12 0081624 4 - SHACKLE PLATE

2501.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2501.2
GROUP 2502 - REAR SPRING AND SHOCK ABSORBER

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


PART NO.
1 0402AA0540N LEAF SPRING ASSEMBLY REAR 2
2 0084777 SILENT BLOCK BUSH 2
3 0912593 BUSH PIVOT END 2
13 0402BA0281N SHOCK ABSORBER REAR 2
16 SF0302021 NUT NYLOC M12 x 1.25 4
0402BA1770N KIT SHOCK ABSORBER BUSHING REAR 1
CONSIST OF:
14 0402BA1760N 4 - BONDED SLEEVE
15 G120389 4 - WASHER SHOCK ABSORBER
GROUP 2502 - REAR SPRING AND SHOCK ABSORBER

0402BA2350N KIT REAR SUSPENSION MOUNTING 1


CONSIST OF:
4 04000A0110N 2 - PIN SPRING PIVOT
5 6116220 6 - PLAIN WASHER M16
6 SF0302020 6 - NUT NYLOC M16 x 1.5
7 04000A0140N 2 - PLATE SPRING CLIP TOP
8 0402BA0240N 4 - CLIP SPRING
9 04000A0130N 2 - PLATE SPRING CLIP BOTTOM
10 0080149 8 - NYLOCK NUT G12.70 mm(1/2 - 20)
11 SF0101101 4 - BOLT HEX M16 x 1.5 - 110
12 04020A0200N 4 - SHACKLE PLATE 80
15 G120389 4 - WASHER SHOCK ABSORBER
17 G191758 2 - GREASE NIPPLE 3.175mm (1/8")
NPTF STRGHT
18 0402BA0120N BOLT HEX M12 x 1.25 - 65 2

2502.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2502.2
GROUP 2601 - HOOD

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


PART NO.
1 28346CED ASSY BONNET - CED 1
2 0029546 CENTRAL LOCK UNIT UPPER 1
3 6106208 PLAIN WASHER M6 8
4 3106226 8 - SCR HEX HD M6 x 1 - 16 NS
5 0028330 ASSY BONNET HINGE LH 1
6 0028530 ASSY COVER BONNET HINGE 2
7 6110214 8 - PLAIN WASHER M10 NS
8 6510214 LOCKWASHER SPRING M10 8
9 3110208 HEX SCREW M10 x 1.25 - 30 8
10 0028333 ASSY REINF PLATE 4
11 0028334 ASSY BONNET HINGE RH 1
12 SF0201061 SCR HEX HD M8 x 1.25 - 25 H 4
13 6508212 4 - LOCK WASHER SPRING M8 NS
14 6108212 4 - WASHER PLAIN M8 NS
15 6506208 SPRING LOCK WASHER M6 8
16 0107AN0060N WEATHER STRIP BONNET 2
GROUP 2601 - HOOD

17 0028302 WEATHER-STRIP BONNET FRONT 1


18 0028709 WEATHER-STRIP BONNET REAR 1
01060K0980N KIT P.U. FOAM BONNET 1
CONSIST OF :
0029436 1 - P.U. FOAM BONNET INNER LH
0029437 1 - P.U. FOAM BONNET INNER RH
0029438 1 - P.U. FOAM BONNET OUTER LH
0029439 1 - P.U. FOAM BONNET OUTER RH

2601.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2601.2
GROUP 2602A - FENDER RIGHT

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


PART NO.
1 0102CN0350A ASSEMBLY FENDER RH - CED 1
2 0028470 FILLER STRIP SIDE PNL TO FENDER 1
3 0028468 PLATE RETAINER FENDER MTG 1
4 G120214 5 - SPRING LOCK WSHR G7.94mm (5/16") NS
5 G446363 PLAIN WASHER G 9.53mm (3/8") ID 5
6 5108206 5 - NUT HEX M8 x 1.25 NS
7 0072998 STAY BRKT VERT DASH TO FENDER 1
8 6110214 2 - PLAIN WASHER M10 NS
9 6510214 SPRING LOCK WASHER M10 2
10 SF0201059 SCREW HEX M10 x 1.5 - 20 2
11 0073000 STAY BRKT HOR DASH TO FENDER 1
12 0979727 BRKT HOOD PROP RETAINER 1
13 0102EK0010N STAY ROD BONNET 1
14 0028367 HOLDER STAY ROD BONNET 1
GROUP 2602A - FENDER RIGHT

15 3106226 2 - SCREW HEX M6 x 1 - 16 NS


16 0074475 COVER SPLASH APRON FRT FDR RH 1
17 0074769 CLIP COVER SPLASH APRN 6
18 SF0201061 SCREW HEX HEAD M8 x 1.25 - 25 2
19 6506208 WASHER SPRING L M6 2
22 0097573 GRIP HANDLE BONNET STAY ROD 1

2602A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2602A.2
GROUP 2602B - FENDER LEFT

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


PART NO.
1 0102CF0080A ASSEMBLY FENDER LH - CED 1
2 0028470 FILLER STRIP SIDE PNL TO FENDER 1
3 0028468 PLATE RETAINER FENDER MTG 1
4 G120214 5 - SPRING LOCK WSHR G7.94mm (5/16") NS
5 G446363 PLAIN WASHER G 9.53mm (3/8") ID 5
6 5108206 5 - NUT HEX M8 x 1.25 NS
7 0072997 STAY BRKT VERT DASH TO FENDER 1
8 6110214 2 - PLAIN WASHER M10 NS
9 6510214 SPRING LOCK WASHER M10 2
10 SF0201059 SCREW HEX M10 x 1.5 - 20 2
11 0072999 STAY BRKT HOR DASH TO FENDER 1
12 0074474 COVER SPLASH APRON FRT FDR LH 1
13 0074769 CLIP COVER SPLASH APRN 6
16 SF0201061 SCREW HEX HEAD M8 x 1.25 - 25 2
GROUP 2602B - FENDER LEFT

2602B.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2602B.2
GROUP 2603 - RADIATOR GUARD AND GRILL

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


PART NO.
1 0102BN0020G RADIATOR GRILL 1
2 55060A0020N COMBI SCREW M6 x 1.00 - 25 8
3 6506208 PLAIN WASHER G6.35mm (1/4") 30
4 6106208 PLAIN WASHER M6 30
5A 0028651 BEZZLE HEAD LAMP LH 1
5B 0028652 BEZZLE HEAD LAMP RH 1
6 0029552 CSK CROSS RES TAP
SCR 10 x 16 - 44mm (1-3/4") 4
7 28368CED ASSY FRONT FACIA - CED 1
8 3106226 20 - SCR HEX HD M6 x 1.0 - 16 NS
9 0102DF0940N AIR DEFL FRAME ASSY COMP NS
GROUP 2603 - RADIATOR GUARD AND GRILL

10 0028408 ASSY LOCK PLATE (BONNET) 1


11 0029557 BONNET BUFFER 2

CONTINUE …

2603.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2603.2
GROUP 2603 - RADIATOR GUARD AND GRILL

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


PART NO.
12 6508212 17 - LOCK WASHER SPRING M8 NS
13 5108206 2 - NUT HEX M8 x 1.25 NS
14 0102FN0010N COVER HEAD LAMP RH 1
14 0102FN0020N COVER HEAD LAMP LH 1
15 0029547 BONNET CENTRAL LOCK LOWER UNIT 1
16 SF0201061 SCREW HEX M8 x 1.25 - 25 9
18 G446363 PLAIN WASHER G9.53mm (3/8") 3
19 0029550 LOCK PLATE (BONNET) 1
20 0029548 CABLE BONNET RELEASE 1
21 3106226 2 - SCR HEX HD M6 x 1.0 - 16 NS
22 19000A1660N TIE ROD ASSY DASH TO FRONT END 2
GROUP 2603 - RADIATOR GUARD AND GRILL

23 6108212 4 - WASHER PLAIN M8 NS


25 5108206 6 - NUT HEX M8 x 1.25 NS

2603.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2603.4
GROUP 2604 - FOOT STEPS

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


PART NO.
1 0108JF0400N ASSY SIDE FOOT STEP COMP 2
2 3108224 SCREW HEX HD M8 x 1.25 - 20 8
3 G120214 8 - SPRING LOCK WSHR G21.17mm (5/16") NS
4 G120394 PLAIN WASHER G9.53mm (3/8") 8

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2604.1
GROUP 2605 - BODY MOUNTINGS

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


PART NO.
BODY MTG
0067973 INSULATOR LOWER 10
0067980 ASSY WASHER & TUBE 10
0067981 BOLT SPECIAL POINTED M10 x 1.5 - 56 10
A006360 WASHER PEDAL SHANK DRAFT PAD 2
02020D0060N SPACER BODY MTG 2
02020D0080N 2 - WASHER NS
02020D0110N 2 - BOLT SP POINTED M10 x 1.5 - 89 NS
02020D0050N INSULATOR BODY MTG LOWER 2
02020D0040N INSULATOR BODY MTG UPPER 2
5462447 INSULATOR BODY HOLD DOWN UPPER 10
6510214 LOCKWASHER SPRING M10 10
SF0302022 2 - NUT NYLOC M10 x 1.5 NS
SF0401036 WASHER PLAIN G9.5 10
GROUP 2605 - BODY MOUNTINGS

CARGO MTG.
0104AF0790N PACKING CARGO 12
5112206 NUT HEX M12 x 1.5 12
6512216 12 - LOCKWASHER SPRG M12 NS
SF0101090 BOLT HEX M12 x 1.25 - 55 12
G120389 PLAIN WASHER 12
G120396 PLAIN WASHER 12
0074074 SNUBBER BODY MTG 2

2605.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2605.2
GROUP 2606 - ASSEMBLY INSTRUMENT PANEL

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


PART NO.
1 0112AN0730N INSTRUMENT PANEL ASSY 1
2 SF0201060 BOLT HEX HEAD M8 x 1.25 - 20 2
3 0112AN0760N AUDIO EXTENSION BOX 1
4 6108212 8 - PLAIN WASHER M8 NS
5 5308202 6 - NYLOC NUT M8 x 1.25 NS
6 0112AN0160A GRAB HANDLE IP 1
7 0112AN0490A GLOVE BOX ASSY 1
8 0029663 BRKT SUPPORT IP CENTRE 2
9 3106228 SCREW HEX HEAD M6 x 1.0 - 20 2
10 6506208 SPRING LOCK WASHER M6 2
11 6106208 PLAIN WASHER M6 2
GROUP 2606 - ASSEMBLY INSTRUMENT PANEL

12 19000A0220A PLAIN WASHER M6 2


13 19000A0200A HEX HD BOLT M6 x 1 - 16 2
14 01050K0290A CAP POWER WINDOW SW 6
15 01050K0240A SCREW 4.2 x 20 2
16 0028799 CLUSTER RING 1
17 0029418 DECAL CONTROL PANEL 1
18 01050K0300A CAP CIGAR LIGHTER 1
19 01050K0360A STRIKER PLATE 1
20 0112AN0900A SWITCH PLATE 1
21 0029412 SIDE BEADING 2
22 0028800 COVER STEERING COLUMN 1
23 0029410 ASH TRAY 2
24 0112AN0840N GLOVE BOX LOCK ASSY 1
25 0029411 FRONT BEADING 1
26 0029403 ASSY INSTRUMENT PANEL MTG CAP 1
CONSISTS OF:
01050K0070G 1 - IP CAP NO. 1 NS
01050K0080G 1 - IP CAP NO. 2 NS
01050K0090G 1 - IP CAP NO. 3 NS
01050K0100G 1 - IP CAP NO. 4 NS
01050K0110G 1 - IP CAP NO. 5 NS
01050K0120G 1 - IP CAP NO. 6 NS

2606.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2606.2
GROUP 2607A - BODY SHELL ASSEMBLY GROUP 2607A - BODY SHELL ASSEMBLY

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


PART NO.
1 0101AF1120A BODY SHELL ASSY LESS DOORS - CED 1
67627CED ASSY COWL SIDE INNER LH - CED 1
67628CED ASSY COWL SIDE INNER RH - CED 1
0101BF1780A FLOOR ASSY FRONT - CED 1
0101BF1820A PANEL ASSY CENTRE FLOOR - CED 1
0101CF0610A PANEL ASSY DASH - CED 1
28305CED PNL COWL TOP - CED 1
28445CED PANEL ASSY FRT PILLAR INNER LH - CED 1
28446CED PANEL ASSY FRT PILLAR INNER RH - CED 1
28768CED ASSY FRONT PILLAR OUTER LH - CED 1
28769CED ASSY FRONT PILLAR OUTER RH - CED 1
0101DF0480A PANEL ROOF - CED 1

2607A.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2607A.2
GROUP 2607B - CARGO BOX

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


PART NO.
1 01000F0210A CARGO ASSY WITH TAIL GATE - CED 1
2 0104AF0800A BRKT ASSY SIDE PNEL HOLDING A - CED 1
3 0104AF0810A BRKT ASSY SIDE PNEL HOLDING B - CED 1
4 0104EF0540N HINGE ASSEMBLY 10
5 0104EF0050A PANEL SIDE ASSY COMPLETE - CED 2
6 0104EF0060A UNDERBODY CARGO ASSY COMP - CED 1
7 0104EF0080A FUEL LID ASSEMBLY - CED 1
8 0104FF0080A CAB PROTECTOR ASSEMBLY - CED 1
9 0104GF0010A PANEL REAR - CED 1
10 0104GF0050A BRACKET ASSY TAIL LAMP RH - CED 1
11 0104GF0060A BRACKET ASSY TAIL LAMP LH - CED 1
12 6108212 127 - WASHER PLAIN M8 NS
13 6508212 127 - LOCK WASHER SPRING M8 NS
14 2108226 SCREW HEX M8 x 1.25 - 50 16
15 3108224 SCR HEX HD M8 x 1.25 - 20 93
GROUP 2607B - CARGO BOX

16 6506208 WASHER SPRING M6 2


17 3106226 2 - SCREW HEX M6 x 1 - 16 NS
18 0039330 33 - NUT PROJ WELD HEX M8 x 1.25 NS
19 0104EF0070A BRACKET FENDER PANEL - CED 8
20 0104CF0210A PANEL FENDER - CED 4

2607B.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2607B.2
GROUP 2608 - DOORS AND FITTINGS (FRONT)

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


PART NO.
1 67540CED ASSEMBLY DOOR FRT WELDG RH - CED 1
1 01030K0010A ASSEMBLY DOOR FRT WELDG LH - CED 1
2 67578CED ASSEMBLY HINGE FRONT DOOR - CED 4
3 6508212 20 - LOCK WASHER SPRING M8 NS
4 SF0202015 SCREW HEX FLANGE M8 x 1.25 - 14 20
9 G120392 PLAIN WASHER 1/4 8
10 7903001681 SCR PAN HD SLOTTED M6 x 1 - 10 8
21 0029200 ASSY W/STRIP FRONT DOOR - RH 1
21 0029201 ASSY W/STRIP FRONT DOOR - LH 1
26 0088490 ARM REST 2
27 SF0207003 SCREW PAN HD M6 x 1 - 25 4
GROUP 2608 - DOORS AND FITTINGS (FRONT)

28 0074974 GLASS RUN CHANEL FRONT DOOR 2


29 01030K0060N DOOR CHECK BELT ASSEMBLY 2
30 0067720 WEATHER STRIP FRT DR RH 1
30 0067719 WEATHER STRIP FRT DR LH 1
31 0034365 CLIP BEADING 24
32 0067509 ASSY RET RN CHANEL FRT BTM - RH 1
32 0067510 ASSY RET RN CHANEL FRT BTM - LH 1
33 0067515 ASSY RET RN CHNL FRT DR RR BTM - RH 1
33 0067516 ASSY RET RN CHNL FRT DR RR BTM - LH 1
42 0067708 GLASS DOOR FRONT RH 1
42 0067707 GLASS DOOR FRONT LH 1
50 7903057013 ELASTIC WASHER M6 8
51 0105EF0140N ASSY TRIM PAD FRONT DOOR - LH 1
51 0105EF0150N ASSY TRIM PAD FRONT DOOR - RH 1
52 0080559 ASSY TRIM PAD CLIP 4
53 01070F0100N PLASTIC COVER LH 1
53 01070F0110N PLASTIC COVER RH 1

CONTINUE….

2608.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2608.2
GROUP 2608 - DOORS AND FITTINGS (FRONT) GROUP 2608 - DOORS AND FITTINGS (FRONT)

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


PART NO.
5 0087757 LATCH ASSY FRONT DOOR - LH 1
5 0087758 LATCH ASSY FRONT DOOR - RH 1
6 0114DG0540N SCREW CSK PH X-RECESS M/ ENCAP 8 6
7 6106208 PLAIN WASHER M6 6
8 0080147 ASSY HANDLE DOOR INNER - LH 1
8 0080148 ASSY HANDLE DOOR INNER - RH 1
11 0067715 COVER HANDLE INNER 2
12 4308302 SCREW PAN HD TAPG No. 8 x 9.5 2
13 0039751 CLIP ATTACH DOOR LOCK LINK 4
14 0067938 ASSY HANDLE DOOR OUTER - LH 1
14 0067953 ASSY HANDLE DOOR OUTER - RH 1
15 SF0301025 NUT HEX M6 - 1 4
16 0039855 CLIP SNAP LINK DOOR LOCK 2
17 0039856 PIN LINK DOOR LOCK HANDLE 2
22 0039780 SPACER DOOR STRIKER 2
23 0039779 ASSY DOOR STRIKER 2
24 6608212 WASHER EXT TOOTH C/S M8 4
25 3208204 SCREW C/S SLTD M8 x 1.25 - 16 4
43 0114AF0100N KIT LOCK WITH COMMON KEY 1
44 0068492 CLIP LOCK CYLINDER 2
45 0039751 CLIP ATTACH DOOR LOCK LINK 2
46 0088249 LINK LOCK CYL DOOR LOCK - LH 1
46 0088250 LINK LOCK CYL DOOR LOCK - RH 1
47 0068409 CLIP ATTACH DOOR LOCK LINK 2
48 0080143 LINK INR HANDLE TO DOOR LOCK - LH 1
48 0080144 LINK INR HANDLE TO DOOR LOCK - RH 1
49 0080145 LEVER DOOR LOCK INNER HANDLE - LH 1
49 0080146 LEVER DOOR LOCK INNER HANDLE - RH 1

CONTINUE….

2608.3 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2608.4
GROUP 2608 - DOORS AND FITTINGS (FRONT)

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


PART NO.
34 0080004 ASSY WINDOW REGULATOR FRT DR - LH 1
34 0080005 ASSY WINDOW REGULATOR FRT DR - RH 1
35 0074553 ASSY BOTTOM CHNL WINDOW REG - RH 1
35 0074554 ASSY BOTTOM CHNL WINDOW REG - LH 1
36 0039742 W/STRIP GLASS BOTTOM CHANNEL 4
37 0105FN0012N REVEAL MOULDING ASSY FRONT DR 4
38 0034365 CLIP BEADING 24
39 0039744 ESCUTCHEON HANDLE WINDOW REG 2
40 0039743 HANDLE WINDOW REGULATOR 2
41 3205204 SCREW C/S SLTD M5 x 0.8 - 12 2
18 7903001681 SCREW HEX M6 x 1.0 - 10 12
GROUP 2608 - DOORS AND FITTINGS (FRONT)

19 7903057013 ELASTIC WASHER M6 12


20 6106208 PLAIN WASHER M6 12

2608.5 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2608.6
GROUP 2610A - TAIL GATE AND FITTINGS

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


PART NO.
1 0104GF0750A TAIL GATE ASSEMBLY COMPLETE - CED 1
2 0104AF0820N PLATE LOCK - RH 2
2 0104AF0750N PLATE LOCK - LH 2
3 0104AF1140N BRACKET ASSEMBLY LOCK PLATE U 4
4 0104AF0760N ROD LOCK - LH 2
4 0104AF0770N ROD LOCK - RH 2
5 6108212 18 - WASHER PLAIN M8 NS
6 6508212 18 - LOCK WASHER SPRING M8 NS
7 3108224 SCR HEX HD M8 x 1.25 - 20 18
8 0104EF0540N HINGE ASSEMBLY 2
9 0069030 NUT NYLOC M12 x 1.5 4
10 0104AF0830N BACK PLATE BRACKET LOCK PLATE 4
11 SF0201060 SCREW HEX M8 x 1.25 - 20 10

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2610A.1
GROUP 2610B - PLUGS

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


PART NO.
0057650 PLUG FRT FLR PANEL 10
0057751 PLUG FRT FLR PNL 4
0057752 PLUG DASH / RR FLR PNL 4
0057754 PLUG RUBBER 25.4mm (1" DIA) 9
0057755 PLUG RUBBER 19.05 (3/4" DIA) 3
0059520 PLUG INST PNL HOLE 4
0068413 PLUG BC DOOR 2
0068452 PLUG SEAT BELT 6
0070028 PLUG PLASTIC 7.4 MM DIA 2
0079880 PLUG S/CAB C/BOX FLR 4
0107FA0010N PLUG SEAT BELT 1
0107FG0270N RUBBER PLUG - DIA 31 12
0107FK0030N STICKER HOLE PLUG 9
0107FN0030N GROMMET DASH PANEL 4

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2610B.1
GROUP 2611 - BODY TRIMMING

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


PART NO.
1 0028414 GLASS WINDSHIELD LAMINATED TINT 1
2 0028415 WEATHER - STRIP WINDSHIELD GLASS 1
3 01090F0010N MIRROR ASSY REAR VIEW INSIDE 1
4 0114DG0540N SCREW CSK PH X - RECESS MENCAP 8
5 0067809 COVER MIRROR BRKT 1
6 0088631 REAR VIEW MIRROR RH 1
7 SF0207002 SCREW PAHD CR M6 x 1 - 16 2
8 028592 ASSY SUNVISOR RH - GRAND
8 0105DF0010N ASSEMBLY SUNVISOR LH 1
9 0028431 RETAINER SUNVISOR 2
10 0105GF0390N TRIM PAD COWL SIDE INNER RH 1
10 0105GF0400N TRIM PAD COWL SIDE INNER LH 1
11 0108EF0800N DECAL BOLERO PIK UP FB PS 1
12 0108BK0120N MAHINDRA LOGO 1
GROUP 2611 - BODY TRIMMING

13 0108EF0300N COVER ASSY VENTILATOR OUTER RH 1


13 0108EF0310N COVER ASSY VENTILATOR OUTER LH 1
14 0111EF0050N GLASS REAR WINDOW PANEL 1
15 0111EF0060N WEATHER STRIP REAR WINDOW SCDC 1
16 01050F0600N VENTILATOR ASSY INNER 2
17 0105HF0150N DECAL MAHINDRA 1
0206AD0070N PLASTIC W CLIP 2
0105CF0170N KIT ROOF AND SIDE TRIM REXINE
01050K0030N DECAL BHARAT STAGE II 1

2611.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2611.2
GROUP 2612 - PLATES AND COVERS

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


PART NO.
1 0102AK0030N COVER TRANSM FRT FLOOR 1
2 SF0101102 BOLT HEX M6 x 1 - 25 18
3 G120386 WASHER PLAIN (G7.94mm) 5/16" 10
4 0027967 TRANS COVER ASSY 2WD 1
5 6106208 PLAIN WASHER M6 8
6 51060A0020N BOLT SPECIAL 4
7 0102AK0070N PLATE ASSY COVER 1
8 0059762 PLATE RETAINER - T/M CVR GROMMET 1
9 0105AK0230N GROMMET GEAR LEVER 1
10 6506208 WASHER SPRING L M6 8

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2612.1
GROUP 2613 - DRIVER SEAT GROUP 2614 - FRONT PASSENGER SEAT

FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV FIG. NO. PART NO. DESCRIPTION QTY. NEW / REV
PART NO. PART NO.
1 0110AF0750N SEAT ASSEMBLY DRIVER 1 1 0110AF0760N SEAT ASSEMBLY CO DRIVER 1
2 0074355 SCREW HEX HEAD 4 2 0074355 SCREW HEX HEAD 4
3 01100A0020N SPRING LOCK WASHER M10 4 3 01100A0020N SPRING LOCK WASHER M10 4
4 01100A0010N PLAIN WASHER M10 4 4 01100A0010N PLAIN WASHER M10 4

2613.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2614.1
GROUP 2617 - FRONT BUMPER

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


PART NO.
1 0119AF0220A BUMPER ASSY FRONT - CED 1
2 0028572 BRACKET BUMPER MTG LH 1
2 0028573 BRACKET BUMPER MTG RH 1
3 G120388 WASHER PLAIN G11.11mm (7/16") ID 6
4 6510214 LOCKWASHER SPRING M10 6
5 SF0201059 SCREW HEX M10 x 1.5 - 20 6
6 0001BF0020N FRONT REGISTRATION PLATE 1
7 3106228 SCREW HEX M8 x 1.25 - 25 2
8 SF0402033 WASHER SPRING L M6 2
9 6106208 PLAIN WASHER M6 2
10 SF0301025 NUT HEX M6 x 1 2
11 19000A1460N SUPPORT TUBE FRT BUMPER 2
12 2308204 CAP HD.SQ.NK.BOLT M8 x 1.25 - 20 2
13 6508212 2 - LOCK WASHER SPRING M8 NS
GROUP 2617 - FRONT BUMPER

14 6108212 2 - WASHER PLAIN M8 NS


15 5108206 2 - NUT HEX M8 x 1.25 NS

2617.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2617.2
GROUP 2618 - FENDER EXTENSION AND MUD FLAP GROUP 2618 - FENDER EXTENSION AND MUD FLAP

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


PART NO.
1 0102CF0760N FRT FENDER EXTN RH 1
1 0102CF0770N FRT FENDER EXTN LH 1
2 SF0207005 SCREW PAN HEAD CR G4.8 x 1.06 - 19 12
3 G120391 WASHER PLAIN #10 12
4 SF0301028 NUT HEX G4.8 x 1.05 12
5 0108BK0340N MUD FLAP FRT FENDER RH 1
5 0108BK0350N MUD FLAP FRT FENDER LH 1
6 3106226 4 - SCREW HEX M6 x 1 - 16 NS
7 G120380 LOCK WASHER SPRING 1/4 4
8 0099488 WASHER SPECIAL ACC CABLE 4
9 5108206 4 - NUT HEX M8 x 1.25 NS
10 01080A0020N MUD FLAP REAR WHEEL 2
11 3108224 SCR HEX HD M8 x 1.25 - 20 4
12 6508212 8 - LOCK WASHER SPRING M8 NS
13 6108212 8 - WASHER PLAIN M8 NS
14 5108206 4 - NUT HEX M8 x 1.25 NS

2618.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2618.2
GROUP 2619 - TOOLS

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


PART NO.
1 0002AF0110N ASSEMBLY SCREW JACK 1
2 0094813 WHEEL WRENCH 21MM 1
3 19000A1040N MAIN OPERATING LEVER 1
4 19000A1050N JACK HANDLE 1
0002BA0010N TOOL KIT 1
CONSIST OF :
5 0002BA0020N 1 - BAG-TOOL KIT NS
6 0002BA0040N 1 - D E O SPANNER 12 mm x 13 mm NS
7 0002BA0030N 1 - D E O SPANNER 8 mm x 10 mm NS
8 0002BA0050N 1 - SCREW DRIVER NS
9 0094815 1 - SLIP JOINT PLIER NS

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2619.1
GROUP 2620 - FLOOR TRIMMING

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


PART NO.
1 0105AF1630N KIT FLOOR MAT (FB BS 2)
1 0105AF1640N KIT FLOOR MAT (FB BS 3)
GROUP 2620 - FLOOR TRIMMING

2620.1 BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2620.2
GROUP 2621 - SEAT BELT

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


PART NO.
1 0080486 KIT SEAT BELT FRT SEAT 1

BOLERO RHD SC PS DIESEL MDI TC 3200 2WD - VERSION 1 - SEPTEMBER 2007 2621.1

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