Mahindra THAR 2009 User manual

ISSUED : SEPTEMBER 2009
Mahindra THAR
OWNER'S MANUAL

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Foreword
Thank you for buying a MAHINDRA vehicle. We trust
it meets your expectations & will provide you with years
of enjoyable motoring. This OWNER'S MANUAL has been
prepared for the reference of the Owner & it is hoped
that this will enable him to acquire working knowledge
of MAHINDRA THAR
Contents include vehicle specifications, driving notes &
maintenance schedule.
Owners are advised to get all the repairs & maintenance
work, done by our Authorised Dealers. They are also
advised to use genuine Mahindra Parts manufactured
to original specifications.
Every reasonable effort has been made to ensure that
this booklet is accurate / up to date. The procedures,
specifications, dimensions referred to are subject to
change in accordance with the Company's policy of
constant product improvements.
Please contact nearest Authorized Service Dealer,for
periodical vehicle maintenance & repairs.
MahindraTHAR

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Contents
Do's & Don'ts
Maintenance Procedure
zVehicle Maintenance when Out of Use
zEngine
zClutch
zSteering System
zTyres
zElectrical Equipments
Service Data
zRecommended lubricants
zBulb Specification
zMaintenance Schedule
Information to owner
zManufacturer's Warranty
zScope of Warranty
zEngine & Vehicle Specifications
Identification of Serial Numbers
zChassis
zEngine
zVehicle
Instrument Panel & Controls
Guidelines on Driving
zHints to Driver
zSafety First
zGear Changing
zDriving Techniques in 4-Wheel Drive
Guidelines on Emission
MahindraTHAR

MAHINDRA & MAHINDRA LTD, INTERNATIONAL
OPERATIONS,MAHINDRA TOWRES, 2ND FLOOR,
AUTOMOTIVE SECTOR, WORLI,MUMBAI 400089, INDIA
warrants to retail purchaser of the Motor Vehicle
branded as ‘ MahindraTHAR ‘(hereinafter referred to
as ‘vehicle’) to be free from defects in material and
workmanship under normal use as instructed in t he
Owner’s Manual & Service, under the warranty,
Company’s Authorised dealer will repair or replace any
part thereof, including all equipments or trade limited
to trade accessories (except those governed by
special warranty policy stipulated by respective
manufacturers, like tyres and batteries etc.)
originally supplied by us subject to all other terms
and conditions specified herein below found to be
defective in materials or workmanship in Company
/ Dealer opinion within 2 years or before such
vehicle has been driven 50,000 kms. from the date
of delivery of the Vehicle to the retail customer( the
Original Purchaser), whichever occurs earlier.
For the purpose of this warranty,the term ‘ Product ’means
and includes only new vehicles manufactured by the
company and / or sold by the Company’s Authorised
Dealers.
This warranty is limited to the delivery to the purchaser,
at the Authorised Dealer’s workshop or at any other place
at the discretion of the company,of the part orparts
whether new or repaired, in exchange for those
acknowledged by the Dealer to be defective and endorsed
by the company to that effect. The parts so repaired or
replaced shall also be warranteed for quality and
workmanship but such warranty shall be co-terminus with
this warranty.
Manufacturer’s Warranty
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This warranty shall not apply to and Company shall in no way
be liable for any vehicle which shall have been repaired outside
and Authorised Company’s Service Station or which has been
altered or modified or built upon in any way or which has
been subjected to misuse, negligence or accident.
This Warranty is in lieu of all other Warranties express or
implied, and no person, agent or representative of the
Company is authorised to give any other warranties on the
Company’s behalf or to assume for it any other liability in
connection, with the vehicle.
The Company’s responsibility is limited to the terms of this
Warranty and it shall not be answerable for personal injuries
or consequential or resulting liability, damage or loss arising
from any defects.
The Company’s Liability under this Warranty is dependent
upon the strict observance by the Purchaser, of the following
provisions :
a) The purchaser shall take Pre-Delivery Inspection,
b) All the paid services are mandatory to be carried out as
per the stipulated maintenance period Kilometers /
month in service till the full completion of the warranty
period at any of Mahindra authorised service outlets to
avail the warranty benefits.
c) Repairs or replacements will be performed by the
Authorised Dealer of the Company, subject to the
reporting of the vehicle to the nearest Authorised
Dealer’s workshop.
d) We further reserve the right, at anytime or times, without
notice, or revise, modify, discontinue or change any of
the models of our vehicles or any party thereof and
neither company nor the seller with incurr any liability
or obligations to the purchaser by reasons or any
revisions, modifications, discontinuation or changes.
Manufacturer’s Warranty
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MahindraTHAR

e) The Purchaser shall at all times in the operation of vehicle
use only those brands of lubricating oils, lubricants or
fuel, as recommended by the Company,
f) The judgement of the Company or its Auhtoirsed Dealers
in all cases of claims shall be final and conclusive and
the purchaser agrees to accept its decision on all
questions as to defects and to the exchange of part of
parts. The replaced parts shall be the property of the
Company.
g) Claims arising from this Warranty will be recognised only
if they are ascertained / confirmed by the Authorised Dealer
and notified to the Company without delay, after the defect
has been ascertained.
Warranty is applicable in case :
a) Repairs are required because of the following reasons.
i) The Vehicle is not operated / used as per the
recommendation in the Owner’s Manual or;
ii) The Vehicle is subjected to accidents, or theft or fire;
iii) The Vehicle is subjected to abnormal use such as racing,
rallying or participation in any other sports competitions.
iv) Any modification are carried out.
b) Appearance Items :
Any slight imperfections in paint, chrome and trim and
other decorative parts, deterioration of exterior item,
trim and other decorative part due to normal exposure
or use is not covered under the terms of Warranty.
Manufacturer’s Warranty
(6) MahindraTHAR

c) Door and windshield glass breakage and fused bulbs
are not covered under Warranty.
d) Normal Maintenance Service Replacement Items :
Filters, Brake or clutch innings, wiper blades, Belts,
Cables, Spring Bushings, U-Joints Cross, Water Pump
Kits, Tie Rod Ends, Bell-crank Kit, Hoses, Kits and Bulbs,
Spark plugs, Condenser. Please note that this list is
neither exclusive nor exhaustive and the decision of
the Company shall be final in this regard.
e) Property Items :
The following are propriety items and warranty is
provided by the respective Manufacturers under their
warranty terms. Any complaint on the following items,
are to be referred to the respective manufacturers of
these items / or their authorised local agents for
warranty claim / repairs / replacements. In case of
difficulty Company’s dealer will assist purchaser to
conclude the complaint satisfactorily. Their decision
will be final on warranty.
1. Tyres
2. Fuel Injection Pump
3. Battery
f) Company makes on Warranty nor assume any liability in
respect of any defect in metal or other material in any part,
device of trade accessories which would not have been
discovered by ordinary factory inspection.
g) Repairs required due to following reasons :
i) Due to unauthorised modifications of the vehicle which in
any way affects the stability or reliability of the components
of the basic vehicle.
ii) Continued usage in spite of awareness of defects of the
components of the basic vehicle.
iii) Excess / heavy load beyond the carrying capacity of
the vehicle affecting the basic structure of the Vehicle.
Manufacturer’s Warranty
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MahindraTHAR

(8)MahindraTHAR
NEF CRDE 2.49L ENGINE
Engine Specification
Cylinder block - Cast Iron
Cylinder Liner - Wet replaceable
Crank Shaft - Forged Steel, 5 Bearing journal
Connecting rods - Forged Steel
Main bearings - Aluminium tin Si
Pistons - Aluminium
Cylinder Head - Cast Iron
Cam shaft - Chilled casting, 3 Bearing
Turbo Charger - Model K03-2070, Make: TEL
Valves - Overhead, Rocker Arm operated
Timing - Electronic control
Lubrication - Pressure lubrication
Cooling - By water
Bore - 94 mm
Stroke - 90 mm
Cubic capacity ( cc ) - 2498
Compression ratio - 17.8:1
Operating cylcle - 4 stroke ( order 1-3-4-2 )
Cylinders - In line arrangement
Max Power - 79KW± 2 @ 3800 RPM
Max Torque - 247Nm ± 4 @ 1800-2200 RPM
Weight of the engine - 287 ±2 Kg with flywheel
%
%

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MahindraTHAR
Dimensions :
Vehicle Specification Bolero THAR
Dimensions mm
Wheel base (WB) 2426
Overall length (OL) 3920
Overall Height (OH) 1928
Tread - Front (T) 1445
Tread - Rear (R) 1336
Ground Clearance (G) 200
Overhang Front (OF) 580
Overhang Rear (OR) 930
Approach Angle (AA) 460
Departure Angle (DA) 300
Overall Width (OW) 1765
Note : Specification subject to change without prior notice.
DRIVE LINE
ITEM
Transmission NGT 530R,V4 GEAR RATIO
1st 3.78 : 1
2nd 2.09 : 1
3rd 1.38 : 1
4th 1.00 : 1
5th 0.79 : 1
Reverse 3.52 : 1
Transfer Gear ratio : High 1 : 1
Low 2.48 : 1
Axle ratio 4.30 : 1
WEIGHTS :
Kerb weight ( Kg ) 1750
GVW ( Kg ) 2200
Front Axle Capacity ( Kg ) 1100
Rear Axle capacity ( Kg ) 1700
Seating Capacity ( Nos ) 1+1
(Including driver)
Towing Capacity( Kg ) 750

Model Features Table
DESCRIPTION MAHINDRABOLERO THAR
ENGINE NEF CRDe 2.49 Litres
TRANSMISSION NGT 530R
AXLE RATIO 4.3 : 1
STEERING POWER STEERING
AIR CONDITIONING SYSTEM HEATER
TRANSFER CASE FOR 4WD MANUAL SHIFT ( STANDARD )
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MahindraTHAR
zChassis Number / VIN Number
The Vehicle chassis number is stamped on the right side
chassis member below the front fender. It is also stamped
on the Name, Number & instruction plate located on the right
side of the engine compartment for LHD vehicle & on left
side of the engine compartment for RHD vehicle.
zEngine Serial Number
This number is punched on cylinder block on front pad (Near
water pump).
zVehicle Serial Number
The vehicle serial number is stamped on the name, number
& instruction plate fixed on the right side of the engine
compartment for LHD vehicle & on left side of the engine
compartment for RHD vehicle.
Identification of Serial Numbers
MAI-2kk-bx-45596

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Instruments
1. Speedometer
2. Odometer
3 . Tripmeter/reset knob
4 . Fuel Gauge
5 . Temperature Gauge
6. Tachometer
INSTRUMENTSINSTRUMENTS
INSTRUMENTSINSTRUMENTS
INSTRUMENTS
INSTRUMENTSINSTRUMENTS
INSTRUMENTSINSTRUMENTS
INSTRUMENTS IN CLUSTERIN CLUSTER
IN CLUSTERIN CLUSTER
IN CLUSTER
1.1.
1.1.
1. SpeedometerSpeedometer
SpeedometerSpeedometer
Speedometer
This indicates the speed at which the vehicle is
driven in km/hr.
2.2.
2.2.
2. OdometerOdometer
OdometerOdometer
Odometer
The odometer indicates cumulative kilometers
covered by the vehicle.
3.3.
3.3.
3. Tripmeter & Reset knobTripmeter & Reset knob
Tripmeter & Reset knobTripmeter & Reset knob
Tripmeter & Reset knob
The tripmeter indicates the distance travelled
during a particular trip or period. Press the reset
knob to return the tripmeter indication to zero.
4.4.
4.4.
4. Fuel GaugeFuel Gauge
Fuel GaugeFuel Gauge
Fuel Gauge
Indicates the approximate level of fuel in the tank.
It indicates at E-Empty; 1/2 - Half, F - Full.
5.5.
5.5.
5. Temperature GaugeTemperature Gauge
Temperature GaugeTemperature Gauge
Temperature Gauge
It indicates the operating temperature of the engine
in 0C so that you may guard against overheating.
6.6.
6.6.
6. TachometerTachometer
TachometerTachometer
Tachometer
It indicates the engine speed in thousands of
revolutions per minute.
Note : Do not over rev the engine. Operating the
engine at high RPM may cause severe engine
damage.

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MahindraTHAR
Instruments
.
1.1.
1.1.
1. Odometer/Trip meter selector knobOdometer/Trip meter selector knob
Odometer/Trip meter selector knobOdometer/Trip meter selector knob
Odometer/Trip meter selector knob
The speedometer indicates vehicle speed in km/h. The
odometer records the total distance the vehicle has
been driven. The trip meter can be used to measure
the distance travelled on short trips or between fuel
stops.
When the ignition switch is turned to ‘ON’ the display
shows the odometer or trip meter. The display shows
three types of indication; odometer, trip meter A and
trip meter B.
Push the selector knob quickly to switch the indication
among the three. You can use the two trip meters
(A and B) independently.
Push the selector knob for a little while (about 3
seconds) to reset the trip meter to zero.
TRIP A
TRIP B
ODO
About 3 seconds
TRIP BTRIP A

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Indications of Warning Lamps
1. Check Engine Malfunction MIL :1. Check Engine Malfunction MIL :
1. Check Engine Malfunction MIL :1. Check Engine Malfunction MIL :
1. Check Engine Malfunction MIL : When the lamp lights up
and glows continuously indicates Engine Fault (other than EMS).
Arrange for checking at the nearest Mahindra Authorised Dealer
immediately.
2. Rear Fog Indicator :2. Rear Fog Indicator :
2. Rear Fog Indicator :2. Rear Fog Indicator :
2. Rear Fog Indicator : The lamp will glow when the rear fog
lamps are ON.
3. Headlight High Beam Indication:3. Headlight High Beam Indication:
3. Headlight High Beam Indication:3. Headlight High Beam Indication:
3. Headlight High Beam Indication: Is illuminated when
headlights high beam is ON or when headlight flash-to-pass is
used.
4. Battery Charging Warning Light :4. Battery Charging Warning Light :
4. Battery Charging Warning Light :4. Battery Charging Warning Light :
4. Battery Charging Warning Light : Lights up when the ignition
switch is in the IGN position. Goes OFF as soon as the engine
starts. If the light remains ON even after the engine has started,
it indicates that the battery is not being charged or malfunction
of alternator. In this case, park the vehicle safely at road side
and check the drive belt for looseness / breakage. If drive belt
is okay, switch off all unnecessary electrical equipment and
contact a Mahindra Authorised Dealer immediately.
Note :Note :
Note :Note :
Note :
Do not continue driving if the engine drive belt is broken or
loose. This will cause engine overheat & poor braking.
Check Engine Malfunction
11
11
1
22
22
2
33
33
3
44
44
4

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MahindraTHAR
5. Low Engine Oil Pressure Warning Light :5. Low Engine Oil Pressure Warning Light :
5. Low Engine Oil Pressure Warning Light :5. Low Engine Oil Pressure Warning Light :
5. Low Engine Oil Pressure Warning Light : Lights up when the
ignition switch is in the IGN position, Goes OFF as soon as the
engine starts. If the light remains ON even after the engine has
started, or comes ON while driving, stop immediately, and check
the engine oil level. If low, add engine oil to the MAX level and
check the light again. If still ON contact Mahindra Authorised
Dealer Immediately.
Note :Note :
Note :Note :
Note :
Do not run the engine with low engine oil pressure warning
light ON. Otherwise it may damage the engine.
66
66
6. Parking Brake ON & Low Brake Fluid Warning Lamp :. Parking Brake ON & Low Brake Fluid Warning Lamp :
. Parking Brake ON & Low Brake Fluid Warning Lamp :. Parking Brake ON & Low Brake Fluid Warning Lamp :
. Parking Brake ON & Low Brake Fluid Warning Lamp : The
parking light and, the low brake fluid warning light, are
illuminated as long as the parking brake is applied. If light
does not go off after releasing the parking brake, there may
be problem with the vehicle braking system.
Warning :Warning :
Warning :Warning :
Warning :
Do not drive the vehicle if the light is illuminated even after
releasing the hand brake or if it illuminates while driving. Add
brake fluid to bring the level up to the ‘MAX’ mark. If the problem
still persists, avoid driving and have Mahindra Authorised Dealer
check/correct the braking system as soon as possible.
II
II
I
II
II
I
II
II
I
PP
PP
P
i() P
()
Indications of Warning Lamps
55
55
5
66
66
6

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7. Engine Coolant Temperature Gauge :7. Engine Coolant Temperature Gauge :
7. Engine Coolant Temperature Gauge :7. Engine Coolant Temperature Gauge :
7. Engine Coolant Temperature Gauge : Indicates the
temperature of the engine’s coolant. At normal operating
temperature 6 bars will be showing in LCD bar graph. High
temperature LED will glow when the temperature reaches 110°C
along with 7 bars blinking with buzzer. In such a condition, switch
off the AC and observe. If still the problem persists, pull over
the Vehicle, switch OFF ignition and contact the nearest Mahindra
Authorized Dealer.
CAUTION :CAUTION :
CAUTION :CAUTION :
CAUTION :
Do not continue driving with an overheated engine. It may
cause damage to the engine.
8. Water in Fuel Indication :8. Water in Fuel Indication :
8. Water in Fuel Indication :8. Water in Fuel Indication :
8. Water in Fuel Indication : when water accumulated in Fuel
Filter reaches the maximum permissible limit, the indicator gives
warning to remove water and clean the fuel filter. (Instruction
for how to drain the water is given in the Self Maintenance
Section (Page no.41) or contact a Mahindra Authorised Dealer.)
CAUTION :CAUTION :
CAUTION :CAUTION :
CAUTION :
Continued driving with water accumulation in the fuel filter will
cause damage to the fuel pump/other fuel system components.
Water in Fuel Indication
Indications of Warning Lamps
88
88
8
77
77
7

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MahindraTHAR
Instruments (With Digital Cluster)
9. Seat Belt Warning :9. Seat Belt Warning :
9. Seat Belt Warning :9. Seat Belt Warning :
9. Seat Belt Warning : The light reminds to fasten seat belts &
it will light up when the driver has not worn the seat belt with
the ignition key is IGN position/when vehicle is in motion. The
lamp will remain illuminated until the seat belt is fastened
properly.
10. Check EMS (Engine Management System) Warning Lamp10. Check EMS (Engine Management System) Warning Lamp
10. Check EMS (Engine Management System) Warning Lamp10. Check EMS (Engine Management System) Warning Lamp
10. Check EMS (Engine Management System) Warning Lamp
::
::
: As soon as the ignition key is switched ON, the lamp lights up
and goes OFF in few seconds indicating normal status. The lamp
will blink / glow continuously indicating the presence of fault in
EMS. The vehicle needs attention by Mahindra Authorised Dealer
immediately.
11. Turn Indicator :11. Turn Indicator :
11. Turn Indicator :11. Turn Indicator :
11. Turn Indicator : Flashes when the indicator lamps are
operated or hazard switch is turned on. A sudden increase in
the rate of flashing may indicate failure of one or more of the
indicator bulbs.
12. Glow Plug Indicator :12. Glow Plug Indicator :
12. Glow Plug Indicator :12. Glow Plug Indicator :
12. Glow Plug Indicator : When ‘ON’ indicates that pre - heating
is on.It goes out when the glow plug is warm.Do not crank the
engine when the glow plug is ‘ON’ , to avoid excessive load on
battery and ensureeffective starting.
Left Turn I ndicator Right Turn I ndicator
1010
1010
10
1111
1111
11
99
99
9
1212
1212
12

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Controls
Heater Controls :Heater Controls :
Heater Controls :Heater Controls :
Heater Controls :
1. Heater Switch :
The knob is turned clockwise, the heater comes ‘ON’.
2. Blower Switch :
Air flow can be controlled in three stages - low, medium,
high.
3. Lock & Unlock the Steering Wheel :
To lock :
Remove the key at the ‘Lock’ position. Turn the steering
wheel until it is locked.
To unlock :
Turn the key to the "ACC" position while moving the
steering wheel slightly.
Heater
Switch Blower
Switch
Steering Lock
33
33
3
1 & 21 & 2
1 & 21 & 2
1 & 2

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MahindraTHAR
Bonnet locking / unlocking :Bonnet locking / unlocking :
Bonnet locking / unlocking :Bonnet locking / unlocking :
Bonnet locking / unlocking :
To Open :
Pull the release lever located below the instrument
panel on right side for RHD vehicle and on left side
for LHD vehicle. Then pull open the lever below the
bonnet and open the bonnet.
To Close :
Just drop the bonnet gently and press it, if required.
Opening and Closing the Bonnet :
1. Ensure that the vehicle is in neutral gear and set
the parking brake. Pull the bonnet release lever to
position B from A and release which is located under
extreme LH /RH corners ( LH for LHD models &
RH for RHD models ) of the instrument panel. This
will release the bonnet lock and bonnet will pop
up slightly.
2. Stand in front of the vehicle, lift the additional lock
lever located under the bonnet centre with a finger
and lift the bonnet up.
Caution :
Make sure that the bonnet is fully closed and locked
before driving.
Controls
Lever

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Side Ventilation Louver Central Ventilation Louver
zz
zz
zCentre & side vents
The airflow volume can be adjusted
with the rotary controls at the sides.
The air vanes can be adjusted
horizontally & vertically by swivelling
the vents up / down or sideways.
For up/down or
sideways air flow.
Rotary Control for
volume control
Controls
Air Ventillation Louvers