Mahindra THAR 2010 User manual

2010
Vehicle Dismantling Manual
Mahindra THAR
© 2010 Mahindra & Mahindra Ltd. All rights reserved. This Manual may be reproduced or copied, in whole or part
without the written permission of Mahindra & Mahindra Ltd

Table of Content
Vehicle Dismantling Manual .................................................................................... 1
Airbag Deployment in End-of-Life Vehicles ........................................................... 2
Component Parts Deemed to be Non Reusable..................................................... 4
Introduction ............................................................................................................... 5
Vehicles Activity Area .............................................................................................. 7
Activity Area - Doors and Glazing ........................................................................... 9
Activity Area - Exterior.............................................................................................. 12
Activity Area - Instrumental Panel........................................................................... 16
Activity Area - Seat ................................................................................................... 18
Activity Area - Interior............................................................................................... 20
Activity Area - Engine ............................................................................................... 22
Abbreviation .............................................................................................................. 27

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Vehicle Dismantling Manual
Caution
Provide additional support when a vehicle is on a hoist in the following ways:
• Before removing parts, support the opposite end. This helps to prevent the vehicle
slipping off.
• Before removing the major components, chain the vehicle frame to the hoist pads at the
same end as the removal, this helps to avoid a tip-off.
Disconnect the battery prior to fluid removal and dismantling in order to reduce risk of fire
and personal injuries.
Always wear safety goggles when working with fuel inn order to protect the eyes from
splash.
Fuel vapors are highly flammable. A fire could occur if an ignition source is present. Never
drain or store fuel in an open container, due to the possible of any fire or explosion. Have a
dry chemical (Class B) fire extinguisher nearby always.
Relieve the fuel system pressure before dismantling fuel system component in order to
reduce the risk of fire accident and personal injuries.
Drain the fuel completely from the system like fuel injector nozzle, the fuel pump, fuel pipe
lines and the fuel tank. Draining the fuel will reduce the risk of fire accident and personal
injury.
Provide proper ventilation, when working with fuel in enclosed areas where fuel vapors can
collect. The lack of adequate ventilation may result in personal injuries.
While performing disassembly on or near the Airbag (SRS) components or the wiring point of
those components, cautions to be followed are listed below (Applicable only on the models having
SRS system).
• Be careful when handling the SRS sensor.
• Do not Strike or jolt a SRS sensor.
• Do not carry the inflator module by the wires or the connector on the inflator module.
• Make sure the airbag opening points away from your side.
• Follow the airbag (SRS) deployment procedure available before carrying out
the vehicle dismantling.
• Provide free space for the airbag to expand in case of an accidental deployment.
Note: If fail to follow these cautions could cause airbag deployment or some personal
injuries.

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Airbag Deployment in End-of-Life Vehicles
Airbag Deployment in End-of-Life Vehicles (Single Stage Airbags)
Important Warning
An Airbag that has been removed from a vehicle should never be installed in any other
vehicle. We oppose reuse of airbag or any of its components. It must be noted that;
•An airbag may not work effectively even when it is taken from a vehicle of same make,
model and year of manufacturing.
•The difference between airbag systems are much more than just the trim covers
inclosing them.
•Installation of wrong airbag module or improper installation could increase the risk of
serious injury or death during collision.
•Any modification of airbag module, like; incorrect mounting, airbag size, inflator module
output, airbag vent size, airbag folding method or painting the cover surface could have
adverse effect on protection offered by airbag.
Removal or deployment of airbags before scrapping a vehicle eliminates the potential for
hazardous reactions during processing. A live airbag initiator can potentially discharge even
after it is separated from airbag assembly during processing. Airbags that have not been
fully deployed can cause human injury, damage of equipment. If special handling proce-
dures are followed, airbags can be safely deployed and then recycled with the rest of the
vehicle or shipped separately to a recycling facility.
Single Stage Air-Bags
Such airbags have one initiator and a single charge of gas generating material. Single
stage airbags have one pair of wires that connects to the airbag module.
Important Safety Information
•The removal, handling, storage and deployment of airbags require special care. Only
trained professionals should perform this work. Personal performing these operations
should wear appropriate protection
•Only trained technicians should perform this work. Personal performing these
operations should wear appropriate protection, including eye and ear protection, during
air bag deployment.
•Do not dispose of a live (undeployed/partially deployed) air bag through normal disposal
channels until after it has been fully deployed.
Deployment of Airbags
Situations may arise that require the disposal of a live (undeployed/partially deployed) air
bag. If the entire vehicle is to be scrapped, the air bag must be deployed within the vehicle.

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Recommended Procedure for Airbags Deployment
Whenever possible, full deployment of all air bags should take place in the vehicle prior to
vehicle recycling and disposal.
1. Disconnect the cables from the vehicle's battery(ies).
2. Wait at least 30 minutes for the energy-reserve capacitor to discharge.
3. Make a jumper-wiring harness of two wires 30 feet or longer for remote deployment of
the air bag. If the vehicle is equipped with two-stage air bags, additional harnesses will
be required.
4. At one end of the harness, connect the two leads together to reduce the chance of
unwanted deployment.
5. Locate and disconnect the wires leading to all airbags system.
6. Cut the wires leading to the air bags, leaving at least 4 inches to splice into the jumper.
7. Connect the ends of the jumper-wiring harness to the ends of the wires leading to the
air bag modules. Alligator clips may be used. Use tape or other insulating material to
make sure that the two leads do not make contact with each other. Both stages of a
two-stage air bag may be deployed at the same time by twisting together the corre-
sponding wires from each stage, or the two stages may be wired and deployed sepa-
rately.
8. Make sure that all air bag modules are properly mounted and secure in the vehicle.
9. Clear all loose items from the path of the air bag's deployment (for example, clear the
front seat for driver air bag deployment).
10.Notify all the people in the area that air bag deployment is about to occur, and move
everyone at least 30 feet from the vehicle.
11.Separate the leads on the wiring harness (from step 4) and touch the leads to the
terminals of a 12-volt automotive battery. Once the contact is made, airbag deployment
will occur. Make certain that both stages of a two-stage air bag have deployed.
12.Leave the fully deployed air bag(s) in the vehicle, or remove for separate recycling.
13.Some air bag modules may be hot. Allow the air bag to cool for approximately 20
minutes and the dust to settle before approaching the vehicle. Keep water and other
liquids away from the air bags. If powder from the air bag contacts the skin, wash with
water.
Note: Always disconnect the wires to avoid static electricity. Static electricity can
deployed the airbags system.

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Component Parts Deemed to be Non Reusable
The below mentioned component parts of the vehicles belonging to the category M1
and to the category N1which must not be reused in the construction of new vehicle.
List of Component Parts
- All airbags (¹), including cushions pyrotechnic actuators, electronic control units and
sensors (wherever applicable).
- Automatic or non automatic seat belt assemblies, including webbing, buckles retractors,
pyrotechnic actuators.
- Seats (only in the case where safety belts anchorages and/or airbags are incorpo-rated
in the seat).
- Steering lock assemblies acting on the steering column.
- Immobilisers, including transponders and electronic control units.
- Emission after-treatment systems (e.g. catalytic converters, particulate filters).
- Exhaust silencers.
(¹) when the air bags is inserted inside the steering wheel, the steering wheel itself act as an air bag
system.

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Introduction
This manual contain the Dismantling procedures of the following vehicle.
MODEL MAKE ENGINE TRANSMISSION
Thar Mahindra NEF - CRDe NGT 530 R

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Vehicle Dismantling Manual for Mahindra Thar

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Vehicles Activity Area
mahindra
0.01
ENGINE OIL
0.10
FRONT AXLE OIL
0.09
STEERING OIL
0.04
FR RH - TIRE
0.03
COOLANT
0.07
BRAKE OIL
0.02
BATTERY
0.04
FR LH - TIRE
0.04
RR LH - TIRE
0.11
REAR AXLE OIL
0.08
CLUTCH OIL
0.06
TRANSMISSION OIL
0.05
TRANSFER CASE OIL

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Area: Pretreatment
Model: Thar
Information and Comments
Total Volume or Weight = Weight of single part material x Quantity.
S:No Part Name Material Qty Weight (kg/lit)
0.01 Engine oil for NEF CRDe E IV OIL 6lit
0.02 Battery MULTIPLE 1 19.62 kg
0.03 Coolant COOLANT Coolant 3.3 lit
Water 7.7 lit
0.04 Tires EPDM 5 81.0 kg
0.05 Transfer case oil OIL 0.8 lit
0.06 Transmission oil OIL 1.80 lit
0.07 Brake fluid OIL 0.45 lit
0.08 Clutch fluid OIL 0.3 lit
0.09 Steering oil OIL 1.3 lit
0.10 Front axle oil OIL 1.85 lit
0.11 Rear axle oil OIL 1.85 lit

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Activity Area - Doors and Glazing
1.04 RH
Glass
1.03 RH
EPDM
1.03 LH
EPDM
1.01
Glass
1.02
EPDM 1.05 RH
PVCX
1.11 RH
PVCX
1.11 LH
PVCX
1.06 RH
PVCX
1.05 LH
PVCX
1.12
PVCX
1.10 LH
PVCX
1.10 RH
PVCX
1.08 RH
EPDM
1.08 LH
EPDM
1.09
EPDM 1.06 LH
PVCX
1.07 RH
EPDMX
1.07 LH
EPDMX
1.04 LH
Glass
EPDMX
Glass
EPDM
PVCX
PVC
mahindra

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Area: Doors and Glazing
Model: Thar
S:No Part Name Material Qty Weight Removal Tooling
1.01 Assembly glass
windshield
clear Glass 17.65 kg
Push the top side edges of the
windshield weather strip down-
wards and remove the windshield
glass assembly completely.
12” Thin bladed screw
driver (2nos)
1.02 Weather strip wind shield
glass EPDM 11.30 kg Draw off the windshield glass
weather strip from the windshield
glass. Manually
1.03 Weather strip
front door
opening inner EPDM 20.60 kg Draw off front door weather strip,
by removing its plastic fasteners. Manually
1.04 Glass window
front door Glass 25.96 kg
Remove the door inner trims and
the front door glass mounting
bolts (M6 - 2nos) from the win-
dow regulator.
10mm Socket, Ratchet with
4” extension
1.05 Weather strip
side rail upper PVCX 20.02 kg Draw off the upper side rail weather strip. Manually
1.06 Weather strip
side rail lower PVCX 20.04 kg Draw off the lower side rail weather strip. Manually
1.07 Seal front door
window glass EPDMX 20.58 kg Draw off the front window glass seal. Manually
1.08 Weather strip
tail gate EPDM 20.10 kg Draw off the tail gate weather strip. Manually

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Information and Comments
Total Volume or Weight = Weight of single part material x Quantity.
1.09 Weather strip
tail gate bottom EPDM 10.11 kg Draw off the tail gate bottom weather strip. Manually
1.10 Reveal molding
outer PVCX 20.28 kg Draw off the glass run channel flock from the door. 12” Thin bladed screw driver
1.11 Weather strip
front door side
rail upper PVCX 20.43 kg Draw off the front door upper side
weather strip. Manually
1.12 Weather strip
assembly rear
arch PVCX 10.48 kg Draw off the rear arch weather
strip. Manually
S:No Part Name Material Qty Weight Removal Tooling

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Activity Area - Exterior
2.17
MULTIPLE
2.14 RH
MULTIPLE
2.14 LH
MULTIPLE
2.12 FR-LH
PP
2.12 FR-RH
PP 2.12 RR-RH
PP
2.11 RH
NR 2.05 RH
PP
2.04 RH
FRP
2.03 RH
MULTIPLE
2.02 RH
MULTIPLE
2.01 RH
MULTIPLE
2.01 LH
MULTIPLE
2.02 LH
MULTIPLE
2.03 LH
MULTIPLE 2.04 LH
FRP
2.05 LH
PP
2.11 LH
NR
2.12 RR-LH
PP
2.16
FRP
2.15
PVCX
2.13 RH
PVCX 2.13 LH
PVCX
2.10 LH
MULTIPLE
2.10 RH
MULTIPLE
2.09
MULTIPLE
2.08 RH
MULTIPLE
2.08 LH
MULTIPLE
2.07 LH
PP
2.07 RH
PP
2.06 RH
FRP
2.06 LH
FRP
PP
PVCX
MULTIPLE
NR
FRP

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Area: Exterior
Model: Thar
S:No Part Name Material Qty Weight Removal Tooling
2.01 Front turn
signal lamp
assembly Multiple 2 0.508 kg
Remove the front turn signal lamp
assembly mounting nuts (M6-
2nos) and disconnect the front
turn signal lamp harness connec-
tion.
10mm Socket and Ratchet
2.02 Assembly head
lamp Multiple 22.25 kg
Remove the head lamp assembly
mounting bolts (M6-3nos) and dis-
connect the front lamp harness
connection.
10mm Socket, Ratchet
with 4” extension
2.03 Lamp assem-
bly side marker Multiple 2 0.11 kg Remove the lamp assembly side
marker assembly mounting screws
(M4-2nos).
9” Thin bladed screw
driver
2.04 Front fender
extension FRP 21.40 kg Remove the front fender exten- sion mounting screws (M4-5nos). 9” Star headed screw driver
2.05 Mud flap front
fender PP 20.38 kg Remove the front fender mud flap mounting bolts (M6-2nos). 10mm Socket, Ratchet with 4” extension
2.06 Rear wheel
arch FRP 22.60 kg Remove the rear wheel arch mounting screws (M4-4nos). 9” Star headed screw driver
2.07 Mud flap rear
wheel NR 20.87 kg Remove the rear wheel mud flap mounting bolts (M8-2nos). 13mm Socket, Ratchet with 4” extension

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2.08
Rear combina-
tion lamp (Tail
lamp LH and
RH)
Multiple 21.04 kg Remove the rear combination lamp
mounting nuts (M6-3nos). 10mm Socket, Ratchet with 4” extension
2.09 Assembly num-
ber plate lamp Multiple 10.34 kg Remove the number plate lamp
assembly mounting nuts (M6-
2nos).
10mm Socket, Ratchet
with 4” extension
2.10 Reflex reflector
rear Multiple 20.09 kg Remove the rear reflex reflector mounting nuts (M4-1no). 8mm Socket, Ratchet with 4” extension
2.11 Apron rubber front wheel
housing NR 20.56 kg Remove the front wheel rubber
housing apron mounting plastic
fasteners (6nos).
12” Thin bladed screw
driver
2.12 End cap side
foot step PP 40.33 kg Remove the end cap side food step mounting screw (M4-2nos).
8mm Socket, Ratchet and
12” Thin bladed screw
driver
2.13 Weather strip
rear bumper PVCX 20.48 kg Draw off the rear bumper weather strip. Manually
2.14 Rear view mir-
ror outside Multiple 20.71 kg Remove the outside rear view mir-
ror assembly mounting screws
(M6-2nos).
9” Star headed screw
driver
2.15 Weather strip
front bumper PVCX 10.54 kg Draw off the rear bumper weather strip. Manually
2.16 Canopy rein-
forcement FRP 13.40 kg Remove the vehicle canopy com-
pletely and remove the canopy
reinforcement. Manually
S:No Part Name Material Qty Weight Removal Tooling

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Information and Comments
Total Volume or Weight = Weight of single part material x Quantity.
2.17 Canopy Multiple 14.45 kg Remove the canopy holding rods mounting bolts (M6-4nos) and can-
opy holding flaps. 10mm Socket and Ratchet
S:No Part Name Material Qty Weight Removal Tooling

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Activity Area - Instrumental Panel
3.02
EPDM
3.03
PP
3.01
MULTIPLE
PP
MULTIPLE
EPDM