Mahindra THAR 2009 Owner'S Manual Download Page 8

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Mahindra THAR

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

Summary of Contents for THAR 2009

Page 1: ...ISSUED SEPTEMBER 2009 Mahindra THAR OWNER S MANUAL ...

Page 2: ... 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...

Page 3: ...ricants z Bulb Specification z Maintenance Schedule Information to owner z Manufacturer s Warranty z Scope of Warranty z Engine Vehicle Specifications Identification of Serial Numbers z Chassis z Engine z Vehicle Instrument Panel Controls Guidelines on Driving z Hints to Driver z Safety First z Gear Changing z Driving Techniques in 4 Wheel Drive Guidelines on Emission MahindraTHAR ...

Page 4: ...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 Aut...

Page 5: ...he 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...

Page 6: ...sed 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 partic...

Page 7: ...horised 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...

Page 8: ... 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 R...

Page 9: ...gle AA 460 Departure Angle DA 300 Overall Width OW 1765 Note Specification subject to change without prior notice DRIVE LINE I T E M 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 ...

Page 10: ...able DESCRIPTION MAHINDRABOLEROTHAR 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 10 MahindraTHAR ...

Page 11: ...artment for LHD vehicle on left side of the engine compartment for RHD vehicle z Engine Serial Number This number is punched on cylinder block on front pad Near water pump z Vehicle 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 Identific...

Page 12: ...e vehicle 3 3 3 3 3 Tripmeter Reset knob Tripmeter Reset knob Tripmeter Reset knob Tripmeter 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 Gauge Fuel Gauge Fuel Gauge Fuel Gauge Fuel Gauge Indicates the approximate level of fuel in the tank It indicates...

Page 13: ...e 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 ...

Page 14: ...d 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 indi...

Page 15: ...6 6 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...

Page 16: ...ed 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 t...

Page 17: ... 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...

Page 18: ...r 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 3 3 3 3 3 1 2 1 2 1 2 1 2 1 2 ...

Page 19: ...ess 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 addi...

Page 20: ...e 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 ...

Page 21: ... 21 MahindraTHAR Steering Column Controls Combination Switch ...

Page 22: ...y pressing the side knobs provided on lock 3 Sun visors Sun visors protect the eyes from bright light They can be lowered released from the retention clips and swivelled sideways towards the door z Smoking in the Vehicle Avoid smoking inside the vehicle Smoking in the vehicle spoils the ambience and the interiors of the vehicle z Do not toss a cigarette out of the window It may land on somebody or...

Page 23: ...cle for safety check z Frequent eye on the dash board is essential to monitor the functioning of various systems z While parking in down gradient engage the gear shift lever in reverse position with hand brake on z Do not add cold water to the hot engine leads to crack in engine components z Be aware of the maintenance needs of the vehicle z Do not operate starter for more than 15 seconds at a tim...

Page 24: ...idle Turn the key to OFF position Caution Abruptly stopping the engine after a long journey may damage the engine Idle the engine for some time before switching it OFF GuidelinesonDriving Starting stoppingengine StartingtheEngine z Apply the parking brake fully z Insert the key into the ignition switch and turn it into the IGN position z If the vehicle is equipped with glow plug wait for preheat g...

Page 25: ...adually at idling speed z Do not drive over 60 km hr z Avoid sudden acceleration and full throttle z Do not drive for a long time at a single speed Either increase or decrease the speed at intervals z Do not drive slowly with the transmission in high gear z Avoid hard braking New brakes need to be broken in by moderate use for the first 300 km 200 miles These recommendations should be followed whe...

Page 26: ...e addition of standard transfer case NOTE 5 Speed transmission Transfer case require separate lubrication for each unit as they have no cross over oil passage At each Transmission service check the filler plugs of transmission transfer case should be removed the lubricant refilled to level if necessary SHIFTING PATTERN TRANSMISSION TRANSFERCASE Singlelever Manual 2WDH 4WDH N 4WDL 1 1 1 1 1 3 3 3 3...

Page 27: ... Do not try to back down with the clutch released only the brakes holding the vehicle By shifting to reverse it is possible to start the engine without depressing clutch Let the vehicle move backward with the starter When engine starts control the downward speed with the accelerator Down hill Shift to 4WD range first gear Do not use clutch brakes Now the vehicle can proceed safely down a grade slo...

Page 28: ...ormal stopping distance So it make sense to keep a good distance from other vehicles people and objects on you path z Maintain tyres Tyres do not provide adequate traction once the tread wears below two thirds of the tread depth Check tyres regularly and replace them atappropriate intervals Maintain the recommended tyre pressure in the tyres at all times z While braking accelerating or turning avo...

Page 29: ...ing in Low Visibility Being able to see clearly in all directions and being visible to other drivers is important in all weather conditions This is more difficult in bad weather conditions To be seen more clearly during daylight hours turn the headlights ON Inspect the windshield wipers and washers regularly Keep the windshield washer reservoir full If the windshield wiper blades start to streak t...

Page 30: ...DURE FOR ELECTRIC T F CASE WITH AUTO LOCK FREE RUNNING HUBS SHIFT PROCEDURE FOR ELECTRIC T F CASE WITH AUTO LOCK FREE RUNNING HUBS SHIFT PROCEDURE FOR ELECTRIC T F CASE WITH AUTO LOCK FREE RUNNING HUBS From 2H to 4H or l Drive in a stright line up to maximum speed of 30 km hr l Do not depress the clutch pedal l Shift the lever quickly and smoothly to position 4H From 4H to 4L or l Stop the vehicle...

Page 31: ...locking hubs To Release the locking hubs To Release the locking hubs To Release the locking hubs To Release the locking hubs Shift from 4WD to 2WD Reverse the vehicle in a stright line for about a meter An auidble Click will indicate that the hubs have been released Unlocking is necessarily required to be done to isolate front axle transfer case from transmission from front wheels Caution Caution ...

Page 32: ... not recommended l Never select the 4WD mode if wheels are slipping Stop the slipping or spinning before selecting the 4WD modes Transfer Case Shifting Guidelines for 4WD 4 Wheel Transfer Case Shifting Guidelines for 4WD 4 Wheel Transfer Case Shifting Guidelines for 4WD 4 Wheel Transfer Case Shifting Guidelines for 4WD 4 Wheel Transfer Case Shifting Guidelines for 4WD 4 Wheel Drive Models Drive Mo...

Page 33: ... the buckle slot until a firm click is heard Check the buckle for security by tugging sharply on the webbing To unbuckle simply press the release button on the buckle The retractor mechanism ensures that the correct tension slack in the webbing is preserved Slack belt webbing vastly increase the chances of injury during an accident Care must be taken to avoid the use of polishes acids oils chemica...

Page 34: ...hicle checked at authorized service station z Allow your engine to warm up after a cold start z Drive the vehicle in correct gears Avoid sudden accelerations decelerations z Stop the engine if the engine has to idle for longer duration z Avoid clutch riding check the clutch play z Get your vehicle emission checked periodically z Do not use adulterated fuel z Use genuine parts recommended oils lube...

Page 35: ...eaks and any damages Each time the vehicle is raised for an oil change Whenever a change is noticed in the noise of the exhaust system Whenever the tail pipe end of the exhaust system is found rusty A catalytic converter is an exhaust gas after treatment device fitted in the exhaust system of your vehicle to reduce pollu tion It converts harmful unburned hydrocarbons and carbon monoxide into harml...

Page 36: ...Maintain electrolyte level in the battery using distilled water Keep battery terminals clean cable joints tight Apply Vaseline petrolium jelly on terminals 10 Disconnect alternator battery electrical connection while carrying out welding work on the vehicle Observe correct polarity when connecting battery terminals Dont s 1 Do not run the vehicle with leaky air pipes fuel pipes water hoses 2 Do no...

Page 37: ... vehicle stands on the wheel Body Coat rust proof to all bright metal Cover up with upholstery Engine Topping up the Engine Oil The engine oil level should be maintained at little below high mark on the dipstick must never be allowed to fall below the low While checking the oil level park the vehicle on a level ground with the engine shut down Withdraw the dipstick from its holder clean refit With...

Page 38: ...to higher intake resistance and can reduce the driveability of the vehicle Servicing Instructions z It is adviced to service air filter through Mahindra Dealer Service Centre z Periodically clean the air filter element Every 10 000 kms or 6 months on paved road OR Every 5 000 kms or 3 months on dusty road OR When service indicator shows red band z Replace element When service indicator shows red b...

Page 39: ...ticorrosion protection if concentration 15 and above The recommended coolants are BASF Glycentine or Total Finolf Glacelf Supra at a ratio of water coolant of 70 30 50 50 30 70 For ambient temperature upto 100 C 110 C to 200 C 200 C to 350 C respectively Use of alcohol as an anti freeze is not recommended Use the anti freeze when the operating temperature falls below 00 C Caution Never remove the ...

Page 40: ... when frequent starting difficulties are encountered noise or black smoke is coming from the exhaust Caution z Since the fuel is the lubricant do not crank the engine for extended periods with fuel lines disconnected or empty fuel tank Air Filter Radiator Fuel Injection System Fuel Filter Fuel Filter Fuel Filter Fuel Filter Fuel Filter Draining water from fuel filter The fuel filter warning light ...

Page 41: ...d grade oil z Use only recommended coolant Air Filter Radiator Fuel Injection System Fuel Tank z Clean the tank at regular intervals once in a year z Ensure that no foreign matter or water enters during filling the fuel tank z Ensure that breather system is not clogged Tips for Improving Fuel Efficiency z Maintain correct tyre pressure Under inflated tyres result in increased running resistance le...

Page 42: ...ing vehicle The procedure for filling oil in reservoir is as follows z Fill the reservoir nearly full Crank the engine for 10 seconds without if possible allowing it to start z Check for any leakage in the system z Start the engine steer the vehicle from full left to full right turn 3 4 times Add fluid if necessary to maintain the level up to the filter top Check refill reservoir up to H mark on d...

Page 43: ...e without oil in the Power steering system This will result in serious damage to the pump z Regularly check fluid fluid level in the power steering reservoir z Remove cause of steering column misalignment z Investigate correct any external leaks no matter how minor z Do not attempt to weld any broken steering gear component Use genuine component of steering only z Keep the tyres inflated to correc...

Page 44: ...RecommendedLubricationChart API CH4 80W 90 44 MahindraTHAR ...

Page 45: ...Maintenance Schedule 45 MahindraTHAR ...

Page 46: ...Maintenance Schedule 46 MahindraTHAR ...

Page 47: ...Maintenance Schedule 47 MahindraTHAR ...

Page 48: ...Maintenance Schedule 48 MahindraTHAR ...

Page 49: ...Maintenance Schedule 49 MahindraTHAR ...

Page 50: ...Recommended Odometer Repair Servicing dealer s Services at KM Date Reading KM Order No Signature with stamp PDI 5000 10000 20000 30000 40000 50000 Record of Services Performed 50 MahindraTHAR ...

Page 51: ...Recommended Odometer Repair Servicing dealer s Services at KM Date Reading KM Order No Signature with stamp 60000 70000 80000 90000 100000 Record of Services Performed 51 MahindraTHAR ...

Page 52: ...the figure To loosen rotate in the opposite direction remove the wheel from the hanger bracket SpareWheelMounting Jack mounting position in the vehicle z Jacking position for front wheels z Jacking position for rear wheels is below rear axle z Jack is kept in tool box below the front LH Seat 52 MahindraTHAR ...

Page 53: ...ytime anywhere under the influence of alcohol or drugs is dangerous to you to your family the passengers and to everyone else on the road Alcohol or drugs reduce your awareness and lead to accidents DrivingLongDistances When you are driving over long distances follow these tips so that you have a safe journey z Never drive more than 150 kms at a time Switch drivers even if you are not tired z Lack...

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Mahindra THAR 2009, Owner'S Manual

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