Mahindra THAR 2010 Vehicle Dismantling Manual Download Page 20 | Manualshive

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Thar

Vehicle Dismantling Manual

Activity Area - Instrumental Panel

3.02
EPDM

3.03
PP

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MULTIPLE

PP

MULTIPLE

EPDM

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Summary of Contents for THAR 2010

Page 1: ...10 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 ...

Page 2: ......

Page 3: ... 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 ...

Page 4: ......

Page 5: ...n 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 ...

Page 6: ...harge 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 ...

Page 7: ...ages 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 Notif...

Page 8: ...ors 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 conv...

Page 9: ...5 Vehicle Dismantling Manual Thar Introduction This manual contain the Dismantling procedures of the following vehicle MODEL MAKE ENGINE TRANSMISSION Thar Mahindra NEF CRDe NGT 530 R ...

Page 10: ...6 Thar Vehicle Dismantling Manual Vehicle Dismantling Manual for Mahindra Thar ...

Page 11: ...vity Area m a h i n d r a 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 ...

Page 12: ...t kg lit 0 01 Engine oil for NEF CRDe E IV OIL 6 lit 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 ...

Page 13: ... 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 m a h i n d r a ...

Page 14: ...oor opening inner EPDM 2 0 60 kg Draw off front door weather strip by removing its plastic fasteners Manually 1 04 Glass window front door Glass 2 5 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 2 0 02 kg Draw off the upper side rail weather strip Manually 1 0...

Page 15: ...ather strip Manually 1 10 Reveal molding outer PVCX 2 0 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 2 0 43 kg Draw off the front door upper side weather strip Manually 1 12 Weather strip assembly rear arch PVCX 1 0 48 kg Draw off the rear arch weather strip Manually S No Part Name Material Qty Weight Remova...

Page 16: ... 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 ...

Page 17: ...t 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 2 1 40 kg Remove the front fender exten sion mounting screws M4 5nos 9 Star headed screw driver 2 05 Mud flap front fender PP 2 0 38 kg Remove the front fender mud flap mounting bolts M6 2nos 1...

Page 18: ... wheel rubber housing apron mounting plastic fasteners 6nos 12 Thin bladed screw driver 2 12 End cap side foot step PP 4 0 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 2 0 48 kg Draw off the rear bumper weather strip Manually 2 14 Rear view mir ror outside Multiple 2 0 71 kg Remove the outside ...

Page 19: ...ments Total Volume or Weight Weight of single part material x Quantity 2 17 Canopy Multiple 1 4 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 ...

Page 20: ...16 Thar Vehicle Dismantling Manual Activity Area Instrumental Panel 3 02 EPDM 3 03 PP 3 01 MULTIPLE PP MULTIPLE EPDM ...

Page 21: ...t material x Quantity S No Part Name Material Qty Weight Removal Tooling 3 01 Panel Instru mental Multiple 1 9 70 kg Remove the instrumental panel mounting bolts M6 6nos 10mm Socket Ratchet with 4 extension 3 02 Rubber strip EPDM 1 0 57 kg Peel off the instrumental panel rub ber strip Manually 3 03 Horn pad PP 1 0 12 kg Snap fit Manually ...

Page 22: ...le Dismantling Manual Activity Area Seat PP PUR 4 01 FR RH PUR 4 06 PP 4 06 PP 4 06 PP 4 06 PP 4 02 FR RH PUR 4 05 LH PP 4 04 LH PP 4 04 RH PP 4 05 RH PP 4 02 FR LH PUR 4 03 FR RH PUR 4 01 FR LH PUR m a h i n d r a ...

Page 23: ...g bolts M12 4nos and remove the front seat back cushion cover by cutting out the copper tags 16mm Socket Ratchet and wire cutter 4 03 Seat head rest er LH and RH PUR 2 0 36 kg Remove the head rester by press ing the head rest adjuster and remove the head rester cover by cutting out the copper tags Wire cutter 4 04 Front seat re cliner knob LH and RH PP 2 0 03 kg Remove the recliner control knob mo...

Page 24: ...20 Thar Vehicle Dismantling Manual Activity Area Interior 5 01 RH PP 5 01 LH PP 5 02 PP 5 03 RH PP 5 03 LH PP PP m a h i n d r a ...

Page 25: ...moval Tooling 5 01 Front door trim pad PP 2 1 52 kg Remove the front door trim pad holding screws M4 10nos 9 Star headed screw driver 5 02 Tail door inner trim pad PP 1 0 80 kg Remove the tail door inner trim pad holding screws M4 11nos 9 Star headed screw driver 5 03 Handle door pull inner PP 2 0 08 kg Remove the inner door pull handle mounting screws M6 2nos 9 Star headed screw driver ...

Page 26: ... PVC PE ABSX 6 02 FRP 6 01 ABSX 6 13 ABS 6 12 NBRX 6 15 NBRX 6 16 PAX 6 17 AEM 6 09 EPDM 6 18 SR 6 19 EPDM 6 20 EPDM 6 23 EPDM 6 21 EPDM 6 22 EPDM 6 07 PE 6 11 EPDM 6 10 EPDM 6 08 MULTIPLE 6 14 EPDMX 6 26 RH EPDMX 6 26 LH EPDMX 6 03 FRP 6 28 PVC 6 04 EPDM 6 24 HDPE 6 25 HDPE 6 06 HDPE 6 05 EPDM 6 27 EPDM ...

Page 27: ...ting bolts M6 2nos 10mm Socket Ratchet and 4 extension 6 04 Hose inlet cool ant recovery tank EPDM 1 0 018 kg Snap fit Manually 6 05 Hose outlet coolant recov ery tank EPDM 1 0 09 kg Snap fit Manually 6 06 Coolant recov ery tank cap HDPE 1 0 04 kg Snap fit Manually 6 07 Engine oil fill ing cap PE 1 0 04 kg Remove the engine oil filler cap with its O ring Manually 6 08 Air filter assem bly Multiple...

Page 28: ...r filter outlet hose Multiple 1 0 55 kg Remove the air filter outlet hose by loosing the hose wire gripple studs 2nos 13mm Socket Ratchet and 8 extension 6 16 Air filter outlet hose coupling connector Air cleaner to Turbo charger PAX 1 0 09 kg Remove the air filter outlet hose cou pling by loosing the hose wire grip ple studs 2nos 13mm Socket Ratchet and 8 extension 6 17 Turbo charger inlet hose A...

Page 29: ...steering deliver hose clip 2nos Clip plier 6 23 Radiator inlet hose EPDM 1 0 19 kg Remove the radiator inlet hose by loosing the hose gripple studs 2nos 7mm Socket Ratchet and 8 extension 6 24 Windshield washer tank HDPE 1 0 20 kg Remove the windshield water tank mounting bolts M6 2nos 10mm Socket and Ratchet 6 25 Radiator cool ant reservoir HDPE 1 0 20 kg Remove the radiator coolant reser voir mo...

Page 30: ...mation and Comments Total Volume or Weight Weight of single part material x Quantity 6 28 Beading radia tor guard PVC 1 0 19 kg Remove the radiator guard beading holding clips 13nos Manually S No Part Name Material Qty Weight Removal Tooling ...

Page 31: ...te 17 PCX Polycarbonate Blend 18 TPU Thermoplastic Polyurethane 19 TPUX Thermoplastic Polyurethane Blend 20 NR Natural Rubber 21 NRX Natural Rubber Blend 22 EPDM Ethylene Propylene Diene Monomer 23 EPDMX Ethylene Propylene Diene Monomer Blend 24 NBR Acrylonitrile Butadiene Rubber 25 NBRX Acrylonitrile Butadiene Rubber Blend 26 CSM Chloro Sulphonyl Polyethylene 27 CSMX Chloro Sulphonyl Polyethylene...

Page 32: ...28 Vehicle Dismantling Manual Thar ...

Page 33: ...Vehicle Dismantling Manual Mahindra THAR Revised 26 MAY 2010 2010 ...

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