Mahindra THAR: Vehicle Dismantling Manual

Vehicle Dismantling Manual
Mahindra THAR
2010
© 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
Downloaded from www.Manualslib.com manuals search engine

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


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).
Note: If fail to follow these cautions could cause airbag deployment or some personal
injuries.
• 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.
Thar 1

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.
Thar 2

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.
Note: Always disconnect the wires to avoid static electricity. Static electricity can
deployed the 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.
Thar 3

Component Parts Deemed to be Non Reusable

The below mentioned component parts of the vehicles belonging to the category M1
and to the category N1 which 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.
Thar 4

Introduction
This manual contain the Dismantling procedures of the following vehicle.
MODEL MAKE ENGINE TRANSMISSION
Thar Mahindra NEF - CRDe NGT 530 R
Thar 5

Vehicle Dismantling Manual for Mahindra Thar
Thar 6

Vehicles Activity Area

0.08
0.07
CLUTCH OIL
0.03 BRAKE OIL
COOLANT
0.02
BATTERY
0.01
ENGINE OIL
0.11
REAR AXLE OIL
ma
hin
dra
0.05
TRANSFER CASE OIL
0.04
RR LH - TIRE
0.10
0.04 FRONT AXLE OIL 0.06
FR RH - TIRE TRANSMISSION OIL
0.09 0.04
STEERING OIL FR LH - TIRE
Thar 7

Area: Pretreatment
Model: Thar
S:No Part Name Material Qty Weight (kg/lit)
0.01 Engine oil for NEF CRDe E IV OIL 6 lit

0.02 Battery MULTIPLE 1 19.62 kg
Coolant 3.3 lit

0.03 Coolant COOLANT
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
Information and Comments

Total Volume or Weight = Weight of single part material x Quantity.
Thar 8

Activity Area - Doors and Glazing
1.04 RH
Glass 1.04 LH
Glass
1.12
PVCX
ma
hin
dra
1.01
Glass
1.08 RH 1.08 LH
1.02 EPDM EPDM
EPDM 1.05 RH
PVCX 1.05 LH
PVCX
1.09
1.11 RH 1.06 LH
EPDM
1.06 RH PVCX PVCX
PVCX
1.11 LH
PVCX
1.10 RH
PVCX
PVC
1.07 RH 1.10 LH
PVCX EPDMX PVCX
EPDM
EPDMX
1.03 RH 1.07 LH
1.03 LH
EPDM EPDMX
Glass EPDM
Thar 9

Area: Doors and Glazing

Model: Thar
S:No Part Name Material Qty Weight Removal Tooling
Push the top side edges of the

Assembly glass
windshield weather strip down- 12” Thin bladed screw
1.01 windshield Glass 1 7.65 kg
wards and remove the windshield driver (2nos)
clear
glass assembly completely.
Weather strip Draw off the windshield glass

1.02 wind shield EPDM 1 1.30 kg weather strip from the windshield Manually
glass glass.
Weather strip
Draw off front door weather strip,
1.03 front door EPDM 2 0.60 kg Manually
by removing its plastic fasteners.
opening inner
Remove the door inner trims and

Glass window the front door glass mounting 10mm Socket, Ratchet with
1.04 Glass 2 5.96 kg
front door bolts (M6 - 2nos) from the win- 4” extension
dow regulator.
Weather strip Draw off the upper side rail

1.05 PVCX 2 0.02 kg Manually
side rail upper weather strip.
Weather strip Draw off the lower side rail
side rail lower weather strip.
Seal front door Draw off the front window glass

1.07 EPDMX 2 0.58 kg Manually
window glass seal.
Weather strip Draw off the tail gate weather
1.08 EPDM 2 0.10 kg Manually
tail gate strip.
Thar 10

Weather strip Draw off the tail gate bottom

1.09 EPDM 1 0.11 kg Manually
tail gate bottom weather strip.
Reveal molding Draw off the glass run channel 12” Thin bladed screw
1.10 PVCX 2 0.28 kg
outer flock from the door. driver
Weather strip
Draw off the front door upper side
1.11 front door side PVCX 2 0.43 kg Manually
weather strip.
rail upper
Weather strip
Draw off the rear arch weather
1.12 assembly rear PVCX 1 0.48 kg Manually
strip.
arch

Thar 11

Activity Area - Exterior
2.17
MULTIPLE
2.16
FRP
2.09
MULTIPLE 2.13 RH
PVCX 2.13 LH
2.10 RH PVCX
2.14 RH 2.14 LH
MULTIPLE
MULTIPLE MULTIPLE
2.06 RH 2.08 RH
FRP MULTIPLE 2.10 LH
MULTIPLE
2.03 RH 2.04 RH
MULTIPLE 2.12 FR-RH 2.08 LH
FRP
PP 2.12 RR-RH MULTIPLE
2.07 RH
2.02 RH PP
PP
MULTIPLE 2.03 LH
2.06 LH 2.07 LH
2.11 RH MULTIPLE
2.04 LH FRP PP
NR
2.05 RH FRP
FRP 2.01 RH PP 2.12 RR-LH
MULTIPLE PP
NR 2.02 LH 2.12 FR-LH
2.11 LH
MULTIPLE MULTIPLE PP
NR
PP 2.01 LH 2.05 LH
PVCX MULTIPLE PP
2.15
PVCX
Thar 12

Area: Exterior
Model: Thar
Remove the front turn signal lamp

Front turn assembly mounting nuts (M6-
2.01 signal lamp Multiple 2 0.508 kg 2nos) and disconnect the front 10mm Socket and Ratchet
assembly turn signal lamp harness connec-
tion.
Remove the head lamp assembly

Assembly head mounting bolts (M6-3nos) and dis- 10mm Socket, Ratchet
2.02 Multiple 2 2.25 kg
lamp connect the front lamp harness with 4” extension
connection.
Remove the lamp assembly side

Lamp assem- 9” Thin bladed screw
2.03 Multiple 2 0.11 kg marker assembly mounting screws
bly side marker driver
(M4-2nos).
Front fender Remove the front fender exten- 9” Star headed screw
2.04 FRP 2 1.40 kg
extension sion mounting screws (M4-5nos). driver
Mud flap front Remove the front fender mud flap 10mm Socket, Ratchet
2.05 PP 2 0.38 kg
fender mounting bolts (M6-2nos). with 4” extension
Rear wheel Remove the rear wheel arch 9” Star headed screw
2.06 FRP 2 2.60 kg
arch mounting screws (M4-4nos). driver
Mud flap rear Remove the rear wheel mud flap 13mm Socket, Ratchet
2.07 NR 2 0.87 kg
wheel mounting bolts (M8-2nos). with 4” extension
Thar 13

Rear combina-
tion lamp (Tail Remove the rear combination lamp 10mm Socket, Ratchet
lamp LH and mounting nuts (M6-3nos). with 4” extension
RH)
Remove the number plate lamp

Assembly num- 10mm Socket, Ratchet
2.09 Multiple 1 0.34 kg assembly mounting nuts (M6-
ber plate lamp with 4” extension
2nos).
Reflex reflector Remove the rear reflex reflector 8mm Socket, Ratchet with
rear mounting nuts (M4-1no). 4” extension
Apron rubber Remove the front wheel rubber

12” Thin bladed screw
2.11 front wheel NR 2 0.56 kg housing apron mounting plastic
driver
housing fasteners (6nos).
8mm Socket, Ratchet and
End cap side Remove the end cap side food
2.12 PP 4 0.33 kg 12” Thin bladed screw
foot step step mounting screw (M4-2nos).
driver
Weather strip Draw off the rear bumper weather

rear bumper strip.
Remove the outside rear view mir-
Rear view mir- 9” Star headed screw
2.14 Multiple 2 0.71 kg ror assembly mounting screws
ror outside driver
(M6-2nos).
Weather strip Draw off the rear bumper weather

front bumper strip.
Remove the vehicle canopy com-
Canopy rein-
2.16 FRP 1 3.40 kg pletely and remove the canopy Manually
forcement
reinforcement.
Thar 14

Remove the canopy holding rods

2.17 Canopy Multiple 1 4.45 kg mounting bolts (M6-4nos) and can- 10mm Socket and Ratchet
opy holding flaps.

Thar 15

Activity Area - Instrumental Panel
3.02
EPDM
3.03
PP
3.01
MULTIPLE
EPDM
PP
MULTIPLE
Thar 16

Area: Instrumental panel

Model: Thar
Panel Instru- Remove the instrumental panel 10mm Socket, Ratchet

mental mounting bolts (M6-6nos). with 4” extension
Peel off the instrumental panel rub-

3.02 Rubber strip EPDM 1 0.57 kg Manually
ber strip.
3.03 Horn pad PP 1 0.12 kg Snap fit Manually

Thar 17

Activity Area - Seat
4.03 FR-RH
PUR
ma
hin
dra
4.06
4.06 4.06 4.06
PP
PP PP PP
4.01 FR-RH 4.01 FR-LH

PUR PUR
4.05 RH
PP
4.04 RH
PP
4.05 LH
PP
4.02 FR-RH
PUR
PP
4.04 LH
PUR PP
4.02 FR-LH
PUR
Thar 18

Area: Seats
Model: Thar
Remove the seat assembly mount-

Front seat back
ing bolts (M12-4nos) and remove 16mm Socket, Ratchet and
4.01 cushion (LH PUR 2 2.06 kg
the front seat back cushion cover wire cutter
and RH)
by cutting out the copper tags.
Remove the seat assembly mount-

Front seat base
ing bolts (M12-4nos) and remove 16mm Socket, Ratchet and
4.02 cushion (LH PUR 2 1.94 kg
the front seat back cushion cover wire cutter
and RH)
by cutting out the copper tags.
Remove the head rester by press-

Seat head rest- ing the head rest adjuster and
4.03 PUR 2 0.36 kg Wire cutter
er (LH and RH) remove the head rester cover by
cutting out the copper tags.
Front seat re-
Remove the recliner control knob 6” Star headed screw
4.04 cliner knob (LH PP 2 0.03 kg
mounting screws (M2-1no). driver
and RH)
Front seat re- Remove the recliner cover mount-

6” Star headed screw
4.05 cliner cover (L PP 2 0.10 kg ing screws (M3-1no) and (M4-
driver
H and RH) 1no).
Head rester Press the bottom end of the head

4.06 PP 4 0.07 kg Manually/Pliers
adjuster rest adjuster gently.

Thar 19

Activity Area - Interior
5.02
PP
ma
hin
dra
5.01 RH
PP
5.03 RH
5.01 LH
PP
PP
5.03 LH
PP
PP
Thar 20

Area: Interior
Model: Thar
Front door trim Remove the front door trim pad 9” Star headed screw
5.01 PP 2 1.52 kg
pad holding screws (M4-10nos). driver
Tail door inner Remove the tail door inner trim pad 9” Star headed screw
5.02 PP 1 0.80 kg
trim pad holding screws (M4-11nos). driver
Handle door Remove the inner door pull handle 9” Star headed screw
5.03 PP 2 0.08 kg
pull inner mounting screws (M6-2nos). driver

Thar 21

Activity Area - Engine
6.14 EPDMX
6.26 RH
6.26 LH
EPDMX
EPDMX
6.10
EPDM
6.07
PE
6.21 6.24
EPDM HDPE
6.22 6.01
6.13 EPDM ABSX
ABS 6.15 6.27
NBRX EPDM
ABSX 6.12 6.06

6.08 NBRX HDPE
PVC 6.05
MULTIPLE
PE
EPDM
6.16
HDPE PAX
6.02 6.04
EPDMX
FRP EPDM
PAX
6.17 6.20
FRP 6.18 6.25
6.09 AEM EPDM
SR HDPE
NBRX EPDM
SR
6.03
FRP
ABS
6.19 6.23
EPDM EPDM EPDM
AEM 6.11
6.28
MULTIPLE EPDM
PVC
Thar 22

Area: Engine
Model: Thar
Engine NVH Remove the engine NVH cover 13mm Socket, Ratchet
6.01 ABSX 1 1.78 kg
cover mounting bolts (M10-3nos). and 4” extension
Shroud upper Remove the radiator upper shroud 10mm Socket, Ratchet
6.02 FRP 1 0.35 kg
radiator mounting bolts (M6-2nos). and 4” extension
Shroud lower Remove the radiator lower shroud 10mm Socket, Ratchet
6.03 FRP 1 0.35 kg
radiator mounting bolts (M6-2nos). and 4” extension
Hose inlet cool-

0.018
6.04 ant recovery EPDM 1 Snap fit Manually
kg
tank
Hose outlet
6.05 coolant recov- EPDM 1 0.09 kg Snap fit Manually
ery tank
Coolant recov-
6.06 HDPE 1 0.04 kg Snap fit Manually
ery tank cap
Engine oil fill- Remove the engine oil filler cap with
6.07 PE 1 0.04 kg Manually
ing cap its O-ring.
Air filter assem- Remove the Air filter assembly 13mm Socket, Ratchet
bly mounting bolts (M8-3nos). and extension
Remove the air cleaner inlet hose,

Air filter inlet 7mm Socket, Ratchet
6.09 EPDM 1 0.18 kg by loosing the hose grapple studs
hose and 8” extension
(1no).
Thar 23

Brake booster Remove the brake vacuum hose clip

6.10 EPDM 1 0.19 kg Clip plier
vacuum hose (2nos).
Remove the intercooler outlet hose,

Hose inter 7mm Socket, Ratchet
6.11 EPDM 1 0.19 kg by loosing the hose gripple studs
cooler outlet and 8” extension
(2nos).
Breather inlet Remove the breather inlet hose clip

6.12 NBRX 1 0.12 kg Clip plier
hose (2nos).
Engine fuse
6.13 ABS 1 0.02 kg Snap fit Manually
box
Weather strip Draw off the rear bonnet weather

6.14 EPDMX 1 0.24 kg Manually
bonnet rear strip.
Remove the air filter outlet hose, by

Air filter outlet 13mm Socket, Ratchet
6.15 Multiple 1 0.55 kg loosing the hose wire gripple studs
(2nos).
Air filter outlet

hose coupling Remove the air filter outlet hose cou-
13mm Socket, Ratchet
6.16 connector (Air PAX 1 0.09 kg pling, by loosing the hose wire grip-
and 8” extension
cleaner to ple studs (2nos).
Turbo charger)
Remove the turbo charger inlet hose,
Turbo charger 13mm Socket, Ratchet
6.17 AEM 1 0.18 kg by loosing the hose wire gripple
inlet hose and 8” extension
studs (2nos).
Remove the turbo charger outlet

Turbo charger 7mm Socket, Ratchet
6.18 SR 1 0.21 kg hose, by loosing the hose gripple
outlet hose and 8” extension
studs (2nos).
Thar 24

Remove the turbo charger outlet

Intercooler in- 7mm Socket, Ratchet
6.19 EPDM 1 0.18 kg hose, by loosing the hose gripple
let hose and 8” extension
studs (2nos).
Remove the radiator outlet hose, by

Radiator outlet 7mm Socket, Ratchet
6.20 EPDM 1 0.24 kg loosing the hose gripple studs
(2nos).
Power steering
Remove power steering oil reservoir
6.21 oil reservoir EPDM 1 0.16 kg Clip plier
inlet hose clip (2nos).
suction hose
Power steering
Remove power steering deliver hose
6.22 oil reservoir EPDM 1 0.04 kg Clip plier
clip (2nos).
delivery hose
Remove the radiator inlet hose, by

Radiator inlet 7mm Socket, Ratchet
6.23 EPDM 1 0.19 kg loosing the hose gripple studs
(2nos).
Windshield Remove the windshield water tank 10mm Socket and

6.24 HDPE 1 0.20 kg
washer tank mounting bolts (M6-2nos). Ratchet
Radiator cool- Remove the radiator coolant reser- 10mm Socket and
6.25 HDPE 1 0.20 kg
ant reservoir voir mounting bolts (M6-2nos). Ratchet
Weather strip
6.26 EPDMX 2 0.22 kg Draw off the bonnet weather strip. Manually
bonnet side
Remove the engine inlet manifold

Engine mani- 7mm Socket, Ratchet
6.27 EPDM 1 0.43 kg hose, by loosing the hose gripple
fold inlet hose and 8” extension
studs (2nos).
Thar 25

Beading radia- Remove the radiator guard beading

6.28 PVC 1 0.19 kg Manually
tor guard holding clips (13nos).

Thar 26

Abbreviation
1. PE - Poly Ethylene
2. PEX - Poly Ethylene Blend
3. PP - Poly Propylene
4. PPX - Poly Propylene Blend
5. PVC - Poly Vinyl Chloride
6. PVCX - Poly Vinyl Chloride Blend
7. ABS - Acrylonitrille Butadiene Styrene
8. ABSX - Acrylonitrille Butadiene Styrene Blend
9. PA - Poly Amide
10. PAX - Poly Amide Blend
11. PET - Poly Ethylene Terephthalate
12. PETX - Poly Ethylene Terephthalate Blend
13. PBT - Poly Butylene Terephthalate
14. PBTX - Poly Butylene Terephthalate Blend
15. PES - Polyethersulfone
16. PC - Polycarbonate
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 Blend
28. ACM - Acrylic Rubber
29. ACMX - Acrylic Rubber Blend
30. AEM - Vamac Rubber
31. AEMX - Vamac Rubber Blend
32. SR - Silicone Rubber
33. SRX - Silicone Rubber Blend
34. PUR - Polyurethane Rubber
35. PURX - Polyurethane Rubber Blend
36. HDPE - High Density Polyehtylene
37. SRS - Supplemental Restraint System
38. NVH - Noise Vibration Harshness
Thar 27

Thar 28

Mahindra THAR
2010
Revised
26 MAY 2010

Mahindra THAR: Vehicle Dismantling Manual

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Vehicle Dismantling Manual

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Vehicle Dismantling Manual .................................................................................... 1

Airbag Deployment in End-of-Life Vehicles ........................................................... 2

Component Parts Deemed to be Non Reusable ..................................................... 4

Vehicles Activity Area .............................................................................................. 7

Activity Area - Exterior.............................................................................................. 12

Activity Area - Instrumental Panel ........................................................................... 16

Activity Area - Seat ................................................................................................... 18

Activity Area - Interior ............................................................................................... 20

Activity Area - Engine ............................................................................................... 22

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Vehicle Dismantling Manual

• Be careful when handling the SRS sensor.

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Airbag Deployment in End-of-Life Vehicles

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Component Parts Deemed to be Non Reusable

List of Component Parts

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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

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S:No Part Name Material Qty Weight (kg/lit)

0.01 Engine oil for NEF CRDe E IV OIL 6 lit

Coolant 3.3 lit

0.04 Tires EPDM 5 81.0 kg

0.06 Transmission oil OIL 1.80 lit

0.07 Brake fluid OIL 0.45 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

Information and Comments

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Activity Area - Doors and Glazing

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Area: Doors and Glazing

S:No Part Name Material Qty Weight Removal Tooling

Push the top side edges of the

Weather strip Draw off the windshield glass

Remove the door inner trims and

Weather strip Draw off the upper side rail

Seal front door Draw off the front window glass

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S:No Part Name Material Qty Weight Removal Tooling

Weather strip Draw off the tail gate bottom

Information and Comments

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Activity Area - Exterior

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S:No Part Name Material Qty Weight Removal Tooling

Remove the front turn signal lamp

Remove the head lamp assembly

Remove the lamp assembly side

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S:No Part Name Material Qty Weight Removal Tooling

Remove the number plate lamp

Apron rubber Remove the front wheel rubber