Mahindra THAR 2010 Vehicle Dismantling Manual
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Mahindra THAR 2010 Vehicle Dismantling Manual

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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

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Summary of Contents for Mahindra THAR 2010

  • Page 1 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...

  • Page 3: Table Of Contents

    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....................

  • Page 5: Vehicle Dismantling Manual

    Vehicle Dismantling Manual 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.

  • Page 6: Airbag Deployment In End-Of-Life Vehicles

    Vehicle Dismantling Manual 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, •...
  • Page 7 Vehicle Dismantling Manual 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. Disconnect the cables from the vehicle's battery(ies). Wait at least 30 minutes for the energy-reserve capacitor to discharge. Make a jumper-wiring harness of two wires 30 feet or longer for remote deployment of the air bag.

  • Page 8: Component Parts Deemed To Be Non Reusable

    Vehicle Dismantling Manual Component Parts Deemed to be Non Reusable The below mentioned component parts of the vehicles belonging to the category M and to the category N 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).

  • Page 9: Introduction

    Vehicle Dismantling Manual Introduction This manual contain the Dismantling procedures of the following vehicle. MODEL MAKE ENGINE TRANSMISSION Thar Mahindra NEF - CRDe NGT 530 R Thar...
  • Page 10 Vehicle Dismantling Manual Vehicle Dismantling Manual for Mahindra Thar Thar...

  • Page 11: Vehicles Activity Area

    Vehicle Dismantling Manual Vehicles Activity Area 0.08 0.07 CLUTCH OIL BRAKE OIL 0.03 COOLANT 0.02 BATTERY 0.01 ENGINE OIL 0.11 REAR AXLE OIL 0.05 TRANSFER CASE OIL 0.04 RR LH - TIRE 0.10 0.04 0.06 FRONT AXLE OIL FR RH - TIRE TRANSMISSION OIL 0.04 0.09...
  • Page 12 Vehicle Dismantling Manual Area: Pretreatment Model: Thar S:No Part Name Material Weight (kg/lit) 0.01 Engine oil for NEF CRDe E IV 6 lit 0.02 Battery MULTIPLE 19.62 kg Coolant 3.3 lit 0.03 Coolant COOLANT Water 7.7 lit 0.04 Tires EPDM 81.0 kg 0.05 Transfer case oil...

  • Page 13: Activity Area - Doors And Glazing

    Vehicle Dismantling Manual Activity Area - Doors and Glazing 1.04 RH Glass 1.04 LH Glass 1.12 PVCX 1.01 Glass 1.08 RH 1.08 LH 1.02 EPDM EPDM EPDM 1.05 RH 1.05 LH PVCX PVCX 1.09 1.06 LH 1.11 RH EPDM PVCX 1.06 RH PVCX PVCX...
  • Page 14 Vehicle Dismantling Manual Area: Doors and Glazing Model: Thar S:No Part Name Material Weight Removal Tooling Push the top side edges of the Assembly glass windshield weather strip down- 12” Thin bladed screw 1.01 windshield Glass 7.65 kg wards and remove the windshield driver (2nos) clear glass assembly completely.
  • Page 15 Vehicle Dismantling Manual S:No Part Name Material Weight Removal Tooling Weather strip Draw off the tail gate bottom 1.09 EPDM 0.11 kg Manually tail gate bottom weather strip. Reveal molding Draw off the glass run channel 12” Thin bladed screw 1.10 PVCX 0.28 kg...

  • Page 16: Activity Area - Exterior

    Vehicle Dismantling Manual Activity Area - Exterior 2.17 MULTIPLE 2.16 2.09 MULTIPLE 2.13 RH PVCX 2.13 LH PVCX 2.10 RH 2.14 RH 2.14 LH MULTIPLE MULTIPLE MULTIPLE 2.08 RH 2.06 RH MULTIPLE 2.10 LH MULTIPLE 2.03 RH 2.04 RH 2.12 FR-RH 2.08 LH MULTIPLE MULTIPLE...
  • Page 17 Vehicle Dismantling Manual Area: Exterior Model: Thar S:No Part Name Material Weight Removal Tooling Remove the front turn signal lamp Front turn assembly mounting nuts (M6- 2.01 signal lamp Multiple 0.508 kg 2nos) and disconnect the front 10mm Socket and Ratchet assembly turn signal lamp harness connec- tion.
  • Page 18 Vehicle Dismantling Manual S:No Part Name Material Weight Removal Tooling Rear combina- tion lamp (Tail Remove the rear combination lamp 10mm Socket, Ratchet 2.08 Multiple 1.04 kg lamp LH and mounting nuts (M6-3nos). with 4” extension Remove the number plate lamp Assembly num- 10mm Socket, Ratchet 2.09...
  • Page 19 Vehicle Dismantling Manual S:No Part Name Material Weight Removal Tooling Remove the canopy holding rods 2.17 Canopy Multiple 4.45 kg mounting bolts (M6-4nos) and can- 10mm Socket and Ratchet opy holding flaps. Information and Comments Total Volume or Weight = Weight of single part material x Quantity. Thar...

  • Page 20: Activity Area - Instrumental Panel

    Vehicle Dismantling Manual Activity Area - Instrumental Panel 3.02 EPDM 3.03 3.01 MULTIPLE EPDM MULTIPLE Thar...
  • Page 21 Vehicle Dismantling Manual Area: Instrumental panel Model: Thar S:No Part Name Material Weight Removal Tooling Panel Instru- Remove the instrumental panel 10mm Socket, Ratchet 3.01 Multiple 9.70 kg mental mounting bolts (M6-6nos). with 4” extension Peel off the instrumental panel rub- 3.02 Rubber strip EPDM...

  • Page 22: Activity Area - Seat

    Vehicle Dismantling Manual Activity Area - Seat 4.03 FR-RH 4.06 4.06 4.06 4.06 4.01 FR-LH 4.01 FR-RH 4.05 RH 4.04 RH 4.05 LH 4.02 FR-RH 4.04 LH 4.02 FR-LH Thar...
  • Page 23 Vehicle Dismantling Manual Area: Seats Model: Thar S:No Part Name Material Weight Removal Tooling Remove the seat assembly mount- Front seat back ing bolts (M12-4nos) and remove 16mm Socket, Ratchet and 4.01 cushion (LH 2.06 kg the front seat back cushion cover wire cutter and RH) by cutting out the copper tags.

  • Page 24: Activity Area - Interior

    Vehicle Dismantling Manual Activity Area - Interior 5.02 5.01 RH 5.03 RH 5.01 LH 5.03 LH Thar...
  • Page 25 Vehicle Dismantling Manual Area: Interior Model: Thar S:No Part Name Material Weight Removal Tooling Front door trim Remove the front door trim pad 9” Star headed screw 5.01 1.52 kg holding screws (M4-10nos). driver Tail door inner Remove the tail door inner trim pad 9”...

  • Page 26: Activity Area - Engine

    Vehicle Dismantling Manual Activity Area - Engine 6.14 EPDMX 6.26 RH 6.26 LH EPDMX EPDMX 6.10 EPDM 6.07 6.21 6.24 EPDM HDPE 6.22 6.01 EPDM ABSX 6.13 6.15 6.27 NBRX EPDM 6.12 ABSX 6.06 6.08 NBRX HDPE 6.05 MULTIPLE EPDM 6.16 HDPE 6.04...
  • Page 27 Vehicle Dismantling Manual Area: Engine Model: Thar S:No Part Name Material Weight Removal Tooling Engine NVH Remove the engine NVH cover 13mm Socket, Ratchet 6.01 ABSX 1.78 kg cover mounting bolts (M10-3nos). and 4” extension Shroud upper Remove the radiator upper shroud 10mm Socket, Ratchet 6.02 0.35 kg...
  • Page 28 Vehicle Dismantling Manual S:No Part Name Material Weight Removal Tooling Brake booster Remove the brake vacuum hose clip 6.10 EPDM 0.19 kg Clip plier vacuum hose (2nos). Remove the intercooler outlet hose, Hose inter 7mm Socket, Ratchet 6.11 EPDM 0.19 kg by loosing the hose gripple studs cooler outlet and 8”...
  • Page 29 Vehicle Dismantling Manual S:No Part Name Material Weight Removal Tooling Remove the turbo charger outlet Intercooler in- 7mm Socket, Ratchet 6.19 EPDM 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...
  • Page 30 Vehicle Dismantling Manual S:No Part Name Material Weight Removal Tooling Beading radia- Remove the radiator guard beading 6.28 0.19 kg Manually tor guard holding clips (13nos). Information and Comments Total Volume or Weight = Weight of single part material x Quantity. Thar...

  • Page 31: Abbreviation

    Vehicle Dismantling Manual Abbreviation Poly Ethylene Poly Ethylene Blend Poly Propylene Poly Propylene Blend Poly Vinyl Chloride PVCX Poly Vinyl Chloride Blend Acrylonitrille Butadiene Styrene ABSX Acrylonitrille Butadiene Styrene Blend Poly Amide 10. PAX Poly Amide Blend 11. PET Poly Ethylene Terephthalate 12.
  • Page 32 Vehicle Dismantling Manual Thar...
  • Page 33 Mahindra THAR 2010 Vehicle Dismantling Manual Revised 26 MAY 2010...

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