Mahindra THAR 2009 Owner's Manual

OWNER'S MANUAL

Mahindra THAR

ISSUED : SEPTEMBER 2009

Foreword

Thank you for buying a MAHINDRA vehicle. We trust
it meets your expectations & will provide you with years
of enjoyable motoring. This OWNER'S MANUAL has been
prepared for the reference of the Owner & it is hoped
that this will enable him to acquire working knowledge
of MAHINDRA THAR

Contents include vehicle specifications, driving notes &
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.

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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 policy of
constant product improvements.

Please contact nearest Authorized Service Dealer,for
periodical vehicle maintenance & repairs.

Mahindra THAR

Contents

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

Mahindra THAR

Do's & Don'ts
Maintenance Procedure

z Vehicle Maintenance when Out of Use
z Engine
z Clutch
z Steering System
z Tyres
z Electrical Equipments

Service Data

z Recommended lubricants
z Bulb Specification
z Maintenance Schedule

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Manufacturer’s Warranty

MAHINDRA & MAHINDRA LTD,
OPERATIONS,MAHINDRA TOWRES, 2ND FLOOR,

AUTOMOTIVE SECTOR, WORLI,MUMBAI 400089, INDIA

warrants to retail purchaser of the Motor Vehicle
branded as ‘ MahindraTHAR ‘(hereinafter referred to
as ‘vehicle’) to be free from defects in material and
workmanship under normal use as instructed in t he
Owner’s Manual & Service, under the warranty,
Company’s Authorised dealer will repair or replace any
part thereof, including all equipments or trade limited
to trade accessories (except those governed by
special warranty policy stipulated by respective
manufacturers, like tyres and batteries etc.)
originally supplied by us subject to all other terms
and conditions specified herein below 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.

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INTERNATIONAL

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 Authorised
Dealers.

This warranty is limited to the delivery to the purchaser,
at the Authorised Dealer’s workshop or at any other place
at the discretion of the company,of the part orparts
whether new or repaired, in exchange for those
acknowledged by the Dealer to be defective and endorsed
by the company to that effect. The parts so repaired or
replaced shall also be warranteed for quality and
workmanship but such warranty shall be co-terminus with
this warranty.

Mahindra THAR

Manufacturer’s Warranty

This warranty shall not apply to and Company shall in no way
be liable for any vehicle which shall have been repaired outside
and Authorised Company’s Service Station or which has been
altered or modified or built upon in any way or which has
been subjected to misuse, negligence or accident.

This Warranty is in lieu of all other Warranties express or
implied, and no person, agent or representative of the
Company is authorised to give any other warranties on the
Company’s behalf or to assume for it any other liability in
connection, with the vehicle.

The Company’s responsibility is limited to the terms of this
Warranty and it shall not be answerable for personal injuries
or consequential or resulting liability, damage or loss arising
from any defects.

The Company’s Liability under this Warranty is dependent
upon the strict observance by the Purchaser, of the following
provisions :

Mahindra THAR

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
avail the warranty benefits.

c) Repairs or replacements will be performed by the

Authorised Dealer of the Company, subject to the
reporting of the vehicle to the nearest Authorised
Dealer’s workshop.

d) We further reserve the right, at anytime or times, without

notice, or revise, modify, discontinue or change any of
the models of our vehicles or any party thereof and
neither company nor the seller with incurr any liability
or obligations to the purchaser by reasons or any
revisions, modifications, discontinuation or changes.

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Manufacturer’s Warranty

e) The Purchaser shall at all times in the operation of vehicle

use only those brands of lubricating oils, lubricants or
fuel, as recommended by the Company,

f) The judgement of the Company or its Auhtoirsed Dealers

in all cases of claims shall be final and conclusive and
the purchaser agrees to accept its decision on all
questions as to defects and to the exchange of part of
parts. The replaced parts shall be the property of the
Company.

g) Claims arising from this Warranty will be recognised only
if they are ascertained / confirmed by the Authorised 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 participation in any other sports competitions.
iv) Any modification are carried out.

b) Appearance Items :

Any slight imperfections in paint, chrome and trim and

other decorative parts, deterioration of exterior item,

trim and other decorative part due to normal exposure

or use is not covered under the terms of Warranty.

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Mahindra THAR

Manufacturer’s Warranty

c) Door and windshield glass breakage and fused bulbs
are not covered under Warranty.

d) Normal Maintenance Service Replacement Items :

Filters, Brake or clutch innings, wiper blades, Belts,
Cables, Spring Bushings, U-Joints Cross, Water Pump
Kits, Tie Rod Ends, Bell-crank Kit, Hoses, Kits and Bulbs,
Spark plugs, Condenser. Please note that this list is
neither exclusive nor exhaustive and the decision of
the Company shall be final in this regard.

e) Property Items :

The following are propriety items and warranty is
provided by the respective Manufacturers under their
warranty terms. Any complaint on the following items,
are to be referred to the respective manufacturers of
these items / or their authorised 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.

Mahindra THAR

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 not have been
discovered by ordinary factory inspection.

g) Repairs required due to following reasons :

i) Due to unauthorised modifications of the vehicle which in

any way affects the stability or reliability of the components
of the basic vehicle.

ii) Continued usage in spite of awareness of defects of the

components of the basic vehicle.

iii) Excess / heavy load beyond the carrying capacity of

the vehicle affecting the basic structure of the Vehicle.

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Engine Specification

NEF CRDE 2.49L ENGINE

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

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Vehicle Specification Bolero THAR

Dimensions :

WEIGHTS :

Kerb weight ( Kg ) 1750
GVW ( Kg ) 2200
Front Axle Capacity ( Kg ) 1100
Rear Axle capacity ( Kg ) 1700
Seating Capacity ( Nos ) 1+1
(Including driver)
Towing Capacity( Kg ) 750

Dimensions mm
Wheel base (WB) 2426
Overall length (OL) 3920
Overall Height (OH) 1928
Tread - Front (T) 1445
Tread - Rear (R) 1336
Ground Clearance (G) 200
Overhang Front (OF) 580
Overhang Rear (OR) 930
Approach Angle (AA) 46
Departure Angle (DA) 30
Overall Width (OW) 1765

Note : Specification subject to change without prior notice.

Mahindra THAR

DRIVE LINE

ITEM

Transmission NGT 530R,V4 GEAR RATIO
1st 3.78 : 1

2nd 2.09 : 1
3rd 1.38 : 1

4th 1.00 : 1

0

0

5th 0.79 : 1
Reverse 3.52 : 1

Transfer Gear ratio : High 1 : 1

Low 2.48 : 1

Axle ratio 4.30 : 1

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Model Features Table

DESCRIPTION MAHINDRA BOLERO THAR

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 )

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Identification of Serial Numbers

MAI-2kk-bx-45596

z Chassis Number / VIN Number

The Vehicle chassis number is stamped on the right side
chassis member below the front fender. It is also stamped
on the Name, Number & instruction plate located on the right
side of the engine compartment for LHD vehicle & on left
side of the engine compartment for RHD vehicle.

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.

z Engine Serial Number

This number is punched on cylinder block on front pad (Near
water pump).

Mahindra THAR

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Instruments

INSTRUMENTSINSTRUMENTS

INSTRUMENTS

INSTRUMENTSINSTRUMENTS

1.1.

1.

1.1.

IN CLUSTER IN CLUSTER

IN CLUSTER

IN CLUSTER IN CLUSTER

SpeedometerSpeedometer

Speedometer

SpeedometerSpeedometer
This indicates the speed at which the vehicle is
driven in km/hr.

2.2.

OdometerOdometer

2.

Odometer

2.2.

OdometerOdometer
The odometer indicates cumulative kilometers
covered by the vehicle.

3.3.

Tripmeter & Reset knobTripmeter & Reset knob

3.

Tripmeter & Reset knob

3.3.

Tripmeter & Reset knobTripmeter & 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.

Fuel GaugeFuel Gauge

4.

Fuel Gauge

4.4.

Fuel GaugeFuel Gauge
Indicates the approximate level of fuel in the tank.
It indicates at E-Empty; 1/2 - Half, F - Full.

INSTRUMENTSINSTRUMENTS

INSTRUMENTS

INSTRUMENTSINSTRUMENTS

1. Speedometer

2. Odometer
3 . Tripmeter/reset knob
4 . Fuel Gauge
5 . Temperature Gauge

6. Tachometer

5.5.

Temperature GaugeTemperature Gauge

5.

Temperature Gauge

5.5.

Temperature GaugeTemperature Gauge
It indicates the operating temperature of the engine
in 0C so that you may guard against overheating.

6.6.

TachometerTachometer

6.

Tachometer

6.6.

TachometerTachometer
It indicates the engine speed in thousands of

revolutions per minute.
Note : Do not over rev the engine. Operating the
engine at high RPM may cause severe engine
damage.

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Instruments

ODO

TRIP B

About 3 seconds

TRIP A

TRIP BTRIP A

1.1.

Odometer/Trip meter selector knobOdometer/Trip meter selector knob

1.

Odometer/Trip meter selector knob

1.1.

Odometer/Trip meter selector knobOdometer/Trip meter selector knob
The speedometer indicates vehicle speed in km/h. The
odometer records the total distance the vehicle has
been driven. The 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 selector knob for a little while (about 3
seconds) to reset the trip meter to zero.

Mahindra THAR

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Indications of Warning Lamps

11

1

11

Check Engine Malfunction

22

2

22

33

3

33

44

4

44

1. Check Engine Malfunction MIL : 1. Check Engine Malfunction MIL :

1. Check Engine Malfunction MIL : When the lamp lights up

1. Check Engine Malfunction MIL : 1. Check Engine Malfunction MIL :
and glows continuously indicates Engine Fault (other than EMS).
Arrange for checking at the nearest Mahindra Authorised Dealer
immediately.

2. Rear Fog Indicator :2. Rear Fog Indicator :

2. Rear Fog Indicator : The lamp will glow when the rear fog

2. Rear Fog Indicator :2. Rear Fog Indicator :
lamps are ON.

3. Headlight High Beam Indication:3. Headlight High Beam Indication:

3. Headlight High Beam Indication: Is illuminated when

3. Headlight High Beam Indication:3. Headlight High Beam Indication:
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 : Lights up when the ignition

4. Battery Charging Warning Light :4. Battery Charging Warning Light :
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 indicates that the battery is not being charged or malfunction
of alternator. In this case, park the vehicle safely at road side
and check the drive belt for looseness / breakage. If drive belt
is okay, switch off all unnecessary electrical equipment and
contact a Mahindra Authorised Dealer immediately.

Note :Note :

Note :

Note :Note :
Do not continue driving if the engine drive belt is broken or
loose. This will cause engine overheat & poor braking.

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Mahindra THAR

Indications of Warning Lamps

55

5

55

66

6

66

)

(

)

i(

P

5. Low Engine Oil Pressure Warning Light :5. Low Engine Oil Pressure Warning Light :

5. Low Engine Oil Pressure Warning Light : Lights up when the

5. Low Engine Oil Pressure Warning Light :5. Low Engine Oil Pressure Warning Light :
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, or comes ON while driving, stop immediately, and check
the engine oil level. If low, add engine oil to the MAX level and
check the light again. If still ON contact Mahindra Authorised
Dealer Immediately.
Note :Note :

Note :

Note :Note :
Do not run the engine with low engine oil pressure warning
light ON. Otherwise it may damage the engine.

66

. Parking Brake ON & Low Brake Fluid Warning Lamp : . Parking Brake ON & Low Brake Fluid Warning Lamp :

6

. Parking Brake ON & Low Brake Fluid Warning Lamp : The

66

. Parking Brake ON & Low Brake Fluid Warning Lamp : . Parking Brake ON & Low Brake Fluid Warning Lamp :

PP

P

PP

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 brake, there may

II

I

II

be problem with the vehicle braking system.
Warning :Warning :

Warning :

Warning :Warning :

II

I

Do not drive the vehicle if the light is illuminated even after
releasing the hand brake or if it illuminates while driving. Add
brake fluid to bring the level up to the ‘MAX’ mark. If the problem
still persists, avoid driving and have Mahindra Authorised Dealer
check/correct the braking system as soon as possible.

II

II

I

II

Mahindra THAR

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Indications of Warning Lamps

77

7

77

88

8

88

Water in Fuel Indication

7. Engine Coolant Temperature Gauge : 7. Engine Coolant Temperature Gauge :

7. Engine Coolant Temperature Gauge : Indicates the

7. Engine Coolant Temperature Gauge : 7. Engine Coolant Temperature Gauge :
temperature of the engine’s coolant. At normal operating
temperature 6 bars will be showing in LCD bar graph. High
temperature LED will glow when the temperature reaches 110°C
along with 7 bars blinking with buzzer. In such a condition, switch
off the AC and observe. If still the problem persists, pull over
the Vehicle, switch OFF ignition and contact the nearest Mahindra
Authorized 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 : when water accumulated in Fuel

8. Water in Fuel Indication : 8. Water in Fuel Indication :
Filter reaches the maximum permissible limit, the indicator gives
warning to remove water and clean the fuel filter. (Instruction
for how to drain the water is given in the Self Maintenance
Section (Page no.41) or contact a Mahindra Authorised Dealer.)

CAUTION :CAUTION :

CAUTION :

CAUTION :CAUTION :
Continued driving with water accumulation in the fuel filter will
cause damage to the fuel pump/other fuel system components.

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Mahindra THAR