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Mahindra Thar CRDe - User Manual

Mahindra Thar CRDe
261 pages
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© 2012 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part,
without the written permission of Mahindra & Mahindra Ltd.
REPAIR MANUAL
Part 1 of 2
MAN-00190
PUBLICATION. HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT
AUTHORIZED DEALER SERVICE CENTERS.
RELEASED BY
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD.
Rev1 – MAY 2012
www.teknetmahindra.com

Questions and Answers

Mahindra Thar CRDe Specifications

General IconGeneral
BrandMahindra
ModelThar CRDe
CategoryAutomobile
LanguageEnglish

Summary

About the Repair Manual

How to Use This Manual

Safety Instructions

General Precautions

General safety guidelines for vehicle service and operation.

Vehicle Safety

Precautions to prevent damage to the vehicle during servicing.

Vehicle Specification

Vehicle Maintenance

Engine (2.6 L NEF CRDe)

Description

Detailed description of the 2.6L NEF CRDe engine components and operation.

Trouble Shooting

Common engine problems, causes, and remedial actions.

Care of the System

Maintenance recommendations for engine systems like oil, cooling, EGR.

In Car Repairs

Engine repairs performed without removing major assemblies.

Tappet setting

Procedure for adjusting engine valve tappet clearances.

Accessory Belt Tension Adjustment

Steps to check and adjust accessory drive belt tension.

Accessory Belt Remove & Refit

Procedure for removing and installing the accessory drive belt.

High Pressure Pump Removal & Refitment

Steps for removing and refitting the high-pressure fuel pump.

Oil Filter Removal & Refitting

Procedure for removing and replacing the engine oil filter.

Turbocharger Removal & Refitment

Steps for removing and refitting the turbocharger assembly.

Cylinder Head Gasket Removal & Refitment

Procedure for removing and replacing the cylinder head gasket.

Working Principle of Engine Subsystems

Explanation of subsystems like EGR and crankcase ventilation.

Dismantling & Overhauling of the Engine

Comprehensive steps for engine dismantling, inspection, and overhauling.

Removal of the Engine from the Vehicle

Detailed procedure for removing the engine from the vehicle.

Inspection

Guidelines for inspecting engine components for wear and damage.

Assembly

Procedures for reassembling engine components after overhaul.

Technical Specifications & Wear Data

Detailed technical specifications and wear limits for engine components.

Lubricants & Sealants

Recommended lubricants, sealants, and their application for engine.

Torque Specification

Torque values for various engine fasteners and components.

Special Tools

List of special tools required for engine service and repair.

Air Intake System

Description

Overview of the air intake system, including air cleaner and HFM sensor.

Trouble Shooting

Diagnostic steps for common air intake system issues.

Care of the System

Maintenance recommendations for the air intake system.

Air Filter Element - Replace

Procedure for replacing the air filter element.

In Car Repairs

Air intake system repairs performed with the vehicle on.

Air Filter Assembly - Removal

Steps to remove the air filter assembly from the vehicle.

Air Filter Service Indicator - Removal

Procedure to remove the air filter service indicator.

Clean Side Intake Hose - Removal

Steps to remove the clean side intake hose.

Dirty Side Hose - Removal

Procedure to remove the dirty side intake hose.

Intercooler Assembly

Steps for removing and installing the intercooler assembly.

Intake Manifold - Removal

Procedure for removing the intake manifold.

Exhaust Manifold - Removal

Procedure for removing the exhaust manifold.

Turbocharger Removal & Refitment

Steps for removing and refitting the turbocharger.

Working Principle, Inspection & Fitment Procedures of the Turbocharger

Explanation of turbocharger operation, inspection, and fitting.

Technical Specifications

Technical data and specifications for air intake system components.

Cooling System

Description

Overview of the cooling system, its functions and components.

Trouble Shooting

Common cooling system problems, causes, and remedies.

Care of the System

Regular maintenance activities for the cooling system.

Coolant - Replace

Procedure for draining and replacing the engine coolant.

Accessory Drive Belt - Inspect

Guidelines for inspecting the accessory drive belt condition.

Accessory Drive Belt - Replace

Procedure for replacing the accessory drive belt.

Idler & Tensioner Bearing - Inspect

Procedure for inspecting idler and tensioner bearings.

Idler & Tensioner Bearing - Replace

Procedure for replacing idler and tensioner bearings.

Water Pump Removal

Steps to remove the water pump assembly.

Radiator Removal & Re-fitment

Procedure for removing and refitting the radiator.

Dismantling & Assembly of the Cooling System

Steps for dismantling and assembling cooling system components.

Checking the VFD

Procedure to check the functionality of the Viscous Fan Drive (VFD).

Viscous Fan Drive Removal

Steps to remove the viscous fan drive assembly.

Technical Specifications

Technical data for cooling system components and fluids.

Torque Specification

Torque values for cooling system fasteners.

Fuel System

Description

Overview of the fuel system, its components, and operation.

Trouble Shooting

Common fuel system problems, causes, and remedies.

Care of the System

Maintenance recommendations for the fuel system.

Fuel Filter Element - Replace

Procedure for replacing the fuel filter element.

Fuel Tank & Strainer - Clean

Steps for cleaning the fuel tank and strainer.

Fuel Filter - Drain Water Sediments

Procedure for draining water sediments from the fuel filter.

In Car Repairs

Fuel system repairs performed with the vehicle on.

Removal of Injectors

Steps to remove the fuel injectors.

Removal of High Pressure Pump

Procedure for removing the high-pressure fuel pump.

Technical Specification

Technical data for the fuel injection system components.

Emission Control System

Description

Overview of the emission control system and its components.

Working Principle of the Exhaust Gas Recirculation

Explanation of the EGR system's operation for emission control.

Trouble Shooting

Common emission control system problems, causes, and remedies.

Care of the System

Maintenance recommendations for the emission control system.

Checking the System

Procedures for checking the emission control system components.

EGR System

Specific checks and diagnostics for the EGR system.

In Car Repairs

Emission control system repairs performed with the vehicle on.

EGR Valve and Accessories Removal

Procedure for removing EGR valve and related components.

EGR Cooler and EGR Pipe Removal

Steps to remove EGR cooler and pipe.

Technical Specification

Technical data for emission control system components.

Clutch

Description

Overview of the clutch system, its components, and operation.

Trouble Shooting

Common clutch problems, causes, and remedies.

In Car Repairs

Clutch system adjustments and repairs performed with the vehicle on.

Adjustment of Clutch Pedal Height

Procedure to adjust the clutch pedal height.

Bleeding the Clutch

Procedure for bleeding air from the clutch hydraulic system.

Clutch Actuation Mechanism

Explanation of the hydraulic clutch actuation system.

Master Cylinder Overhaul

Steps for overhauling the clutch master cylinder.

Slave Cylinder Overhaul

Procedure for overhauling the clutch slave cylinder.

Clutch Overhaul

Comprehensive steps for clutch overhaul and inspection.

Inspection

Inspection of clutch components for wear and damage.

Flywheel and Clutch System Runout & Alignment Checks

Checks for flywheel runout and clutch system alignment.

Technical Specification

Technical data for clutch components.

List of the MST

List of special tools for clutch service.

Transmission (NGT530 R)

Description

Overview of the NGT530R transmission, its features, and operation.

Trouble Shooting

Common transmission problems, causes, and remedies.

Care of the System

Maintenance recommendations for the transmission system.

Rear Oil Seal Replacement (2 WD)

Procedure for replacing the rear oil seal on a 2WD vehicle.

Gear Position; Gear Neutral Switch Check

Procedure to check gear position and neutral switches.

In Car Repairs

Transmission repairs performed with the vehicle on.

Transmission Removal

Detailed procedure for removing the transmission from the vehicle.

Transmission Case Components

Exploded view and identification of transmission case components.

Transmission Gear Components - Main Shaft Drive Gear & Synchroniser (2 WD & 4 WD)

Breakdown of main shaft gear and synchronizer components for 2WD/4WD.

Shift Control Components

Description of shift control components.

Selection Biasing

Explanation of the selection biasing mechanism in the transmission.

Shift Rail and Shift Fork Assembly - Sectional View

Sectional view and assembly of shift rail and fork.

Transmission Components Disassembly

Detailed steps for disassembling the transmission.

Transmission Components Inspection

Inspection procedures for transmission components.

Transmission Components Assembly

Steps for assembling transmission components.

Double Cone Synchronizer

Assembly procedure for the double cone synchronizer.

Technical Specification

Technical data for the transmission.

Torque Specification

Torque values for transmission fasteners.

List of Special Tools (MST)

List of special tools required for transmission service.

Transfer Case (BW)

Description

Overview of the electronic transfer case and its operation.

Description and Operation

Detailed explanation of the electronic transfer case system and modes.

4 H - Four Wheel High

Operation and use of the 4H mode for traction.

4 L - Four Wheel Low

Operation and use of the 4L mode for maximum traction.

Shifting Procedure

Instructions for shifting between transfer case modes (2H, 4H, 4L).

Shifting Between 2 H and 4 H

Guide for shifting between 2H and 4H modes.

Shifting Between 2 H, 4 H and 4 L

Guide for shifting between 4H to 4L and 4L to 4H modes.

Trouble Shooting Inspection and Verification

Procedures for inspecting and verifying transfer case concerns.

Troubleshooting Chart

Chart detailing transfer case symptoms, causes, and remedies.

In Car Repair

Transfer case repairs performed with the vehicle on.

Transfer Case Removal

Detailed procedure for removing the transfer case from the vehicle.

Inspection

Inspection of transfer case components for damage and wear.

Cleaning

Procedure for cleaning transfer case parts.

Assembly

Steps for assembling transfer case components.

Transfer Case Electric Shift Circuit Diagram

Electrical circuit diagram for the electric shift transfer case.

Self Diagnosis of ECU

Diagnostic procedures for the transfer case ECU and fault codes.

Automatic Locking Hub

Description and construction of the automatic locking hub system.

Automatic Locking Hub Installation and Disassembly

Procedures for installing and disassembling automatic locking hubs.

Technical Specification

Technical data for the transfer case and automatic locking hubs.

List of Special Tools (MST)

List of special tools required for transfer case service.

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