OWNER'S MANUAL

Mahindra THAR

ISSUED : SEPTEMBER 2009

 Foreword

Thank you for buying a MAHINDRA vehicle. We trust Every reasonable effort has been made to ensure that
it meets your expectations & will provide you with years this booklet is accurate / up to date. The procedures,
of enjoyable motoring. This OWNER'S MANUAL has been specifications, dimensions referred to are subject to
prepared for the reference of the Owner & it is hoped change in accordance with the Company's policy of
that this will enable him to acquire working knowledge constant product improvements.
of MAHINDRA THAR
Please contact nearest Authorized Service Dealer,for
Contents include vehicle specifications, driving notes & periodical vehicle maintenance & repairs.
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.

(2) Mahindra THAR

 Contents

Information to owner Do's & Don'ts

z Manufacturer's Warranty
Maintenance Procedure
z Scope of Warranty z Vehicle Maintenance when Out of Use
z Engine & Vehicle Specifications z Engine
z Clutch
Identification of Serial Numbers z Steering System
z Chassis z Tyres
z Engine z Electrical Equipments
z Vehicle
Service Data
Instrument Panel & Controls z Recommended lubricants
z Bulb Specification
Guidelines on Driving z Maintenance Schedule
z Hints to Driver
z Safety First
z Gear Changing
z Driving Techniques in 4-Wheel Drive
Guidelines on Emission

Mahindra THAR (3)

 Manufacturer’s Warranty
MAHINDRA & MAHINDRA LTD, INTERNATIONAL For the purpose of this warranty,the term ‘ Product ’means
OPERATIONS,MAHINDRA TOWRES, 2ND FLOOR, and includes only new vehicles manufactured by the
AUTOMOTIVE SECTOR, WORLI,MUMBAI 400089, INDIA company and / or sold by the Company’s Authorised
warrants to retail purchaser of the Motor Vehicle Dealers.
branded as ‘ MahindraTHAR ‘(hereinafter referred to
as ‘vehicle’) to be free from defects in material and This warranty is limited to the delivery to the purchaser,
workmanship under normal use as instructed in t he at the Authorised Dealer’s workshop or at any other place
Owner’s Manual & Service, under the warranty, at the discretion of the company,of the part orparts
Company’s Authorised dealer will repair or replace any whether new or repaired, in exchange for those
part thereof, including all equipments or trade limited acknowledged by the Dealer to be defective and endorsed
to trade accessories (except those governed by by the company to that effect. The parts so repaired or
special warranty policy stipulated by respective replaced shall also be warranteed for quality and
manufacturers, like tyres and batteries etc.) workmanship but such warranty shall be co-terminus with
originally supplied by us subject to all other terms this warranty.
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.

(4) Mahindra THAR

 Manufacturer’s Warranty
This warranty shall not apply to and Company shall in no way a) The purchaser shall take Pre-Delivery Inspection,
be liable for any vehicle which shall have been repaired outside
and Authorised Company’s Service Station or which has been b) All the paid services are mandatory to be carried out as
altered or modified or built upon in any way or which has per the stipulated maintenance period Kilometers /
been subjected to misuse, negligence or accident. month in service till the full completion of the warranty
period at any of Mahindra authorised service outlets to
This Warranty is in lieu of all other Warranties express or avail the warranty benefits.
implied, and no person, agent or representative of the
Company is authorised to give any other warranties on the c) Repairs or replacements will be performed by the
Company’s behalf or to assume for it any other liability in Authorised Dealer of the Company, subject to the
connection, with the vehicle. reporting of the vehicle to the nearest Authorised
Dealer’s workshop.
The Company’s responsibility is limited to the terms of this
Warranty and it shall not be answerable for personal injuries d) We further reserve the right, at anytime or times, without
or consequential or resulting liability, damage or loss arising notice, or revise, modify, discontinue or change any of
from any defects. the models of our vehicles or any party thereof and
neither company nor the seller with incurr any liability
The Company’s Liability under this Warranty is dependent or obligations to the purchaser by reasons or any
upon the strict observance by the Purchaser, of the following revisions, modifications, discontinuation or changes.
provisions :
Mahindra THAR (5)
 Manufacturer’s Warranty
e) The Purchaser shall at all times in the operation of vehicle
use only those brands of lubricating oils, lubricants or i) The Vehicle is not operated / used as per the
fuel, as recommended by the Company, recommendation in the Owner’s Manual or;
ii) The Vehicle is subjected to accidents, or theft or fire;
f) The judgement of the Company or its Auhtoirsed Dealers iii) The Vehicle is subjected to abnormal use such as racing,
in all cases of claims shall be final and conclusive and rallying or participation in any other sports competitions.
the purchaser agrees to accept its decision on all iv) Any modification are carried out.
questions as to defects and to the exchange of part of
parts. The replaced parts shall be the property of the b) Appearance Items :
Company. Any slight imperfections in paint, chrome and trim and
other decorative parts, deterioration of exterior item,
g) Claims arising from this Warranty will be recognised only trim and other decorative part due to normal exposure
if they are ascertained / confirmed by the Authorised Dealer or use is not covered under the terms of Warranty.
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.

(6) Mahindra THAR

 Manufacturer’s Warranty
c) Door and windshield glass breakage and fused bulbs 1. Tyres
are not covered under Warranty. 2. Fuel Injection Pump
3. Battery
d) Normal Maintenance Service Replacement Items :
Filters, Brake or clutch innings, wiper blades, Belts,
f) Company makes on Warranty nor assume any liability in
Cables, Spring Bushings, U-Joints Cross, Water Pump
respect of any defect in metal or other material in any part,
Kits, Tie Rod Ends, Bell-crank Kit, Hoses, Kits and Bulbs,
device of trade accessories which would not have been
Spark plugs, Condenser. Please note that this list is
discovered by ordinary factory inspection.
neither exclusive nor exhaustive and the decision of
the Company shall be final in this regard. g) Repairs required due to following reasons :
e) Property Items :
i) Due to unauthorised modifications of the vehicle which in
The following are propriety items and warranty is
any way affects the stability or reliability of the components
provided by the respective Manufacturers under their
warranty terms. Any complaint on the following items, of the basic vehicle.
are to be referred to the respective manufacturers of
these items / or their authorised local agents for ii) Continued usage in spite of awareness of defects of the
warranty claim / repairs / replacements. In case of components of the basic vehicle.
difficulty Company’s dealer will assist purchaser to
conclude the complaint satisfactorily. Their decision iii) Excess / heavy load beyond the carrying capacity of
will be final on warranty. the vehicle affecting the basic structure of the Vehicle.

Mahindra THAR (7)

Engine Specification
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
NEF CRDE 2.49L ENGINE Max Power - 79KW± 2 % @ 3800 RPM
Max Torque - 247Nm ± 4 % @ 1800-2200 RPM
Weight of the engine - 287 ±2 Kg with flywheel

Mahindra THAR (8)

 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
DRIVE LINE
Wheel base (WB) 2426
Overall length (OL) 3920 ITEM
Overall Height (OH) 1928
Tread - Front (T) 1445 Transmission NGT 530R,V4 GEAR RATIO
Tread - Rear (R) 1336 1st 3.78 : 1
Ground Clearance (G) 200 2nd 2.09 : 1
Overhang Front (OF) 580 3rd 1.38 : 1
Overhang Rear (OR) 930 4th 1.00 : 1
Approach Angle (AA) 46 0 5th 0.79 : 1
Departure Angle (DA) 30 0 Reverse 3.52 : 1
Overall Width (OW) 1765 Transfer Gear ratio : High 1:1
Note : Specification subject to change without prior notice. Low 2.48 : 1
Axle ratio 4.30 : 1

Mahindra THAR (9)

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 )

Mahindra THAR (10)

Identification of Serial Numbers
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
MAI-2kk-bx-45596 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 (11)

 Instruments
INSTRUMENTS IN CLUSTER
1 . Speedometer
This indicates the speed at which the vehicle is
driven in km/hr.
2 . Odometer
The odometer indicates cumulative kilometers
covered by the vehicle.
3 . Tripmeter & 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 . Fuel Gauge
Indicates the approximate level of fuel in the tank.
It indicates at E-Empty; 1/2 - Half, F - Full.
INSTRUMENTS 5 . Temperature Gauge
1 . Speedometer
It indicates the operating temperature of the engine
2 . Odometer
3 . Tripmeter/reset knob
in 0C so that you may guard against overheating.
4 . Fuel Gauge 6 . Tachometer
5 . Temperature Gauge It indicates the engine speed in thousands of
6 . Tachometer revolutions per minute.
Note : Do not over rev the engine. Operating the
engine at high RPM may cause severe engine
damage.
(12) Mahindra THAR
 Instruments
1 . Odometer/Trip meter selector knob
ODO TRIP A
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
TRIP B
stops.
When the ignition switch is turned to ‘ON’ the display
shows the odometer or trip meter. The display shows
TRIP A TRIP B 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
About 3 seconds
(A and B) independently.
.
Push the selector knob for a little while (about 3
seconds) to reset the trip meter to zero.

(13)
Mahindra THAR
 Indications of Warning Lamps

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

1
and glows continuously indicates Engine Fault (other than EMS).
Arrange for checking at the nearest Mahindra Authorised Dealer
immediately.
Check Engine Malfunction 2. Rear Fog Indicator : The lamp will glow when the rear fog
lamps are ON.
2 3. Headlight High Beam Indication: Is illuminated when
headlights high beam is ON or when headlight flash-to-pass is
used.
4. Battery Charging Warning Light : Lights up when the ignition
switch is in the IGN position. Goes OFF as soon as the engine
3 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.
4
Note :
Do not continue driving if the engine drive belt is broken or
loose. This will cause engine overheat & poor braking.

(14) Mahindra THAR

Indications of Warning Lamps
5. Low Engine Oil Pressure Warning Light : Lights up when the
ignition switch is in the IGN position, Goes OFF as soon as the
5
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 :
Do not run the engine with low engine oil pressure warning
light ON. Otherwise it may damage the engine.
6 . Parking Brake ON & Low Brake Fluid Warning Lamp : The
6 P parking light and, the low brake fluid warning I light, are
illuminated as long as the parking brake is applied. If light

( i )( P ) I does not go off after releasing the parking brake, there may
be problem with the vehicle braking system.
Warning :
Do not drive the vehicle if the I 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.

Mahindra THAR (15)

Indications of Warning Lamps
7. Engine Coolant Temperature Gauge : Indicates the
temperature of the engine’s coolant. At normal operating
7 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 :
Do not continue driving with an overheated engine. It may
8 cause damage to the engine.
8. Water in Fuel Indication : when water accumulated in Fuel
Filter reaches the maximum permissible limit, the indicator gives
warning to remove water and clean the fuel filter. (Instruction
Water in Fuel Indication
for how to drain the water is given in the Self Maintenance
Section (Page no.41) or contact a Mahindra Authorised Dealer.)
CAUTION :
Continued driving with water accumulation in the fuel filter will
cause damage to the fuel pump/other fuel system components.

(16) Mahindra THAR

Instruments (With Digital Cluster)
9 9. Seat Belt Warning : The light reminds to fasten seat belts &
it will light up when the driver has not worn the seat belt with
the ignition key is IGN position/when vehicle is in motion. The
lamp will remain illuminated until the seat belt is fastened
properly.

10. Check EMS (Engine Management System) Warning Lamp

10 : As soon as the ignition key is switched ON, the lamp lights up
and goes OFF in few seconds indicating normal status. The lamp
will blink / glow continuously indicating the presence of fault in
EMS. The vehicle needs attention by Mahindra Authorised Dealer
immediately.

11. Turn Indicator : Flashes when the indicator lamps are

11 operated or hazard switch is turned on. A sudden increase in
the rate of flashing may indicate failure of one or more of the
indicator bulbs.
Left Turn I ndicator Right Turn I ndicator
12. Glow Plug Indicator : When ‘ON’ indicates that pre - heating
is on.It goes out when the glow plug is warm.Do not crank the
12
engine when the glow plug is ‘ON’ , to avoid excessive load on
battery and ensureeffective starting.

Mahindra THAR (17)

 Controls
Heater Controls :
1&2
1. Heater Switch :
The knob is turned clockwise, the heater comes ‘ON’.

2. Blower Switch :
Heater Blower Air flow can be controlled in three stages - low, medium,
Switch Switch high.

3. Lock & Unlock the Steering Wheel :

3
To lock :
Remove the key at the ‘Lock’ position. Turn the steering
wheel until it is locked.
To unlock :
Turn the key to the "ACC" position while moving the
steering wheel slightly.
Steering Lock

(18) Mahindra THAR

Controls

Bonnet locking / unlocking :

To Open :
Pull the release lever located below the instrument
panel on right side for RHD vehicle and on left side
for LHD vehicle. Then pull open the lever below the
bonnet and open the bonnet.
Lever To Close :
Just drop the bonnet gently and press it, if required.
Opening and Closing the Bonnet :
1. Ensure that the vehicle is in neutral gear and set
the parking brake. Pull the bonnet release lever to
position B from A and release which is located under
extreme LH /RH corners ( LH for LHD models &
RH for RHD models ) of the instrument panel. This
will release the bonnet lock and bonnet will pop
up slightly.
2. Stand in front of the vehicle, lift the additional lock
lever located under the bonnet centre with a finger
and lift the bonnet up.
Caution :
Make sure that the bonnet is fully closed and locked
before driving.

Mahindra THAR (19)

 Controls

Air Ventillation Louvers

Side Ventilation Louver Central Ventilation Louver

z Centre & side vents
The airflow volume can be adjusted
with the rotary controls at the sides.
The air vanes can be adjusted
horizontally & vertically by swivelling
the vents up / down or sideways.

Rotary Control for For up/down or

volume control sideways air flow.

(20) Mahindra THAR

Steering Column Controls - Combination Switch

Mahindra THAR (21)

Other Features
1 1. Internal Rear View mirror : Adjust the rear view mirror,
in the day position, by slightly turning or twisting it untill
you see the road behind clearly through the rear glass.
z Caution: Do not adjust the mirror while the vehicle is
moving. If doing so may cause the driver to mishandle
the vehicle and may result in loss of vehicle control.
2. Glove Box : Glove box is provided in instrument panel.
2 It can be kept unlocked condition & can be opened by
pressing the side knobs provided on lock.
3. Sun-visors : Sun-visors protect the eyes from bright light.
They can be lowered, released from the retention clips
and swivelled sideways towards the door.
z Smoking in the Vehicle : Avoid smoking inside the
vehicle. Smoking in the vehicle spoils the ambience and
the interiors of the vehicle.
z Do not toss a cigarette out of the window. It may land
3
on somebody or may result in a fire hazard. Ashtrays have
been provided both in the front and the back for disposing
ash and cigarette butts.
z Take care not to drop the cigarette on the seats. It may
burn holes in the upholstery.

(22) Mahindra THAR

 Guidelines on Driving

Take the following friendly notes as a guideline for driving z Be aware of the maintenance needs of the vehicle.
& enjoy the journey. Every normal precautions should be z Do not operate starter for more than 15 seconds at a
observed during driving the vehicle. time (give some time lapse before trying again).
z Filling the diesel tank at the end of each day will reduce
Hints to driver water condensation in the tank.
z Ensure oil, collant, fuel, fluid levels and carry out other
z Avoid clutch pedal ride as it leads, to premature wear
daily checks (e.g. tyre pressures, bulbs) of clutch plates & consequently clutch slips.
z Make sure that hand brake lever is moved to OFF position
z While washing, ensure water does not enter in to air
before moving. cleaner or electrical parts.
z After completing the "running - in" (approx. 1000 kms),
z Familiarise with the hand tools.
operate in uniform speed as much as possible for getting z Familiarise with legal requirements governing the use of
improved fuel KMPL & to prevent potential failures. your vehicle.
z From time to time keep an eye on the gauges. If any
abnormality is noticed, stop the vehicle for safety &
check.
z Frequent eye on the dash board is essential to monitor
the functioning of various systems.
z While parking in down gradient, engage the gear shift
lever in reverse position with hand brake on.
z Do not add cold water to the hot engine (leads to crack
in engine components).

Mahindra THAR (23)

 Guidelines on Driving
stopping. Not doing so may lead to premature failure of
Starting & stopping engine the turbo-charger bearing.
Starting the Engine
z Apply the parking brake fully.
Starting in Cold Weather or at High Altitudes
To start the engine in cold conditions
z Insert the key into the ignition switch and turn it into the z Turn off all accessories to reduce drain on the battery
IGN position. z Push the accelerator pedal halfway to the floor and hold
z If the vehicle is equipped with glow plug, wait for preheat it there while starting the engine
glow plug light in the instrument cluster to go OFF, during z Do not crank the engine for more than 10 seconds at
cold start. The engine may be started without waiting for a time. When the engine starts, release the accelerator
preheat if the engine is warm. pedal gradually as the engine speeds up and smoothes
Ensure the gear lever is in neutral position. out
Crank the engine by turning the key to START position till z If the engine still fails to start, push the accelerator to
the engine starts. If the engine does not start in the first the floor and hold it there while you crank the engine.
attempt, wait for few seconds and try again. Do this for not more than 10 seconds at a time.
z Let the engine run for at least 10 second before releasing If you haven’t driven the vehicle for several days, or if the
the parking brake. climate is cold, warm up the engine by idling it for a few
z Start driving minutes before driving.
Warning : Release the key immediately after the engine Stopping the Engine
starts; otherwise this may cause serious damage to the Bring the vehicle to a stop and allow the engine to idle. Turn
starter assembly. the key to OFF position.
Caution
Warning : Your vehicle is equipped with a turbo-charger.
Abruptly stopping the engine after a long journey may damage
Idle the engine for a minute after starting and before
the engine. Idle the engine for some time before switching
it OFF.
(24)
Mahindra THAR
 Guidelines on Driving
Instructions for Driving in the Running :
You can assure that your vehicle’s reliability and performance

1,000
by paying extra attention to how you drive during the first
1,000 km. (600 miles).
Follow these instructions during this period.
z After starting the engine, do not rev it up; Warm up

km.
gradually at idling speed.
z Do not drive over 60 km./hr.
z Avoid sudden acceleration and full throttle
z Do not drive for a long time at a single speed; Either
increase or decrease the speed at intervals.
z Do not drive slowly with the transmission in high gear
z Avoid hard braking; New brakes need to be broken-in by
moderate use for the first 300 km. (200 miles)
These recommendations should be followed when the engine
is overhauled or when the brake pads / linings are replaced.

Mahindra THAR (25)

 Gear Shifting

z Vehicle is fitted with 5 speed synchromesh gear box NOTE :

& standard transfer case (in case of 4WD) 5 Speed transmission & Transfer case require separate
z On these vehicle, the gear positions are marked on the lubrication for each unit as they have no cross over oil
gear lever knob. passage. At each Transmission service check, the filler
5 Speed Transmission with Transfer Case plugs of transmission & transfer case should be removed
It gives a choice of 15 forward & 3 reverse power & the lubricant refilled to level if necessary.
comibinations with the addition of standard transfer case.

SHIFTING PATTERN
TRANSMISSION TRANSFER CASE
(Single lever)
(Manual)
1 3
5
2 WDH

N 4 WDH

N
R 4 WDL
2 4

(26)
Mahindra THAR
 Gear Shifting - 4 WD
Mud, Snow & Sand & only the brakes holding the vehicle. By shifting to reverse,
Shift to 4WDH range first gear when traversing without load. it is possible to start the engine without depressing clutch.
Do not shift into any lower gear than is necessary to maintain Let the vehicle move backward with the starter. When engine
headway. Tyre pressure may be reduced by about 0.7 kg/ starts, control the downward speed with the accelerator.
cm2 (10 psi), if additional floatation is required. Down hill
Up hill Shift to 4WD range, first gear. Do not use clutch & brakes.
Shift to 4WDL range, second gear. Drop down to first gear Now the vehicle can proceed safely down a grade slowly with
only when the steepness of the ascent requires the lower gear all 4 wheels turning against engine compression.
to maintain headway. Caution
z As soon as the vehicle finishes, its traversing through the
Note
Over-reving the engine will cause the wheels to start spinning hubs in sand, mud or water, clean the brake drums from
& traction will be lost. foreign abrasive materials sticking to it to avoid the
Getting over the Hump wearing of brake linings.
z When negotiating across slopes or hill, choose as mild
If the wheels start to slip with only a few feet of the ascent
remaining, headway may be maintained by swinging the front an angle as possible (keep moving & make turns quickly).
wheels sharply left & right. This will provide a fresh 'bite' into Do not travel diagonally across a hill unless absolutely
the surface & will usually result in enough traction to necessary.
z For normal driving on hard surfaced roads, 4WD should
complete the climb.
Stall not be used.
z To relieve the build up of torsional stresses, due to
If the vehicle stalls or loses headway when climbing a
steephill, make a fast shift to reverse or first gear. Do not prolonged use of 4WD on hard surface roads, simply drive
depress the clutch. Engine compression will hold the vehicle the vehicle in reverse for several feet or drive off hard
on the hill. Do not try to back down with the clutch released surface momentary to allow tyres to slip.

Mahindra THAR (27)

Driving Tips
Driving in Wet Weather / Snowy Conditions
Wet weather or snow can be dangerous for driving. The
following tips tell you how to avoid accidents in such
conditions :
z Drive slowly : Low driving speed increases the surface
of tyre tread in contact with the road and provides better
traction.
z Maintain safe distances from other vehicles : Wet weather
results in longer stopping (about four times that of
normal stopping distance). So, it make sense to keep a
good distance from other vehicles, people and objects
on you path.
z Maintain tyres : Tyres do not provide adequate traction
once the tread wears below two thirds of the tread depth.
Check tyres regularly and replace them atappropriate
intervals.. Maintain the recommended tyre pressure in the
tyres at all times.
z While braking, accelerating or turning, avoid jerky and
abrupt movements
Apply smooth, even pressure on all controls. Abrupt steering
wheel movements or sudden, hard application of brakes can
cause loss of control.

Mahindra THAR (28)

Driving Tips

z Exercise extra caution while driving in rain after a long

dry spell. After months of dry weather, the first rains
bring grime to the surface of the roads, making it
slippery.
z While driving on wet surfaces, downshift carefully. If the
traction is low it can lock up the drive wheels for a
moment and cause a skid.

Driving in Low Visibility

Being able to see clearly in all directions and being visible
to other drivers is important in all weather conditions. This
is more difficult in bad weather conditions.To be seen more
clearly during daylight hours, turn the headlights ON. Inspect
the windshield wipers and washers regularly. Keep the
windshield washer reservoir full. If the windshield wiper
blades start to streak the windshield or leave parts unwiped.
replace them. Use the defroster to avoid fogging or windshield
on the inside.

Mahindra THAR (29)

 Shifting Driving Modes
Manual Shifting of Driving Modes ( In vehciles with Manual 4WD Shift Lever)
TO SHIFT TRANSFER SHIFT PROCEDURE FOR ELECTRIC T / F CASE WITH AUTO LOCK - FREE - RUNNING HUBS
From 2H to 4H or l Drive in a stright line up to maximum speed of 30 km / hr
l Do not depress the clutch pedal
l Shift the lever quickly and smoothly to position 4H
From 4H to 4L or l Stop the vehicle
From 4L to 4H or l Depress the clutch pedal and shift the lever to the desired mode
From 2H to 4L or
From 4L to 4H

Caution :
Never shift lever to 4WD position if wheels are slipping. Stop
the slipping or spinning before selecting the 2wd modes.

2H Note :
Driving the vehicle in 4WD Low / High mode on dry, hard
N 4H
4L surface may cause damage to the driveline, may cause
excessive tyre wear / unnecessary noise and / or poor fuel
economy, hence not recommended.

(30) Mahindra THAR

Shifting Driving Modes
Wheel Locking Hubs (Only for 4WD vehicles)
Automatic Locking Hubs

Note :
When you shift to 4WD mode, an auidible ‘Click’ will indicate that
automatic locking hubs are engaged and therefore power is being
transmitted to the front wheels. While changing back to the 2WD
mode. the hubs need to be released.

To Release the locking hubs

Shift from 4WD to 2WD
Reverse the vehicle in a stright line for about a meter
An auidble ‘Click’ will indicate that the hubs have been released
Unlocking is necessarily required to be done to isolate front
axle & transfer case from transmission & from front wheels

Caution
If auto - lock hubs make a clattering noise when driving in 2H
mode, stop and move the vehicle about 2 to 3 meters in bacward
direction.

Note :
When engaging & disengaging, the auto-lock hubs will make a
clicking noise. It is normal.
Mahindra THAR (31)
 Shifting Driving Modes
4L - (4WD, low mode) Four wheels are driven. Use while climbing
or descending steep hills, or during hard driving in sand, mud or
deep snow. The ‘4L’ position provides maximum traction. Avoid
execessive speed when driving in ‘4L’ mode.

N- (Only for manual shift transfer case models) No wheels are

driven. Always keep the transfer lever out of the ‘N’ position.
Shift the lever quickly and smoothly when moving across the
‘N’ position with the vehicle stopped.
Transfer Case Shifting Guidelines for 4WD (4-Wheel
Drive ) Models. Need not to stop the vehicle / depress the clutch pedal, when
shiffting between 2H to 4 H and 4 H to 2 H.
2H - (2WD) in this mode only rear wheels are driven. Use
when driving under conditions same as standard 2WD
vehicles. Caution :
l Driving the vehicle in 4WD Low / High mode on dry, hard
4H - (4WD, high mode) Four wheels are driven. Use when surface may cause damage to the driveline, excessive tyre,
driving on roads where it is difficult to drive in 2H position poor fuel economy & unnessary noise, henace not
(i.e. driving at normal speeds on snow covered, icy, wet, recommended.
muddy or sandy road surfaces). Avoid excessive speeds, as
it will cause loss of traction.
l Never select the 4WD mode if wheels are slipping. Stop
the slipping or spinning before selecting the 4WD modes.

(32) Mahindra THAR

 Seat Belt
To fit the belt
The belt allows considerable freedom of body movement to
driver or passenger whilst the vehicle is going at a constant
speed & in a straight line. The belt will get locked, if there
is any rapid change in direction or speed.
Seat Belt Fitting
In order to fit the belt draw the tongue & webbing across
the body from the outboard shoulder to the inboard hip,
where the buckle is located. Push the tongue into the buckle
slot until a firm click is heard. Check the buckle for security
by tugging sharply on the webbing. To unbuckle, simply press
the release button on the buckle.
To unbuckle the belt
The retractor mechanism ensures that the correct tension &
slack in the webbing is preserved. Slack belt webbing vastly
increase the chances of injury during an accident.
Care must be taken to avoid the use of polishes, acids, oils
& chemicals on webbing & if contaminated or damaged or
after a severe vehicle impact, seat belts must be renewed.
For cleaning, soap & water can be used.

Mahindra THAR (33)

 Emission Control - Precautions

As the owner of the vehicle you are responsible for maintaining z Drive the vehicle in correct gears. Avoid
the vehicle in good condition & low emissions from the sudden accelerations & decelerations.
vehicle. z Stop the engine if the engine has to idle for longer
Here are few tips for lower emissions from your vehicle duration.
z Avoid clutch riding & check the clutch play.
z Maintain the recommended tyre pressure. Get the z Get your vehicle emission checked periodically.
tyre pressure checked perioidically. z Do not use adulterated fuel.
z Clean/replace the air filter at regular intervals. z Use genuine parts & recommended oils & lubes.
z Clean the fuel injector nozzles at recommended z Check/adjust the belt tension periodically.
intervals. z Get the tappet clearances checked as recommended
z Change the engine oil/oil filters at recommended (as indicated in maintenance schedule)
intervals. z Do not tamper with the FIP Settings & idling rpm.
z In case your vehicle is emitting excess smoke (Blue/
white / black smoke) get your vehicle checked These tips would not only reduce your vehicle emissions but
at authorized service station. also gives you better performance.
z Allow your engine to warm up after a cold start.

(34) Mahindra THAR

 Diesel Catalytic Converter Caution
z Avoid use of high sulphur diesel. Use only diesel with sulphur
A catalytic converter is an exhaust gas after-treatment device content below 500 ppm.
fitted in the exhaust system of your vehicle to reduce pollu- z Avoid frequent cold starts.
tion. It converts harmful unburned hydrocarbons and carbon z Avoid starting the engine by pushing or towing the vehicle,
monoxide into harmless carbon dioxide and water vapor. or by coasting down a hill.
Care & Maintenance to minimize the possibility of the damage z Do not switch off the engine or interrupt the ignition when
to catalytic converter the gearbox is engaged and the vehicle is in motion.
z Do not idle the vehicle for prolonged periods if idling seems
z Maintain the engine in the proper operating conditions, as rough or any other malfunctions.
per owner’s manual. z Do not run out the fuel tank totally.
z Consult a M & M Authorised Dealer at the earliest in the
z Do not switch off and on ignition while the vehicle coasts
event of irregular engine running following a cold start, misfir- down.
ing, a significant loss of vehicle derivability or other unusual z Do not park or operate the vehicle near combustible materials
malfunctions which may indicate a fault in the ignition system. like dry grass & leaves. This may lead to fire hazards.
z If necessary, drive the vehicle to the nearest outlet for a short
z Avoid driving on water flooded roads
time at low engine speed. z Do not operate the engine in confined areas like garages.
z Check for exhaust system leaks and any damages:
- Each time the vehicle is raised for an oil change.
- Whenever a change is noticed in the noise of the exhaust
system.
- Whenever the tail pipe end of the exhaust system is found
rusty.

Mahindra THAR (35)

 Do's & Dont 's
Do's 10. Disconnect alternator/battery electrical connection while
1. Use recommended lubricants only. Replace oil in engine, carrying out welding work on the vehicle. Observe correct
gear box, rear axle, steering box, master cylinder & oil polarity when connecting battery terminals.
bath air cleaner periodically as per schedule.
2. Use only genuine oil filter & fuel filter elements. Dont 's
3. In order to obtain trouble free & enhanced engine life, 1. Do not run the vehicle with leaky air pipes, fuel pipes
clean air filter element regularly. Replace filter element & water hoses.
when service indicator shows red band even after 2. Do not run the vehicle without a battery in its electrical
cleaning the filter element. circuit as the life of alternator will be reduced.
4. Ensure periodic servicing as per maintenance schedule. 3. Do not open degassing tank cap when engine is hot.
5. Insist on use of genuine Mahindra spare parts for all Never add cold water when engine is hot as this may
replacement. lead to cylinder head/block crack.
6. Allow the starter pinion to come rest before again 4. Do not keep the engine running when the pointer of
attempting to start the engine in order to avoid pinion the temperature guage is in red zone.
& flywheel ring gear damage. 5. Do not use clutch pedal as a foot rest. It will cause
7. Replace thermostat in the event of failure & ensure premature wear of clutch plate, release bearing, clutch
fitment of pressurized radiator cap to get better engine finger & also clutch, which results in less KMPL.
life. 6. Number of passengers carried should be within approved
8. Maintain correct tyre pressures as specified in chart. seating capacity.
Before moving the vehicle release the parking brake. 7. Do not race or rev the engine especially when starting,
9. Maintain electrolyte level in the battery (using distilled This is destructive to engine & will not heat the engine
water). Keep battery terminals clean & cable joints tight. quickly.
Apply Vaseline petrolium jelly on terminals.

(36) Mahindra THAR

 Maintenance Procedure

Vehicle maintenance when out of use Engine

Engine - Start & run the Engine a few minutes once in a Topping up the Engine Oil
week. Drive the vehicle a little forward & backward once The engine oil level should be maintained at little below high
a fortnight. mark on the dipstick & must never be allowed to fall below
Cooling system - Add coolant and water in the ratio the low. While checking the oil level, park the vehicle on a
indicated in section ‘Radiator’. level ground with the engine shut down. Withdraw the dipstick
Electrical - Disconnect the terminals of the battery & store from its holder, clean & refit. Withdraw again & note the level.
it separately. Smear petroleum jelly on the terminals & Top-up as required with the clean correct grade of engine oil.
recharge once in a month. Always drain & fill the oil when engine is warm.
Clutch - Press the clutch pedal to the floor board in fully Note - Start the engine, run at a fast idling speed for about
depressed position. a minute. Stop the engine & after allowing some time oil
Brakes - Operate the brake pedal a few times once a week. level to stabilize, recheck again & top-up if necessary.
Check & top-up brake fluid in master cylinder once in a z Do not mix different brands or grades of oil.
month. z Lubricating oil filter should be replaced at every
Tyres - Maintain the normal tyre pressure & check it once oil change.
in a week. Support the vehicle so that load on the tyres Use oil grade as per lubrication chart for ambient up to -
is relieved & correct the tyre pressure before the vehicle 50C. At lower temperature, use oil of lower viscocity grade.
stands on the wheel.
Body - Coat rust-proof to all bright metal. Cover up with
upholstery.

Mahindra THAR (37)

 Air Filter, Radiator & Fuel Injection System
Servicing Instructions :
z It is adviced to service air filter through Mahindra
Dealer/Service Centre.
z Periodically clean the air filter element :
Every 10,000 kms. (or 6 months) on paved road. OR
Every 5,000 kms. (or 3 months) on dusty road. OR
When service indicator shows red band.
z Replace element :
When service indicator shows red band even after
cleaning the filter element. OR
Every 40,000 kms. (or 2 years) OR
If holes or tears are found in the element.
The air filter is located on the Right Hand (RH) side of Caution :
the engine compartment. A dry type air filter is used. Air Do not operate the vehicle without air filter element.
filter service indicator (SI) is fitted on the hose between
the air filter and engine. This service indicator has to be
checked at every 5000 km. to confirm that red band does
not appear on service indicator. Whenever red band
appears, it means that the air filter element is choked up
and needs servicing. Clogged air filter leads to higher intake
resistance and can reduce the driveability of the vehicle.

(38) Mahindra THAR

 Air Filter, Radiator & Fuel Injection System

Radiator Recovery Tank :

z Use always clean water.
z Flush the radiator once in a year.
z Never pour cold water into warm engine.
z Keep the radiator area free of insects & other things that
restrict air circulation.
Note :
The cooling system should be filled with Blend of clean water
with Ethylene Glycol based coolant. The coolant also provides
anticorrosion protection if concentration 15% and above.
The recommended coolants are : BASF Glycentine or Total
Finolf - Glacelf Supra at a ratio of water : coolant of 70:30,
50:50, 30:70. For ambient temperature upto -100C, -110C to
-200C, -200C to -350C respectively. Use of alcohol as an anti-
freeze is not recommended. Use the anti-freeze when the
operating temperature falls below 00C. Caution :
Never remove the Radiator Tank cap, when the engine is
hot. (If applicable)

(39)
Mahindra THAR
 Air Filter, Radiator & Fuel Injection System
Fuel Injection System :
Fuel Injection Pump (FIP) is of a rotary type. Fuel Filter :
Make : Bosch Draining water from fuel filter-
z FIP is made out of finely machined, close tolerance The fuel filter warning light on indicates that the water from
components, & is lubricated by the diesel fuel used in the the fuel filter to be removed immediately.
engine & not by a separate oil reservoir. It is therefore of z Place a small open container / tray under the drain plug
utmost importance that water & dirt be kept out of the cum sensor to collect the water.
FIP. z Turn the drain plug cum sensor about 2 to 2.5 turns
z FIP requires neither maintenance nor lubrication check the in the anti clockwise direction.
tightness of the piping to avoid any air intake which would z Operate the priming pump until fuel begins to flow clean
cause excess consumption. and clear.
z It is recommended that FIP & injector should always be z After draining, retighten the drain plug cum sensor. Do
given to the authorised dealer for service. not use any tool. Use the priming pump to inspect for
z Check the FIP when frequent starting difficulties are leaks.
encountered & noise or black smoke is coming from the
exhaust.
Caution

z Since the fuel is the lubricant do not crank the engine for
extended periods with fuel lines disconnected or empty fuel
tank.

(40) Mahindra THAR

 Air Filter, Radiator & Fuel Injection System
Fuel Tank z Maintain a clean air-cleaner; Clogged air-cleaner
z Clean the tank at regular intervals once in a year. decreases the amount of air supplied to the engine,
resulting in incomplete combustion and thus, wastage
z Ensure that no foreign matter or water enters during of fuel.
filling the fuel tank.
z Anticipate traffic conditions; Avoid traffic congestions
z Ensure that breather system is not clogged. whenver and wherever possible. This would lead to
considerable fuel savings.
Tips for Improving Fuel Efficiency
z Follow proper driving practices; Do not rest your foot
z Maintain correct tyre pressure; Under-inflated tyres on the clutch or brake pedals unnecessarily; It doesn’t
result in increased running resistance, leading to higher allow transmission of full engine power to the wheels
fuel consumption. and causes premature wear and results in poor fuel
z Maintain proper front-wheel alignment; Improper front- economy.
wheel alignment causes tyres to wear out faster and z Follow the recommended maintenance schedule; Get
exerts more load on the engine, leading to higher fuel your vehicle checked and maintained periodically by the
consumption. Mahindra Authorised Dealer.
z Avoid driving with excess weight; Excess weight increases z Use the air-conditioner only when necessary.
load on the engine, leading to higher fuel consumption z Use only recommended grade fuel
z Avoid excessive engine idling; It is advisable to switch z Use only recommended grade oil
the engine OFF during prolonged waits at traffic signals, z Use only recommended coolant
railway crossings etc.
z Avoid fast start and unnecessary stops; Avoid sudden
acceleration or deceleration

Mahindra THAR (41)

 Steering System
z Avoid looseness in the steering system. Adjust various The procedure for filling oil in reservoir is as follows
connections including the front wheel bearings. :
z Check the wheel alignment by the use of wheel z Fill the reservoir nearly full. Crank the engine for 10
alignment device (available in most equipped shops). seconds without, if possible allowing it to start.
z Correct Toe-in for front wheels (for 4WD)- 8' to 12' z Check for any leakage in the system.
per wheel. Maintain correct alignment. z Start the engine & steer the vehicle from full left to
Power steering system full right turn (3-4 times). Add fluid if necessary to
Power steering with universal joint, reduces effort during maintain the level up to the filter top. Check & refill
steering vehicle. reservoir up to H mark on dipstick.
z System is self bleeded & does not require any bleeding
operation.
z Now the system is ready for driving.
Reservoir

Pump
Steering
Gearbox

(42) Mahindra THAR

 Routine Maintenance
z Always use recommended oil from closed container. Any
dirty oil poured in the system will result in damage to
pump/gear. FRONT REAR TYRE SIZE
z Do not start the engine without oil in the Power steering (LADEN/UNLADEN) (LADEN/UNLADEN)
system. This will result in serious damage to the pump. 2.4 Kg./cm2 2.4 Kg./cm2 P235 70R 16
z Regularly check fluid & fluid level in the power steering Radial Tyre
reservoir.
z Remove cause of steering column misalignment.
z Investigate & correct any external leaks, no matter how
minor.
SPARE
¤
z Do not attempt to weld any broken steering gear ¤ ¤
component. Use genuine component of steering only.
¤ ¤
z Keep the tyres inflated to correct pressure. VEH
FRONT ¤
TYRE ROTATION
Tyres
z Inflate the tyres as per chart.
z For getting a good tyre mileage, it is suggested to rotate
the tyres for every 10000 Kms. Check the tyre for Wheel Bearing
alignment. z Use always recommended wheel bearing grease.
z Lubricate the rear wheel bearings sparingly.
z Don't mix lithium base grease with sodium base
grease as it is harmful to oil seals.

(43)
Mahindra THAR
Recommended Lubrication Chart

API CH4

80W 90

(44) Mahindra THAR

Maintenance Schedule

(45)
Mahindra THAR
Maintenance Schedule

(46)
Mahindra THAR
 Maintenance Schedule

Mahindra THAR (47)

Maintenance Schedule

(48) Mahindra THAR

Maintenance Schedule

Mahindra THAR (49)

Record of Services Performed

Recommended Odometer Repair Servicing dealer's

Services at KM Date Reading KM Order No. Signature with stamp

PDI

5000

10000

20000

30000

40000

50000

(50) Mahindra THAR

Record of Services Performed

Recommended Odometer Repair Servicing dealer's

Services at KM Date Reading KM Order No. Signature with stamp

60000

70000

80000

90000

100000

Mahindra THAR (51)

 Spare Wheel Mounting

SPARE WHEEL MOUNTING : Jack Position

It is provided on the tail gate.
Tighten the spare wheel hanger as shown in the figure. To loosen,
rotate in the opposite direction & remove the wheel from the
hanger bracket.

Jack mounting position in

the vehicle
z Jacking position for front wheels
z Jacking position for rear wheels is
below rear axle
z Jack is kept in tool box below the
front LH Seat.

(52) Mahindra THAR

 Safety

Drinking and Driving : Don’t go together z Do not remove the filler cap from the radiator/degassing
Driving, anytime, anywhere, under the influence of alcohol or tank.
drugs is dangerous to you, to your family, the passengers and z Keep engine and surrounding area clean and free from fuel
to everyone else on the road. Alcohol or drugs reduce your and oil leakages to avoid possible fire risk.
awareness and lead to accidents.
z Play some additional support with the jack for adequate
Driving Long Distances strength.
When you are driving over long distances, follow these tips so z Park the vehicle on a level and hard ground when lifting
that you have a safe journey : vehicle.
z Never drive more than 150 kms at a time. Switch drivers z Ensure stopper is used to arrest the movement of the
even if you are not tired. vehicle.
z Lack of sleep or fatigue may impact your ability to drive z Slow down the vehicle during taking a turn and shifting the
safely gears.
z Exercise your eyes by shifting the focus of your eyes to z Always keep the wind screen clean in order to havbe a clear
different parts of the road. visibility.
z Use stimulating beverages such as coffee or tea. z Avoid applying brakes violently in slippery roads.
z Relax and stay calm. z When the brakes are wet apply brakes slightly in a slow
speed till brake performance becomes normal.
Use of Seat Belts
z In the interest of safety to the driver and passengers of all
four wheelers, wearing of seat belts at all times during the
driving is essential.
z Using a hand phone while driving constitutes nuisance or
danger to the public and hence must be avoided.

Mahindra THAR (53)