Vehicle Dismantling Manual Mahindra Goa Scorpio SUV 2010

Vehicle Dismantling Manual
Mahindra Goa
SUV
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
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 ............................................................................................. 8
Activity Area - Door and Glazing ............................................................................ 10
Activity Area - Exterior ............................................................................................. 14
Activity Area - Instrumental Panel .......................................................................... 19
Activity Area - Seat .................................................................................................. 21
Activity Area - Interior ............................................................................................. 25
Activity Area - Engine .............................................................................................. 28
Abbreviation ............................................................................................................. 34

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 terminal prior to fluid removal and dismantling in order to reduce risk
of fire and personal injuries.
Always wear safety goggles when working with fuel in 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.
Note: If fail to follow these cautions could cause airbag deployment or some per-
sonal 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.
• Provide free space for the airbag to expand in case of an accidental deployment.
• 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.
Goa SUV 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.
Goa SUV 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.
Goa SUV 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.
- 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 incorporated
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.
Goa SUV 4
Introduction
This manual contains the Dismantling procedures of the following vehicle.
MODEL MAKE VARIATION ENGINE TRANSMISSION
GOA Mahindra SUV m_Hawk 530 R
Goa SUV 5
Goa SUV 6
Vehicle Dismantling Manual for Mahindra Goa SUV
Goa SUV 7
Vehicles Activity Area

0.08 0.09
0.03 CLUTCH OIL
BRAKE OIL
COOLANT
0.02
BATTERY
0.01
ENGINE OIL
0.04
REFRIGERANT
0.12
REAR AXLE
OIL
0.06
TRANSFER CASE OIL
0.05 0.05
FR RH - TIRE 0.07 RR LH - TIRE
TRANSMISSION OIL
0.11 0.10
STEERING OIL 0.05
FRONT AXLE OIL
FR LH - TIRE
Goa SUV 8
Area: Pretreatment
Model: Goa SUV
S:No Part Name Material Qty Weight (kg/lit)
0.01 Engine oil Oil 6.5 lit
0.02 Battery Multiple 1 24.22 kg
Coolant 2.7 lit

0.03 Coolant Coolant
Water 7.3 lit
0.04 Refrigerant R134a 0.65 kg
0.05 Tires EPDM 5 81.0 kg
0.06 Transfer case oil Oil 1.90 lit
0.07 Transmission oil Oil 1.55 lit
0.08 Brake fluid Oil 0.65 lit
0.09 Clutch fluid Oil 0.16 lit
0.10 Steering oil Oil 0.85 lit
0.11 Front axle oil Oil 1.20 lit
0.12 Rear axle oil Oil 1.85 lit
Information and Comments

Total Volume or Weight = Weight of single part material x Quantity.
Goa SUV 9
Activity Area - Door and Glazing

1.18 RH 1.03 GLASS
GLASS
1.11 RR-RH
1.06 FR-RH GLASS
1.04 EPDM
GLASS 1.18 LH
1.16 RH
GLASS
GLASS
1.19 RH
1.11 RR-LH EPDM
GLASS
1.06 FR-LH 1.20
GLASS EPDMX
1.16 LH
1.01 GLASS GLASS
1.12 RH 1.15 RH 1.13 RH
EPDM EPDM EPDMX
1.07 RH
1.14 RH
EPDM
EPDMX
1.02 EPDM 1.19 LH
EPDM
1.15 LH
1.10 RH 1.17 RH EPDM
EPDMX EPDM
1.05 RH
EPDMX 1.14 LH
EPDMX
1.08 RH 1.13 LH
EPDMX EPDMX
1.05 LH
EPDMX 1.17 LH
1.09 RH
EPDM
EPDMX EPDMX 1.09 LH
EPDMX 1.10 LH
EPDM
EPDMX
GLASS 1.12 LH
1.08 LH 1.07 LH EPDM
EPDMX EPDM
Goa SUV 10
Area: Door and Glazing

Model: Goa SUV
S:No Part Name Material Qty Weight Removal Tooling
Cut out the bond surface area of

the assembly glass wind shield
from the vehicle. Power hacksaw with thin
Assembly glass
1.01 1 11.3 kg blade and Wind shield hold-
windshield Note: Hold the wind shield glass ing device (Suction cups)
assembly by the glass holder
(Suction cups).
Flip seal wind Draw off the windshield glass flip

1.02 EPDM 1 0.27 kg Manually
shield glass seal.
Cut out the bond surface area of
the assembly glass back window
Assembly glass wind shield from the vehicle. Power hacksaw with thin
1.03 back door win- Glass 1 6.58 kg blade and Wind shield hold-
dow windshield Note: Hold the wind shield glass ing device (Suction cups)
assembly by the glass holder
(Suction cups).
Seal back
Draw off the back door window
1.04 door window EPDM 1 0.66 kg Manually
windshield glass flip seal.
glass
Weather strip Remove the weather strip hold-

1.05 front door EPDMX 2 2.62 kg ing plate mounting screws (M4 - 9” Star headed screw driver
opening inner 3nos).
Remove the door inner trims and

Glass front 10mm Socket, Ratchet with
1.06 Glass 2 5.06 kg the glass mounting bolts (M6 -
door Window 4” extension
2nos) from the window regulator.
Glass
Goa SUV 11
Seal front door Draw off the front window glass

window glass seal.
Weather strip
Draw off the weather strip from 12” Thin bladed screw driv-
1.08 front door waist EPDMX 2 0.34 kg
the door. er
outer
Weather strip
1.09 front door waist EPDMX 2 0.36 kg
the door. er
inner
Weather strip Remove the weather strip hold-
1.10 rear door open- EPDMX 2 2.45 kg ing plate mounting screws (M4 - 9” Star headed screw driver
ing inner 3nos).
Glass clear Remove the door inner trims and

10mm Socket, Ratchet with
1.11 rear door Win- Glass 2 4.78 kg the glass mounting bolts (M6 -
4” extension
dow 2nos) from the window regulator.
Seal rear door Draw off the front window glass

window glass seal.
Weather strip
1.13 rear door waist EPDMX 2 0.32 kg
the door. er
outer
Weather strip
1.14 rear door waist EPDMX 2 0.27 kg
the door. er
inner
Seal rear door

Draw off the seal from the rear
1.15 window glass PVC 2 1.18 kg Manually
door window glass
fix
Goa SUV 12
Draw off the rear door glass fix.

Glass rear door
1.16 Glass 2 1.42 kg After removal of the front door Manually
fix
window glass seal
Dog leg seal Draw off the weather strip from

rear door the ring panel.
Remove the rear glass window

Glass rear door
1.18 Glass 2 4.98 kg mounting special screws (M6- 9” Star headed screw driver
window
3nos).
Seal door win-
1.19 EPDM 2 1.68 kg Draw off the seal glass door seal. Manually
dow glass
Weather strip
Draw off the back door inner
1.20 back door EPDMX 1 1.57 kg Manually
weather strip.
opening inner

Goa SUV 13
Activity Area - Exterior

2.20 RH 2.26 ABS
2.29 RH ABSX
PP
2.27 RR RH
2.21 RH ABS
ABSX 2.27 RR LH
2.13 RH
TPO 2.27 FR RH ABS
ABS
2.12 RH 2.27 FR LH
2.19 RH NR 2.24 RH 2.20 LH
PPX ABS
2.11 RH PPX ABSX
PPX 2.17 RH
2.10 RH 2.18 RH PP 2.28 RH
TPO TPO 2.28 LH
MULTIPLE
2.16 RH MULTIPLE
2.15 RH PP 2.21 LH
TPO 2.25 NR
2.14 RH PP ABSX
2.07 RH ABSX
2.23 PP
2.09 RH 2.29 LH
PP PP 2.24 LH
2.22 PPX PPX
2.08 RH NR
2.04 RH 2.19 LH NR
MULTIPLE 2.06 TPO 2.07 LH 2.13 LH
ABSX TPO
ABS
2.12 LH
NR
2.03 RH 2.04 LH 2.09 LH PPX 2.17 LH
ABSX MULTIPLE 2.02 PPX MULTIPLE PP PP
2.18 LH
TPO
TPO
PURX 2.16 LH
PP 2.08 LH NR TPO
2.11 LH
2.05 PPX 2.15 LH PP
MULTIPLY 2.01 2.10 LH
PURX PPTX 2.03 LH
TPO
MULTIPLE 2.14 LH PP
PPX
MULTIPLE
Goa SUV 14
Area: Exterior
Model: Goa SUV
Fascia front Remove the front fascia bumper 14mm Socket, Ratchet and
2.01 PPTX 1 3.85 kg
bumper mounting nuts (M10-4nos). 6” extension
Assembly front Remove the front applique’s 9” Star headed Screw

2.02 PPX 1 1.86 kg
applique mounting screw (M6-7nos). driver
Remove the fog lamp mounting

Fog lamp As- 9” Star headed Screw
2.03 Multiple 2 1.04 kg screw (M4-3nos) and disconnect
sembly driver
the fog lamp harness connection.
Remove the front head lamp

Head lamp as- assembly mounting bolts (M6- 10mm Socket, Ratchet
2.04 Multiple 2 4.01 kg
sembly 3nos) and disconnect the front with 4” extension
lamp harness connection.
Assembly seal
Remove the seal condenser bot- 13mm Socket, Ratchet
2.05 condenser bot- PURX 1 0.53 kg
tom mounting bolts (M8-2nos). with 8” extension
tom
Remove the wiper mounting nut
8mm Socket, Ratchet and
Plenum appli- (M8-2nos) and plenum applique
2.06 TPO 1 0.97 kg 9” Star headed screw
que assembly assembly mounting screw (M3-
driver
6nos).
Assembly side 12” Thin bladed screw

2.07 ABSX 2 0.05 kg Snap fit
marker lamp driver
Apron rubber Remove the plastic fasteners 12” Thin bladed screw
2.08 NR 2 0.99 kg
front wheel (5nos). driver
Goa SUV 15
Remove the Splash shield mount- 10mm Socket, Ratchet and

Splash shield
2.09 PP 2 1.88 kg ing bolts (M6-2nos) and plastic 12” Thin bladed screw
front
fasteners (6nos). driver
Assembly Remove the wheel arch front trim

2.10 wheel arch TPO 2 1.71 kg assembly, by releasing its snap Manually
front trim fits.
Remove the front door outer trim

Assembly front
2.11 PPX 2 2.28 kg assembly, by releasing its snap Manually
door outer trim
fits.
Remove the rear door outer trim
Assembly rear
2.12 PPX 2 2.11kg assembly, by releasing its snap Manually
door outer trim
fits.
Remove the rear quarter trim

Assembly rear
2.13 TPO 2 1.45 kg assembly, by releasing its snap Manually
quarter trim
fits.
8mm Socket, Ratchet, 9”

Assembly front Remove the front end cap it mud
Thin bladed screw driver
2.14 end cap with PP 2 0.71 kg guard assembly mounting screws
and 6” Star headed screw
mud guard (M3-3nos).
driver
8mm Socket, Ratchet, 9”

Remove the running board rear
Assembly rear Thin bladed screw driver
2.15 PP 2 0.33 kg styled mud flap of end cap assem-
cap and 6” Star headed screw
bly mounting screws (M3-3nos).
driver
Rear styled Remove the rear styled mud flap 10mm Socket, Ratchet
2.16 TPO 2 0.47 kg
mud flap mounting bolts (M6-2nos). with 4” extension
Goa SUV 16
Remove the rear wheel splash

Assembly rear 10mm Socket, Ratchet and
shield assembly mounting bolts
2.17 wheel splash PP 2 0.54 kg 12” Thin bladed screw
(M6-2nos) and plastic fasteners
shield driver
(3nos).
Remove the rear wheel splash

Rear wheel 10mm Socket, Ratchet and
shield front assembly mounting
2.18 splash shield PO 2 0.47 kg 12” Thin bladed screw
bolts (M6-2nos) and plastic fasten-
front driver
ers (2nos).
Remove the rear wheel rubber

Rear wheel 12” Thin bladed screw
2.19 NR 2 0.45 kg apron mounting plastic fasteners
rubber apron driver
(5nos).
Remove the tail lamp and tail lamp 12” Star headed screw
2.20 Tail lamp upper ABSX 2 1.07 kg
upper mounting screws (M6-2nos). driver
Remove the tail lamp lower assem- 10mm Socket, Ratchet

2.21 Tail lamp lower ABSX 2 2.40 kg
bly mounting nuts (M6-3nos). with 4” extension
Remove the rear bumper facial
assembly completely and remove
Rear bumper 12” Star headed screw
the rear bumper facial assembly
2.22 facia assembly PPX 1 1.50 kg driver and 12” Thin bladed
reinforcement mounting screws
reinforcement screw driver
(M6-3nos) and plastic fasteners
(3nos).
Remove the rear bumper facial

Rear bumper
2.23 PP 1 1.54 kg assembly mounting nuts (M12- 16mm Socket and Ratchet
fascia assembly
2nos).
Goa SUV 17

Reinforcement Remove the rear bumper reinforce- 12” Thin bladed screw
2.24 rear bumper PPX 2 0.49 kg
ment mounting fasteners (4nos). driver
end cap
Rubber mat
2.25 NR 1 0.22 kg Snap fit Manually
rear bumper
Remove the rear spoiler assembly

Assembly rear holding nuts (M10-2nos), discon- 13mm Socket, Ratchet
2.26 ABS 1 3.16 kg
spoiler nect the rear wiper hose and dis- with 4” extension
connect harness connector.
Remove the SKI rack (Front &

Assembly SKI 9” Star headed screw
Back) assembly holding screws
2.27 rack (LH and ABS 2 0.62 kg driver and 12” Thin bladed
(M2-2nos) and dismantle the
RH) screw driver
assembly.
Reflex reflector Remove the rear reflex reflector 10mm Socket, Ratchet
rear mounting nuts (M6-1no). with 4” extension
Assembly air Remove the air extractor assem- 12” Star headed screw
2.29 PP 2 0.29 kg
extractor bly mounting screw (M2-3nos). driver

Goa SUV 18
Activity Area - Instrumental Panel
3.05 LH 3.01
PP PPX
3.02
3.05 RH
PPX
PP
12
v
3.04
PPX
PP 3.03
PPX
PPX
Goa SUV 19
Area: Instrumental panel

Model: Goa SUV
Instrumental
Remove the instrumental panel up- 13mm Socket and Ratch-
3.01 panel upper as- PPX 1 5.45 kg
per mounting bolts (M8). et with 4” extension
sembly
Instrumental
Remove the instrumental panel 13mm Socket and Ratch-
3.02 panel lower as- PPX 1 1.51 kg
lower mounting bolts (M8). et with 4” extension
sembly
Glove box as- Remove the instrumental panel

3.03 PPX 1 0.76 kg Manually
sembly holding fasteners.
Center bezel 12” Thin bladed screw

3.04 PPX 1 1.05 kg Snap fit
assembly driver
Air vent assem- 12” Thin bladed screw
3.05 PP 2 0.34 kg Snap fit
bly side driver

Goa SUV 20
Activity Area - Seat
4.15 LH
PUR
4.15 RH
PUR 4.11 PP 4.11 PP
4.11 PP 4.11 PP
4.06 RR-LH
PUR
4.06 RR-RH
PUR 4.11 PP 4.11 PP
4.11 PP 4.14 RH
4.03 FR-RH 4.03 FR-RH 4.11 PP PPX 4.12
PUR PUR PUR 4.14 LH
4.08 LH PPX
PPX 4.11 PP 4.11 PP
4.11 PP 4.11 PP
4.09 LH 4.01
PPX FR-RH 4.07 RR 4.04 RR
PUR 4.13
PUR PUR
PUR
4.10 RH
PP
4.01 FR-LH 4.05 RR
PUR PUR
4.02 FR-RH
PUR 4.09 LH
PPX
PPX
4.02 FR-LH
PP
PUR 4.10 LH
4.08 LH
PUR PP
PPX
Goa SUV 21
Area: Seat
Model: Goa SUV
Front seat back Remove the seat assembly mount-

ing bolts (M12-4nos) and remove 16mm Socket, Ratchet and
4.01 cushion (LH PUR 2 1.99 kg the front seat back cushion cover wire cutter
and RH) by cutting out the copper tags.
Front seat base Remove the seat assembly mount-

ing bolts (M12-4nos) and remove 16mm Socket, Ratchet and
4.02 cushion (LH PUR 2 2.40 kg the front seat back cushion cover wire cutter
and RH) by cutting out the copper tags.
Front seat head Remove the head rest by pressing

the head rest adjuster and remove
4.03 rest (LH and PUR 2 0.47 kg Wire cutter
the head rest cover by cutting out
RH) the copper tags.
Remove the seat assembly mount-
Second row ing bolts (M12-6nos) and remove 16mm Socket, Ratchet and
4.04 seat back PUR 1 2.83 kg the second row seat back cushion wire cutter
cushion cover by cutting out the copper
tags.
4.05 seat base PUR 1 3.88 kg the second row seat back cushion wire cutter
cushion cover by cutting out the copper
tags.
Remove the head rest by pressing
Second row the head rest adjuster and remove
4.06 PUR 2 0.51 kg Wire cutter
seat head rest the head rest cover by cutting out
the copper tags.
Goa SUV 22

4.07 PUR 1 0.32 kg the second row seat back cush- wire cutter
seat arm rest ion cover by cutting out the cop-
per tags.
Front seat re-
Remove the recliner control knob 6” Star headed screw
4.08 cliner knob (LH PPX 2 0.03 kg
mounting screw (M3-1no). driver
and RH)
Front seat re- Remove the recliner cover mount-

6” Star headed screw
4.09 cliner cover (LH PPX 2 0.18 kg ing screws (M3-1no) and (M4-
driver
and RH) 1no).
Remove the recliner cover and

Slider track 6” Star headed screw
4.10 PP 2 0. kg slider track cover mounting screws
cover driver
(M3-1no).
Head rest Press the bottom end of the head

4.11 PP 8 0.14 kg Manually/Pliers
adjuster rest adjuster gently.
Third row seat ing bolts (M12-6nos) and remove 16mm Socket, Ratchet and
4.12 PUR 1 2.56 kg the third row seat back cushion
back cushion wire cutter
cover by cutting out the copper
tags.
Third row seat ing bolts (M12-6nos) and remove 16mm Socket, Ratchet and
4.13 PUR 1 2.76 kg the third row seat back cushion
base cushion wire cutter
cover by cutting out the copper
tags.
Goa SUV 23
Third row seat Remove the third row seat recliner

13mm Socket, Ratchet and
recliner assem- assembly mounting screw (M2-
4.14 PPX 2 0.35 kg 6” Star headed screw
bly (LH and 2nos), (M3-2nos) and mounting
driver
RH) bolts (M8-2nos).
Remove the head rest by pressing
Third row seat the head rest adjuster and remove
4.15 PUR 2 0.51 kg Wire cutter
head rest the head rest cover by cutting out
the copper tags.

Goa SUV 24
Activity Area - Interior

5.11
PPX
5.08RH
PPX
5.05 RH
5.03 RH PPX
PPX 5.08RH
5.10 RH PPX
PPX
5.04 RH 5.07 RR-RH

5.01 RH PP 5.10 LH
PPX 5.12 RH
PPX 5.05 LH PPX
5.07 FR-RH PP PPX
PP
5.06 RH
PPX 5.12 LH
5.07 RR-LH PP
PP
5.02 RH
PPX
5.09 5.03 LH
PPX PPX
5.06 LH
5.01 LH PPX
PPX
5.04 LH
PPX
5.02 LH PPX
PP PPX
Goa SUV 25
Area: Interior
Model: Goa SUV
Trim A pillar Remove the A pillar upper assem-

upper assembly bly trim, by releasing the snap fits.
Trim A pillar Remove the A pillar lower assem-

lower assembly bly trim, by releasing the snap fits.
Remove the drivers cabin seat belt

assembly mounting bolts (M12-
Trim B pillar
5.03 PPX 2 0.53 kg 1no) and remove the B pillar upper 16mm Socket and Ratchet
upper assembly
assembly trims, by releasing the
snap fits.
Remove the drivers cabin seat belt

assembly mounting bolts (M12-
Trim B pillar
5.04 PPX 2 0.66 kg 1no) and remove the B pillar lower 16mm Socket and Ratchet
lower assembly
assembly trims, by releasing the
snap fits.
Remove the passengers cabin seat

belt assembly mounting bolts
Trim C pillar
5.05 PPX 2 0.52 kg (M10-1no) and remove the C pil- 14mm Socket and Ratchet
upper assembly
lar upper assembly trims, by
releasing the snap fits.

Assembly rear belt assembly mounting bolts
5.06 quarter trim PPX 2 3.06 kg (M10-2nos) and remove the rear 14mm Socket and Ratchet
moulded quarter pillar lower assembly trims,
by releasing the snap fits.
Goa SUV 26
Remove the handle mountings 9” Star headed screw

5.07 Grab handle PP 3 0.18 kg
screws (M3-2nos). driver
Grill for rear Remove the rear speaker grill 6” Star headed screw
5.08 PPX 2 0.12 kg
speaker mounting screws (M2-3nos). driver
Remove the front console assem-

Front floor 10mm Socket, Ratchet and
5.09 console PPX 1 4.06 kg bly mounting bolts (M6-2nos) and
9” thin bladed screw driver
assembly the plastic fasteners (2nos).

belt assembly mounting bolts
Trim D pillar
5.10 PPX 2 0.92 kg (M10-1no) and remove the D pil- 10mm Socket and Ratchet
upper assembly
lar upper assembly trims, by
releasing the snap fits.
Remove the rear head assembly

Assembly rear
5.11 PPX 1 0.49 kg header trims, by releasing its snap Manually
header trim
fits.
Air extractor Remove the interior air extractor,

5.12 PP 2 0.11 kg Manually
Interior by releasing its snap fits.

Goa SUV 27
Activity Area - Engine

6.14 EPDM
6.13 6.25
EPDM HDPE
6.24 6.23
CSM 6.22 EPDM
EPDM
6.09
MULTIPLE
6.11 PP 6.21 EPDM
6.08 6.26
6.07 NBRX HDPE
6.28 EPDM
NBRX 6.10 PE
6.20 EPDM
NR 6.06 6.01 PA6 6.27 EPDM
MULTIPLE 6.19 NBRX
PE
ABS 6.15
SR 6.16
MULTIPLE
NBRX 6.05
PP 6.02 PP 6.04 LH HDPE
6.18 PE PP
CSM
PA
PAX
6.03 LH
NBRX
PAX
SR 6.04 RH
PP
PP-TF20
HDPE
6.03 RH
EPDM
6.12 RH PAX 6.12 LH
NR 6.17 PAX NR
Goa SUV 28
Area: Engine
Model: Goa SUV
Assembly top
Remove the top NVH barrier assem- 10mm Socket, Ratchet
6.01 NVH barrier PA 1 1.72 kg
bly mounting bolts (M6-4nos). and 4” extension
EIV
Assembly seal Remove the seal condensor top
10mm Socket and
6.02 condenser top PP 1 0.54 kg assembly radiator top shield mount-
Ratchet
eagle ing bolts (M6-2nos).
Radiator side Remove the radiator side cover 10mm Socket and
6.03 PAX 2 0.24 kg
cover mounting bolts (M6-1no). Ratchet
Assemble seal Remove the condenser RH seal

10mm Socket and
6.04 condenser RH PP 2 0.47 kg assembly (fan side shroud) mount-
Ratchet
eagle ing bolts (M6-2nos).
Radiator cool-
Remove the radiator coolant reser- 10mm Socket and
6.05 ant reservoir HDPE 1 0.18 kg
voir mounting bolts (M6-2nos). Ratchet
tank
Assembly air
Remove the Air cleaner foam 13mm Socket, Ratchet
6.06 cleaner foam Multiple 1 1.74 kg
assembly mounting bolts (M8-3nos). and extension
type
Hose oil sepa- Remove the breather inlet hose clip

6.07 NBRX 1 0.06 kg Clip plier
rator (2nos).
Breather outlet Remove the breather outlet hose clip
6.08 NBRX 1 0.07 kg Clip plier
hose (2nos).
Goa SUV 29
Oil separator - Remove the oil separator mounting 10mm Socket and
EUV bolts (M6-1no). Ratchet
Engine oil fill- Remove the engine oil filler cap with
6.10 PE 1 0.04 kg Manually
ing cap its O-ring.
Engine fuse
6.11 PP 1 0.04 kg Snap fit Manually
box cover
Hood bump
6.12 NR 2 0.04 kg Snap fit Manually
Stop
Brake booster Remove the brake vacuum hose clip

6.13 EPDM 1 0.22 kg Clip plier
vacuum hose (3nos).
Flip seal on the

Draw off the engine compartment flip
6.14 engine com- EPDM 1 0.24 kg manually
seal.
partment
Remove the intercooler inlet hose,

Hose inter 7mm Socket, Ratchet
6.15 SR 1 0.43 kg by loosing the hose gripple studs
cooler inlet and 8” extension
(2nos).
Remove the intercooler outlet hose,

Hose inter- 7mm Socket, Ratchet
6.16 NBRX 1 0.22 kg by loosing the hose gripple studs
cooler outlet and 8” extension
(2nos).
Radiator Remove the radiator shroud primary 10mm Socket and

6.17 PAX 1 0.67 kg
shroud primary assembly mounting bolts (M6-4nos). Ratchet
Remove the air cleaner inlet hose,
Air filter inlet 7mm Socket, Ratchet
6.18 PE 1 0.30 kg by loosing the hose gripple studs
hose and 8” extension
(2nos).
Goa SUV 30
Remove the turbo charger inlet hose,

Turbo charger 13mm Socket, Ratchet
6.19 NBRX 1 0.79 kg by loosing the hose gripple studs
inlet hose and 8” extension
(2nos).
Remove the radiator inlet hose, by

Radiator inlet 7mm Socket, Ratchet
6.20 EPDM 1 0.23 kg loosing the hose gripple studs
hose and 8” extension
(2nos).
Remove the radiator outlet hose, by

Hose radiator 7mm Socket, Ratchet
6.21 EPDM 1 0.81 kg loosing the hose gripple studs
outlet and 8” extension
(2nos).
Hose heater in- Remove the heater inlet hose clip
let (2nos).
Hose heater Remove the heater outlet hose clip

outlet (2nos).
Hose steering
Remove the steering pump delivery
6.24 pump to reser- CSM 1 0.40 kg Clip plier
hose clip (2nos).
voir
Wiper water Remove the wiper water tank mount- 10mm Socket and
6.25 HDPE 1 0.20 kg
tank ing bolts (M6-2nos). Ratchet
Coolant recov- 0.0065

6.26 HDPE 1 Snap fit Manually
ery tank cap kg
Coolant tank 0.012
6.27 EPDM 1 Snap fit Manually
inlet hose kg
Coolant tank
6.28 EPDM 1 0.02 kg Snap fit Manually
outlet hose
Goa SUV 31

Goa SUV 32
Goa SUV 33
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. TPO - Thermo Plastic Olefin
38. SRS - Supplemental Restraint System
39. NVH - Noise Vibration Harshness
Goa SUV 34
Goa SUV 35
Mahindra Goa
SUV
2010
Revised
2 June 2010

Vehicle Dismantling Manual Mahindra Goa Scorpio SUV 2010

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Vehicle Dismantling Manual Mahindra Goa Scorpio SUV 2010

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Vehicle Dismantling Manual

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

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

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

Vehicles Activity Area ............................................................................................. 8

Activity Area - Door and Glazing ............................................................................ 10

Activity Area - Exterior ............................................................................................. 14

Activity Area - Instrumental Panel .......................................................................... 19

Activity Area - Seat .................................................................................................. 21

Activity Area - Interior ............................................................................................. 25

Activity Area - Engine .............................................................................................. 28

Vehicle Dismantling Manual

• Be careful when handling the SRS sensor.

Airbag Deployment in End-of-Life Vehicles

Component Parts Deemed to be Non Reusable

List of Component Parts

MODEL MAKE VARIATION ENGINE TRANSMISSION

GOA Mahindra SUV m_Hawk 530 R

Vehicle Dismantling Manual for Mahindra Goa SUV

Vehicles Activity Area

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

0.01 Engine oil Oil 6.5 lit

0.02 Battery Multiple 1 24.22 kg

Coolant 2.7 lit

0.04 Refrigerant R134a 0.65 kg

0.05 Tires EPDM 5 81.0 kg

0.06 Transfer case oil Oil 1.90 lit

0.07 Transmission oil Oil 1.55 lit

0.08 Brake fluid Oil 0.65 lit

0.09 Clutch fluid Oil 0.16 lit

0.10 Steering oil Oil 0.85 lit

0.11 Front axle oil Oil 1.20 lit

0.12 Rear axle oil Oil 1.85 lit

Information and Comments

Activity Area - Door and Glazing

Area: Door and Glazing

S:No Part Name Material Qty Weight Removal Tooling

Cut out the bond surface area of

Flip seal wind Draw off the windshield glass flip

Weather strip Remove the weather strip hold-

Remove the door inner trims and

S:No Part Name Material Qty Weight Removal Tooling

Seal front door Draw off the front window glass

Glass clear Remove the door inner trims and

Seal rear door Draw off the front window glass

Seal rear door

S:No Part Name Material Qty Weight Removal Tooling

Draw off the rear door glass fix.

Dog leg seal Draw off the weather strip from

Remove the rear glass window

Information and Comments

Activity Area - Exterior

S:No Part Name Material Qty Weight Removal Tooling

Assembly front Remove the front applique’s 9” Star headed Screw

Remove the fog lamp mounting

Remove the front head lamp

Assembly side 12” Thin bladed screw

S:No Part Name Material Qty Weight Removal Tooling

Remove the Splash shield mount- 10mm Socket, Ratchet and

Assembly Remove the wheel arch front trim

Remove the front door outer trim

Remove the rear quarter trim

8mm Socket, Ratchet, 9”

8mm Socket, Ratchet, 9”