2015 TATA SAFARI ECU

99
4.0 4.04.0 4.0
4.0
TRANSFER CASE : TRANSFER CASE :TRANSFER CASE : TRANSFER CASE :
TRANSFER CASE :
(for 4x4 configuration) :From M/s Borg Warner
ECU control Electrical shift
shifting arrangement
mounted on the gear box.
Drive Options : 4X2 HighRatio 1:1
4x4 High Ratio 1:1
4x4 Low Ratio 1:2.48
5.0 5.05.0 5.0
5.0
REAR AXLE : REAR AXLE :REAR AXLE : REAR AXLE :
REAR AXLE :
: Single reduction salisbury
type rear axle with hypoid
gears and semi-floating axle
with limited slip differential
for 4 x 4, without limited slip
differential for 4 x 2
Ratio :4.1 (41 / 10)
6.0 6.06.0 6.0
6.0
FRONT AXLE : FRONT AXLE :FRONT AXLE : FRONT AXLE :
FRONT AXLE :
a) For 4x4 :Independently suspended
with automatic hub locks.
Ratio 4.1 (41 / 10)
b) For 4x2 : Independently suspended
VEHICLE SPECIFICATIONSTRANSFER CASE, AXLE, STEERING & BRAKES TRANSFER CASE, AXLE, STEERING & BRAKESTRANSFER CASE, AXLE, STEERING & BRAKES TRANSFER CASE, AXLE, STEERING & BRAKES
TRANSFER CASE, AXLE, STEERING & BRAKES
7.0 7.07.0 7.0
7.0
STEERING : STEERING :STEERING : STEERING :
STEERING :
Type : Power steering
Ratio : 18.9 :1
Steering Wheel: 380 mm dia with tilt
mechanism for adjusting
height and collapsible
column.
8.0 8.08.0 8.0
8.0
BRAKES : BRAKES :BRAKES : BRAKES :
BRAKES :
Service Brakes : Vacuum assisted independent
hydraulic brakes on front and
rear through tandem master
cylinder & tandem booster.
Camshaft driven vacuum
pump. Bypass valve provided in
rear brake circuit for the vehicle
with ABS.
Front Brake : 302 mm dia ventilated
disc brake with twinpot
caliper.
Rear Brake :295 mm dia drum brake
with auto adjuster,
Load conscious pressure : Provided for rear brakes
reducing valve remote by No ‘LCRV’ for version
pars valvewith ABS
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M A I N T E N A N C EENGINE C ENGINE CENGINE C ENGINE C
ENGINE C
OMP OMPOMP OMP
OMP
AR ARAR AR
AR
T TT T
T
MENT (RHD) MENT (RHD)MENT (RHD) MENT (RHD)
MENT (RHD)
1. Air Filter 2. Service Indicator 3. ABS Hydraulic Modulator
4 . Brake Fluid container 5. Clutch fluid container 6. Engine Oil filler cap
7. Dip Stick 8. Power Steering Fluid container 9. Windshield Washer Fluid container
10. Fuses & Relays Box 11. EMS- ECU 12.Battery
13. Radiator Cap 14. Coolant Tank
ENGINE C ENGINE CENGINE C ENGINE C
ENGINE C
OMP OMPOMP OMP
OMP
AR ARAR AR
AR
T TT T
T
MENT MENTMENT MENT
MENT
38
11
9457
10
14
1
2
6
12
13
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Engine Cooling System Engine Cooling SystemEngine Cooling System Engine Cooling System
Engine Cooling System
If engine overheating occurs, there could be a fault in the
cooling system which may be on account of :
1. Less coolant in the cooling system or dirt/scale having
accumulated inside cooling water passages especially
in the radiator core.
2 . Choking of radiator passages due to foreign material or
damages.
3. Defective thermostat.
4. Defective coolant temperature sensor.
5 . Non operation of electrically operated fans (Controlled
by ECU).
6. Coolant leakage.
7. Radiator cap not sealing properly.
8 . A.C. condenser fan not working
9. Excessive refrigerant charging in the A.C. system.
10. No communication between auxiliary tank and radiator.
P PP P
P
r rr r
r
e ee e
e
v vv v
v
en enen en
en
tion of R tion of Rtion of R tion of R
tion of R
ust F ust Fust F ust F
ust F
or oror or
or
ma mama ma
ma
tion tiontion tion
tion
To prevent rust formation in the radiator use premixed
recommended anti-freeze coolant. This is sufficient to
operate the vehicle upto -40
oC.
C CC C
C
OOLING SY OOLING SYOOLING SY OOLING SY
OOLING SY
STEM STEMSTEM STEM
STEMM A I N T E N A N C E
1.Auxiliary Tank 2. Radiator Pressure Cap
Coolant filling Procedure: Coolant filling Procedure:Coolant filling Procedure: Coolant filling Procedure:
Coolant filling Procedure:
It is recommended that the refilling of the engine coolant
should be carried out at authorized service centre
1. 1.1. 1.
1.
A A A A
A
ir e ir eir e ir e
ir e
v vv v
v
acua acuaacua acua
acua
tion and c tion and ction and c tion and c
tion and c
o oo o
o
olan olanolan olan
olan
t filling ( t filling (t filling ( t filling (
t filling (
V VV V
V
acuum filling) acuum filling)acuum filling) acuum filling)
acuum filling)
Method : Method :Method : Method :
Method :
The coolant refilling in the system is recommended to be
carried out through air evacuation and coolant filling method
for quick filling.
1 . Allow the engine to cool up to ambient temperature.
2 . Keep cabin heater valve (if applicable) at “ON” position
throughout the coolant refilling.
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C CC C
C
OOLING SY OOLING SYOOLING SY OOLING SY
OOLING SY
STEM STEMSTEM STEM
STEMM A I N T E N A N C E
3. The complete cooling system should be drained (old coolant)
before refilling the system.
a. Remove radiator pressure cap
b. Drain the coolant from engine through the drain hole on
thermostat housing lower part. Drain coolant from radiator
through the radiator drain hole.
c. Refit the drain plugs on thermostat housing lower part and
the radiator.
d. Pour fresh water through the filler neck up to top and again
drain the water through the drain holes. This will ensure
removal of the old coolant from the system
e. After flushing out water, secure the drain plugs on radiator
and thermostat housing lower part properly with new
sealing washer.
f. Drain the auxiliary tank and refit the hoses.
4. Take the recommended coolant and water in 1:1 proportion
5. Carry out air evacuation and coolant filling on machine
( Vacuum filling)
( The machine setting to be done as follows,
Quantity to be filled: 6.1 lit approx, back pressure: 1.7 bar)
6. Fill the coolant in auxiliary tank up to “FIRST FILL / REFILL”
mark.
Manual Coolant refilling : Manual Coolant refilling :Manual Coolant refilling : Manual Coolant refilling :
Manual Coolant refilling :
If the air evacuation and coolant filling (vacuum filling) system is
not available, then alternate procedure is as mentioned below.1. Follow sr. no 1 to 4 indicated in Air evacuation and coolant
filling ( Vacuum filling) procedure.
2. Refill the coolant (coolant and water as per recommendation)
through radiator filler neck.
3. When coolant level comes up to radiator filler neck, wait and
allow air bubbles to escape from the system for 2 to 5 min.
Top up coolant in radiator filler neck when level drops.
4. Fill the coolant in the auxiliary tank up to “FIRST FILL / REFILL”
mark.
5. Start the engine and run at idle for 10 min. with open radiator
filler neck. Allow air to escape from the system.Top up coolant
slowly in the radiator filler neck while idling.
6. Stop the engine and allow air bubbles to escape from the
system. Top up coolant through radiator filler neck. Secure
the radiator pressure cap on radiator filler neck.
7. Start the engine and run in stationary condition at 2200 to
2500 rpm till thermostat opens and continue to run for 5
minutes. ( The radiator fans coming on is the indication of
opening the thermostat)
8. Stop the engine and allow it to cool. Open the radiator
pressure cap & top up coolant in radiator filler neck. Secure
the radiator pressure cap on the radiator filler neck.
9. Refill the coolant in the auxiliary tank till “first fill / Refill” level
mark.
10. The coolant refilling is complete now.
11. Ensure that there are no leakages in the completesystem.
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FUEL FIL FUEL FILFUEL FIL FUEL FIL
FUEL FIL
TER & FUEL SY TER & FUEL SYTER & FUEL SY TER & FUEL SY
TER & FUEL SY
STEM STEMSTEM STEM
STEM
6. Refit the drain plug using a new sealing washer. Tighten
drain plug to 5 mkg. torque.
7. Fill, recommended quantity of fresh engine oil in the crank
case and secure the oil filler cap in its place.
8. Start the engine and run for a few minutes. The engine oil
pressure indicator lamp should go ‘off ’ after starting the
engine.
9. Check for engine oil leakages.
10. Stop the engine and recheck engine oil level after a few
minutes. If necessary add oil to bring the level to the upper
mark on the dipstick.
NOTICE NOTICENOTICE NOTICE
NOTICE
Use of reclaimed oil is not recommended
Priming Pump Priming PumpPriming Pump Priming Pump
Priming Pump
Priming pump is used for priming the fuel manually after
overhauling of the engine or after refitment of fuel lines. Pump
the fuel by means of priming pump until all air in the fuel line is
removed. Before cranking the engine ensure that there is no air
in the fuel system.
NOTICE NOTICENOTICE NOTICE
NOTICE
Please do not loosen/remove high pressure pipes and injectors
for air bleeding in the fuel.
M A I N T E N A N C E
F FF F
F
uel & F uel & Fuel & F uel & F
uel & F
ilt iltilt ilt
ilt
er D er Der D er D
er D
r rr r
r
aining ainingaining aining
aining
Loosen drain plugs by 1-2 turn and drain out water and other
sediments from fuel filter bowls depending on operating
conditions to ensure that no water is allowed to enter the fuel
system.
S SS S
S
edimen edimenedimen edimen
edimen
t tt t
t
er er er er
er
W WW W
W
a aa a
a
t tt t
t
er D er Der D er D
er D
r rr r
r
aining ainingaining aining
aining
Water sedimenter is located near fuel tank at rear left hand side
of the vehicle.
Loosen drain plug by 1-2 turns and drain out water and other
sediments from sedimenter when water level indicator lamp
glows in instrument cluster to ensure that no water is
allowed to enter the fuel system.
Sedimenter
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L LL L
L
oad C oad Coad C oad C
oad C
onscious P onscious Ponscious P onscious P
onscious P
r rr r
r
essur essuressur essur
essur
e R e Re R e R
e R
educing educing educing educing
educing
V VV V
V
alv alvalv alv
alv
e (I e (Ie (I e (I
e (I
f fitt f fittf fitt f fitt
f fitt
ed) ed)ed) ed)
ed)
( Not applicable in ABS system) ( Not applicable in ABS system)( Not applicable in ABS system) ( Not applicable in ABS system)
( Not applicable in ABS system)
A load conscious pressure reducing valve eliminates the
possibility of rear wheels from locking and achieves optimum
braking in any load condition of the vehicle.
The valve, is fitted on RH long member connecting it to rear
axle through its link and control spring.
If any, alteration is done in rear suspension, the performance
of this valve will be impaired.
R RR R
R
emot emotemot emot
emot
e B e Be B e B
e B
y-pass y-pass y-pass y-pass
y-pass
V VV V
V
alv alvalv alv
alv
e (I e (Ie (I e (I
e (I
f fitt f fittf fitt f fitt
f fitt
ed) ed)ed) ed)
ed)
(Applicable in ABS system) (Applicable in ABS system)(Applicable in ABS system) (Applicable in ABS system)
(Applicable in ABS system)
The by-pass valve is provided in the rear brake circuit between
tandem master cylinder and ABS unit. The by-pass valve
bypasses the ABS unit in rear only braking (i.e. front brake
failed) condition. The feedback of front line pressure is
provided to the by-pass valve. in case of front brake failure,
the low front line presure being sensed by the by-pass valve
and the 100% brake line pressure from tandem master
cylinder is applied on to the rear brakes without reduction
in pressure.
M A I N T E N A N C EL LL L
L
CR CRCR CR
CR
V (IF FIT V (IF FITV (IF FIT V (IF FIT
V (IF FIT
TED), TED),TED), TED),
TED),
REMO REMO REMO REMO
REMO
TE BY P TE BY PTE BY P TE BY P
TE BY P
ASS ASS ASS ASS
ASS
V VV V
V
AL ALAL AL
AL
VE AND ECU VE AND ECUVE AND ECU VE AND ECU
VE AND ECU
ECU : ECU :ECU : ECU :
ECU :
DICOR engine common rail system consists of ECU, sensors
and actuators. The Electronic control unit (ECU) is a 32 bit
microprocessor which controls the injection parameters as well
as some of the vehicle related outputs. The ECU receives input
from various sensors located on the engine and the vehicle to
decide the injected quantity and injection timing best suited
for the engine to work with maximum efficiency and safety.
ECU is fitted inside the engine compartment.
C CC C
C
AUTIONS AUTIONSAUTIONS AUTIONS
AUTIONS
• •• •
•DO NOT DO NOT DO NOT DO NOT
DO NOT wash engine compartment with high
pressure water
• •• •
•DO NOT DO NOTDO NOT DO NOT
DO NOT tamper with ECU sensors and connectors
• •• •
•DO NOT DO NOTDO NOT DO NOT
DO NOT remove battery connections when the ignition
switch is in ‘ON’ position ( This may damage ECU)
• •• •
•AV AVAV AV
AV
OID OIDOID OID
OID jump start/push start, Use fully charged battery.
• •• •
•DO NO DO NODO NO DO NO
DO NO
T T T T
T run the vehicle if ‘CHECK ENGINE’ lamp on
dashboard is ‘ON.
• •• •
•If any abnormality in performance of engine occurs - like
lack of power- the vehicle to be taken to the
T TT T
T
A AA A
A
T TT T
T
A MO A MOA MO A MO
A MO
T TT T
T
ORS ORSORS ORS
ORS
authorised service outlet.
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M A I N T E N A N C E
R RR R
R
ela elaela ela
ela
y yy y
y
s and s and s and s and
s and
T TT T
T
r rr r
r
ansf ansfansf ansf
ansf
er C er Cer C er C
er C
ase ECU ase ECUase ECU ase ECU
ase ECU
Relays are fitted to protect the voltage drawing units from low
voltage.
Relays are fitted in 2 locations :
1 . In the fuse box situated inside engine compartment.
2 . Behind glove box.
ECU for transfer case is fitted under RH seat.
FUSES & REL FUSES & RELFUSES & REL FUSES & REL
FUSES & REL
A AA A
A
Y YY Y
Y
S AND INTER S AND INTERS AND INTER S AND INTER
S AND INTER
C CC C
C
OOLER OOLEROOLER OOLER
OOLER
Transfercase ECU under driver’s seat
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A L P H A B E T I C A L I N D E X ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX
ALPHABETIC INDEX
A AA A
A
Air Bags 2 2
Aggregate Numbers-Location 1 2
Air Conditioning52, 134
Air Filter & Filter Element 105
Analog Clock 66
Anti Lock Brake System 7 9
Ashtray 6 1
Audio Warning 2 1
Automatic Hub Lock 8 2
B BB B
B
Battery 118
Belt Tension 135
Bonnet Opening / Closing 7 0
Brake Fluid 115
Brakes 7 9
Branded Lubricants 9 5
C CC C
C
Catalytic Converter 132
Central Locking System 13
Child Lock 20
Cigarette Lighter 60
Clutch Fluid 115
Collapsible Steering column 2 1
Combi-Switch 33
Coolants 9 4
D DD D
D
Door Locks 20
Driving Controls 28
Driving in adverse conditions 85
Driving Safety 89
E
ECU 1 1 7
EGR System 132
Engine Compartment 104
Engine Coolant 73
Engine Cooling System 106
Engine oil 72
Engine Oil & Oil Filter 108
Environment Protection 8
F FF F
F
Flat tyre replacement 120
Follow Me Home Headlamp 64
Front & Rear Fog Lights 38
Front / Rear Axle Oil 112
Front Seat 56
Front Windshield / Door Glass Demister 5 4
Fuel 92
Fuel Economy 84
Fuel Gauge 50
Fuel level 72
Fuel Tank Flap Switch 38
Fuel Tank Flap 61
Fuses 130
G GG G
G
Gauges 4 7
Gear Box 78
Gear Box Oil 1 1 0
Gear Shift Lever 32
Glove Box 62
H HH H
H
Hazard Warning 39
Head Lamps & Headlamp Adjustment 113
Headlamp Leveling Switch 40
Headrest 57
Headrest adjustment 1 8
High mounted stop lamp 67
I II I
I
Ignition Switch 29
Immobiliser- Anti Theft Security System 31
Important Information 6,7
Indicators 43
Instrument Cluster 42
J JJ J
J
Jack & Tools 59
Jump Seats 59
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