2015 TATA SAFARI service

128
VEHICLE C VEHICLE CVEHICLE C VEHICLE C
VEHICLE C
ARE AREARE ARE
ARE
FOLL FOLLFOLL FOLL
FOLL
O OO O
O
WING GUIDELINES WING GUIDELINES WING GUIDELINES WING GUIDELINES
WING GUIDELINES
WILL HELP WILL HELP WILL HELP WILL HELP
WILL HELP
Y YY Y
Y
OU OU OU OU
OU
T TT T
T
O BET O BETO BET O BET
O BET
TER TERTER TER
TER
PROTECT YOUR VEHICLE FROM CORROSION PROTECT YOUR VEHICLE FROM CORROSIONPROTECT YOUR VEHICLE FROM CORROSION PROTECT YOUR VEHICLE FROM CORROSION
PROTECT YOUR VEHICLE FROM CORROSION
PROPER CLEANING : PROPER CLEANING :PROPER CLEANING : PROPER CLEANING :
PROPER CLEANING :
In order to protect your vehicle from corrosion it is recommended
that you wash your vehicle thoroughly and frequently in case :
1. There is an heavy accumulation of dirt and mud especially on
the underbody.
2. It is driven in areas having high atmosphere pollution due to
smoke, soot, dust, iron dust & other chemical pollutants.
3. It is driven in coastal areas.
4. The underbody must be thoroughly pressure washed after
every three months.
In addition to regularly washing your vehicle, the following
precautions need to be taken.
PERIODIC INSPECTION : PERIODIC INSPECTION :PERIODIC INSPECTION : PERIODIC INSPECTION :
PERIODIC INSPECTION :
1 . Regularly inspect your vehicle for any damage in the paint
film such as deep scratches and immediately get them
repaired from an authorised service center, as these defects
tend to accelerate corrosion.
2 . Inspect mud liners for damages.
3 . Keep all drain holes clear from clogging.PR PRPR PR
PR
OPER P OPER POPER P OPER P
OPER P
ARKING : ARKING :ARKING : ARKING :
ARKING :
Always park your vehicle in shade to protect it from harsh sunlight
or in a well-ventilated garage so that there is no dampness on
any part of the vehicle.
W WW W
W
ASHING ASHING ASHING ASHING
ASHING
Y YY Y
Y
OUR OUR OUR OUR
OUR
VEHICLE : VEHICLE :VEHICLE : VEHICLE :
VEHICLE :
Follow these tips while washing your vehicle. Follow these tips while washing your vehicle.Follow these tips while washing your vehicle. Follow these tips while washing your vehicle.
Follow these tips while washing your vehicle.
HAND HAND HAND HAND
HAND
W WW W
W
ASH : ASH :ASH : ASH :
ASH :
1 . Always wash your vehicle in shade and when the surface
is at room temperature.
2. Wash with mild car wash soap like "Car Shampoo" and use
a soft 100% cotton cloth to avoid scratches. Please take help
of your dealer to buy the right products.
3. Please be sure that you remove your wristwatch and wear
soft gloves to avoid scratches due to finger rings or nails.
4. To remove stubborn stains and contaminants like tar, use
turpentine or cleaners like "Stain Remover" which is safe
for painted surfaces. Again your dealer can help you in
selecting the right product.
5. Avoid substances like petrol, diesel, kerosene, benzene or
other solvents that cause damage to paint.
6. Dry your vehicle thoroughly to prevent any damp spots.
7. Rinse all surfaces thoroughly to prevent any traces of soap
and other cleaners as this may lead to the formation of
stains on the painted surface later.
M A I N T E N A N C E
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BEL BELBEL BEL
BEL
T T T T
T
TENSION TENSIONTENSION TENSION
TENSIONM A I N T E N A N C E
B BB B
B
elt elt elt elt
elt
T TT T
T
ension : ension :ension : ension :
ension :
Check the conditions of belts on the engine. Examine the edge of
the belt for cracks or fraying.
Check the tension of the belt by pushing on it with your thumb for
Alternator belt and A.C. compressor belt and Power Steering belt
as shown in schematic diagram.
The belts should have deflection of 4 to 6 mm.
If the belt tension is not proper, get it attended at the nearest
authorised service outlet.
Correct tension of the belt is very critical from belt life and belt
noise point of view. It is recommended that belt tension should be
measured with clavis gauge to ensure recommended values as given
below
Alternator / power steering belt Alternator / power steering beltAlternator / power steering belt Alternator / power steering belt
Alternator / power steering belt
•Frequency should be 250 + / - 10HZ for new belt measured
between alternator & power steering pump span.
•New belt to be retensioned to 220 + /- 10 HZ on vehicle
after running for 15 min.
F FF F
F
or c or cor c or c
or c
ompr omprompr ompr
ompr
essor b essor bessor b essor b
essor b
elt eltelt elt
elt
Span AC to dampers
•Frequency should be 200 +/- 10 HZ
•Belt to be retension to 180 +/- 10HZ on vehicle after
running for 15 min.
Alternator / Power Steering Belt Arrangement Alternator / Power Steering Belt ArrangementAlternator / Power Steering Belt Arrangement Alternator / Power Steering Belt Arrangement
Alternator / Power Steering Belt Arrangement
A.C. Compressor Belt Arrangement A.C. Compressor Belt ArrangementA.C. Compressor Belt Arrangement A.C. Compressor Belt Arrangement
A.C. Compressor Belt Arrangement
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( These tips are given for your guidance and preliminary jobs to be done in an emergency situation. In normal case, the problems
should be attended in an Authorised Workshop by following the repair procedures given in Workshop Manual)
SR. NO. SR. NO.SR. NO. SR. NO.
SR. NO.
PROBLEM OBSERVED PROBLEM OBSERVEDPROBLEM OBSERVED PROBLEM OBSERVED
PROBLEM OBSERVED
CAUSE CAUSECAUSE CAUSE
CAUSE
A AA A
A
CTION CTION CTION CTION
CTION
T TT T
T
O BE O BE O BE O BE
O BE
T TT T
T
AKEN AKENAKEN AKEN
AKEN
ENGINE ENGINEENGINE ENGINE
ENGINE
1 . Engine not cranking Dead battery loose or dirty
•Get battery checked&/or changed
battery connections
•Clean and tighten battery
connections
2 . Engine cranks but does not start Air in the fuel system
•Press pear pump for air removal
•Check leakages
Service lamp should glow
•Get defect rectified
EMS fuse blown
•Replace the fuse
3. Engine overheatsCoolant level low
•Top up coolant, check and
correct leakages
Hose collapse / torn
•Get the hose replaced
Low engine oil level
•Add oil
Radiator cap not sealing properly
•Fit the radiator cap correctly
A.C. condensers fans not working
•Get defect rectified
Brakes binding
•Get defect rectified
Electric fan not working
•Get defect rectified
High delivery pressure in A.C.
•Get defect rectified
refrigerant circuit
4 . Charging indicator continuouslyBattery not getting charged
•Get the belt tension adjusted
remains ‘ON’due to loose belt drive Replace if broken
PRELIMINARY TROUBLE SHOOTING
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SR. NO. SR. NO.SR. NO. SR. NO.
SR. NO.
PROBLEM OBSERVED PROBLEM OBSERVEDPROBLEM OBSERVED PROBLEM OBSERVED
PROBLEM OBSERVED
PROBABLE CAUSE PROBABLE CAUSEPROBABLE CAUSE PROBABLE CAUSE
PROBABLE CAUSE
A AA A
A
CTION CTION CTION CTION
CTION
T TT T
T
O BE O BE O BE O BE
O BE
T TT T
T
AKEN AKENAKEN AKEN
AKEN
AIR CONDITIONING AIR CONDITIONINGAIR CONDITIONING AIR CONDITIONING
AIR CONDITIONING
1. Fan motor does not operate Blown fuse • Replace fuse and correct any
wiring short
Faulty connection • Properly connect poor
connections
Faulty motor •Replace motor if no conductance
Faulty or poor •Replace resistor block if defective
connection at resistor
Faulty fan switch • Replace switch
2. Motor operates but air flowObstruction at •Clean evaporator
is minimumevaporator inlet
Air leak • Correctly seal
Faulty thermostat •Adjust or replace thermostat
3. Insufficient cooling, Air flowIncorrect refrigerant quantity or •Get the defect rectified at
normal and compressordefect in system aggregates nearest authorised service
operatingcentre
PRELIMINAR PRELIMINARPRELIMINAR PRELIMINAR
PRELIMINAR
Y Y Y Y
Y
TR TRTR TR
TR
OUBLE SHOO OUBLE SHOOOUBLE SHOO OUBLE SHOO
OUBLE SHOO
TING TINGTING TING
TINGPRELIMINARY TROUBLE SHOOTING
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1. The vehicle has been built to give you thousands of
kilometers of economical and trouble-free performance.
This is however, possible only if this vehicle is
systematically maintained and operated strictly
according to the instructions contained in this book.
2 . The free services should be availed of, at the following
km & time range
1 11 1
1
st stst st
st Free Service Free Service Free Service Free Service
Free Service At 1,000 - 1,500 km OR 1 month
Whichever is earlier
2 22 2
2
nd ndnd nd
nd Free Service Free Service Free Service Free Service
Free Service At 15,000 - 15,500 km OR 12 months
Whichever is earlier
3 33 3
3
rd rdrd rd
rd Free Service Free Service Free Service Free Service
F r e e S e r v i c e At 30,000 - 30,500 km OR 24 months
Whichever is earlier
4 44 4
4
th thth th
th Free Service Free Service Free Service Free Service
Free Service At 45,000 - 45,500 km OR 36 months
Whichever is earlier
5th Free Service 5th Free Service5th Free Service 5th Free Service
5th Free Service At 60,000 - 60,500 km OR 48 months
Whichever is earlier
3 . The respective service coupon should be detached and
handed over to the concerned Servicing Agency for the
service performed.
The selling dealer should fill up details of vehicle
perticulars on the inside cover page of the Owner’s
Manual.
4. These services can be satisfactorily performed only by one
of our Authorised Dealers’/TASC’s/TASP’s Workshops in India,
irrespective of the dealer who sold the vehicle, provided the
vehicle is sent to them at the kilometerages specified and
that this service book is produced before them.
The vehicle is entitled to pre-delivery service with free labour.
After the delivery of the vehicle, in the subsequent
‘5 fr ‘5 fr‘5 fr ‘5 fr
‘5 fr
ee eeee ee
ee
services’ labour would be free but materials, if any services’ labour would be free but materials, if anyservices’ labour would be free but materials, if any services’ labour would be free but materials, if any
services’ labour would be free but materials, if any
w ww w
w
ould b ould bould b ould b
ould b
e char e chare char e char
e char
ged f ged fged f ged f
ged f
or oror or
or
.. ..
.
All services, other than the above, must be paid for both for
materials and labours; material at prevailing rates for the
quantity consumed and labour at our scheduled rates
available with our Authorised Dealers/TASCs/TASPs.
5. In the event of a schedule Service not performed within
specified kilometers the respective coupons will be detached
by the Authorised Dealer’s Workshop when the vehicle is sent
to them next. Should a major service have been missed, all
the works listed for such service must be performed when
the vehicle is taken next to one of our Authorised Dealer’s/
TASC’s/TASP’s Workshop.
6. 6.6. 6.
6.
It is an important condition of our sales policy that It is an important condition of our sales policy thatIt is an important condition of our sales policy that It is an important condition of our sales policy that
It is an important condition of our sales policy that
no warranty claims shall be entertained by us unless no warranty claims shall be entertained by us unlessno warranty claims shall be entertained by us unless no warranty claims shall be entertained by us unless
no warranty claims shall be entertained by us unless
all services upto time of the claim arising have been all services upto time of the claim arising have beenall services upto time of the claim arising have been all services upto time of the claim arising have been
all services upto time of the claim arising have been
performed on the vehicle by one of our Authorised performed on the vehicle by one of our Authorisedperformed on the vehicle by one of our Authorised performed on the vehicle by one of our Authorised
performed on the vehicle by one of our Authorised
D DD D
D
ealer ealerealer ealer
ealer
’’ ’’
’
s / s / s / s /
s /
T TT T
T
ASC ASCASC ASC
ASC
’’ ’’
’
s/T s/Ts/T s/T
s/T
ASP ASPASP ASP
ASP
’’ ’’
’
s s s s
s
W WW W
W
or oror or
or
kshops kshopskshops kshops
kshops
.. ..
.
S P E C I A L I N S T R U C T I O N S
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Failure to carry out the services listed in this book can
cause considerable damage to the vehicle and
inconvenience to you. It is, therefore, in your own interest
to take your vehicle to one of our Authorised Dealer’s,
TASC’s, TASP’s, Workshop for servicing.
7 . All our Authorised Dealer’s/TASC’s Workshops have been
equipped with special tools and are manned by
technical personnel trained by us. Besides, they have
adequate stocks of genuine spare parts for replacement
purposes, should the need arise. Our Authorised
Workshops are therefore in a position to render you any
expert advice and service your vehicle may need. Please
give them an opportunity to serve you, so that you may
obtain economical and trouble free performance
from your vehicle.
8 . For any technical advice concerning your vehicle, please
contact the nearest Authorised Dealer.
S P E C I A L I N S T R U C T I O N S
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S E R V I C E S C H E D U L ESERVICE SCHEDULE SERVICE SCHEDULESERVICE SCHEDULE SERVICE SCHEDULE
SERVICE SCHEDULE
SR SRSR SR
SR
x 1000 km x 1000 kmx 1000 km x 1000 km
x 1000 km
NO NONO NO
NO
OPER OPEROPER OPER
OPER
A AA A
A
TIONS TIONSTIONS TIONS
TIONS
FREQUENCY FREQUENCYFREQUENCY FREQUENCY
FREQUENCY
1-1.5 1-1.51-1.5 1-1.5
1-1.5
15 1515 15
15
30 3030 30
30
45 4545 45
45
60 6060 60
60
75 7575 75
75
90 9090 90
90
105 105105 105
105
GENERAL GENERALGENERAL GENERAL
GENERAL
1 Wash the vehicle & Clean the condenser with compressed air Every Service x x x x x x x x
2 Check & Top up Fluids if required: Coolant, Brake / Clutch Fluid, Battery Electrolyte, Power Every Service x x x x x x x x
Steering Oil, Gear Box Oil, Transfer Case & Front Axle (4X4) / Rear Axle Oil
3 Drain water accumulated in Sedimenter (OR Whenever warning lamp glows) Every Service x x x x x x x x
4 Check Engine Compartment for loose Fasteners, Low pressure fuel lines, Coolant hoses, air hoses, Every Service x x x x x x x x
Vacuum hoses, hydraulic line connections for leakages if any, Attend if necessary
5 Check Underbody for loose Fasteners, hydraulic line connections, Exhaust system / Fuel Pipes for Every Service x x x x x x x x
Damages / Leakages if any. Attend if necessary
6 Apply grease on door latches, door lock, door check stop, striker, bonnet opening lever & lock Every Service x x x x x x x
plate, tailgate hinges & door lock inner ratchet.
7 Check & ensure normal working of engine using Diagnostic Equipment. Every Service x x x x x x x x
2.2L DICOR ENGINE 2.2L DICOR ENGINE2.2L DICOR ENGINE 2.2L DICOR ENGINE
2.2L DICOR ENGINE
1 *Clean air cleaner filter element, Change if red band appears on service indicator even after Every Service x x x x x x x
cleaning
2 *Change engine Oil and Oil filter. Use APICH4+MB228.3 or Higher grade Engine Oil.Every Service x x x x x x x x
OR 1 Year whichever is earlier
3 Check All accessory Drive belts, adjust tension if required, change if damaged Every Service x x x x x x x
OR 1 Year whichever is earlier
4 Change fuel filterEvery Service x x x x x x x
OR 2 Years whichever is earlier
5 *Replace air filter element (OR if RED band appears on Service Indicator) 45,000 km x x
6 Change coolant in the cooling system 60,000 km x
OR 2 Years whichever is earlier
7 Change Sedimenter / Water seperator1,05,000 km x
8 Change Timing Belt & Timing Belt Idler1,05,000 km x
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S E R V I C E S C H E D U L ESERVICE SCHEDULE SERVICE SCHEDULESERVICE SCHEDULE SERVICE SCHEDULE
SERVICE SCHEDULE
SR SRSR SR
SR
x 1000 km x 1000 kmx 1000 km x 1000 km
x 1000 km
NO NONO NO
NO
OPER OPEROPER OPER
OPER
A AA A
A
TIONS TIONSTIONS TIONS
TIONS
FREQUENCY FREQUENCYFREQUENCY FREQUENCY
FREQUENCY
1-1.5 1-1.51-1.5 1-1.5
1-1.5
15 1515 15
15
30 3030 30
30
45 4545 45
45
60 6060 60
60
75 7575 75
75
90 9090 90
90
105 105105 105
105
9 Change vacuum hoses fotr Vacuum Modulator, Turbocharger, EGR valve & throttle valve 60,000 km x
OR 4 Years whichever is earlier
GEAR BOX GEAR BOXGEAR BOX GEAR BOX
GEAR BOX
1 *Change oil in gear box (First at 45,000 KM, there after every 90,000 KM) x x
2 Change oil in transfer case 45,000 KM x x
3 Clean breather in gear box (also Transfer case in case of 4X4)
Every Oil Changexx
PROPELLER SHAFT PROPELLER SHAFTPROPELLER SHAFT PROPELLER SHAFT
PROPELLER SHAFT
1 Grease propeller shaft with grease gun (at slip joint - splines end) & Check Centre bracket 15,000 km x x x x x x x
mounting bolts for looseness. Tighten if necessary
FRONT AXLE (for 4x4) / REAR AXLE FRONT AXLE (for 4x4) / REAR AXLEFRONT AXLE (for 4x4) / REAR AXLE FRONT AXLE (for 4x4) / REAR AXLE
FRONT AXLE (for 4x4) / REAR AXLE
1 Change oil in axle (First at 15,000 KM, there after every 75,000 KM) x x
2 Clean breather in Axle Every Service x x x x x x x
SUSPENSION & STEERING SUSPENSION & STEERINGSUSPENSION & STEERING SUSPENSION & STEERING
SUSPENSION & STEERING
1 Grease idler arm (seal type idler arm) 15,000 km x x x x x x x
2 Check wheel alignment & balancing, chassis height & adjust if necessary 15,000 km x x x x x x x
3 Check condition of rubber bushes in the following & replace if necessary. 1)Top wishbone 30,000 km x x x
2)Lower wishbone 3)Anti roll bars 4)Rear links 5)Panhard rod 6) Vibration damper
4 Check shock absorber, its bushes & steering damper bushes, replace if necessary 30,000 km x x x
5 Grease steering spindle and sleeve 30,000 km x x x
6 Check & adjust front wheel bearing play & Change grease in front hubs 45,000 km x x
7 Change oil in power steering system & change filter element 75,000 km x
CLUTCH & BRAKES CLUTCH & BRAKESCLUTCH & BRAKES CLUTCH & BRAKES
CLUTCH & BRAKES
1 Check parking brakes, adjust if necessary15,000 km x x x x x x x
2 Check front brake pads & rear brake linings. Replace if necessary 15,000 km x x x x x x x
3 Change Clutch & Brake Fluid (Or 2 years whichever is earlier) 30,000 km x x x
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