2015 TATA SAFARI steering

104
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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CL CLCL CL
CL
UT UTUT UT
UT
CH, CH,CH, CH,
CH,
BR BR BR BR
BR
AKE AKEAKE AKE
AKE
,, ,,
,
PO PO PO PO
PO
WER STEERING WER STEERINGWER STEERING WER STEERING
WER STEERING
Clutch Fluid Clutch FluidClutch Fluid Clutch Fluid
Clutch Fluid
The Tata Safari vehicle is equipped with a diaphragm type clutch Which is
hydraulically actuated.
The level of clutch fluid in clutch fluid container should be in between
Min. and Max. marks. If it is not, then add clutch fluid.
In case of spongy or hard clutch pedal, please contact the nearest
Authorised Workshop and get the defect rectified.
Brake Fluid Brake FluidBrake Fluid Brake Fluid
Brake Fluid
Check the level of Brake fluid in Brake fluid container.
It should be in between Min. and Mix. marks.
If it is not, then add brake fluid.
In case of spongy or hard pedal or low brake efficiency, please contact
the nearest Authorised Workshop and get the defect rectified.
Power Steering Fluid Power Steering FluidPower Steering Fluid Power Steering Fluid
Power Steering Fluid
Power steering is fitted for lighter steering effect and easy
manoeuverability. The system consists of steering gear box, hydraulic
pump and hydraulic tank suitably connected by piping. Pump drive is
though ‘V’ belt from engine. Power assistance is available during normal
operating conditions. In case of failure in hydraulic system, the steering
can be operated mechanically with increased steering effort for bringing
the vehicle to Authorised Workshop.
M A I N T E N A N C E
1. Brake Fluid Container
2. Clutch Fluid Container
Power Steering Fluid Container
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POWER STEERING POWER STEERINGPOWER STEERING POWER STEERING
POWER STEERING
Procedure for Oil Filling and Bleeding of Power Procedure for Oil Filling and Bleeding of PowerProcedure for Oil Filling and Bleeding of Power Procedure for Oil Filling and Bleeding of Power
Procedure for Oil Filling and Bleeding of Power
Steering SteeringSteering Steering
Steering (Ensure that Power Steering fluid reservoir is totally
clean before starting the work)
1 . Fill the reservoir nearly full. Crank the engine for 10
seconds without allowing it to start (if possible). If engine
does start, shut the engine immediately. Check & refill
the reservoir repeat atleast three times, each time
checking & refilling the reservoir.
2 . Check for leakage in the system and if noticed take
corrective action.
3 . Start the engine and steer the vehicle from full left to full
right turns 3-4 times.
4 . Add fluid if necessary to maintain the level upto filter top.
NOTICE NOTICENOTICE NOTICE
NOTICE
Do not force the wheel against lock position either
extreme left or right. The power steering pump may get
damaged. Hold it lightly.
5 . When the engine is at steady speed, check for bubble
or foaming in the oil. If present it indicates that air is
getting sucked into the systems. Check the suction
line/fittings and correct if necessary.
6 . Once the system is bled properly and free from foaming
there should not be any appreciable change in oil level
in the reservoir, when the engine is started or stopped
repeatedly.
7 . Now the system is ready for driving.
Final oil level should be at ‘H’ mark on dip stick.
NOTICE NOTICENOTICE NOTICE
NOTICE
* Do not allow fluid level to drop significantly or run out
of the reservoir during the above operation. This may
induce air to the system.
* Do not start the engine without oil in the power steering
system. This will result in serious damage to the
pump. In case of emergency disconnect the pump belt
and then start the engine.
* Always use recommended oil from closed containers.
Any dirty oil poured in the system will result in damage
to pump and gear box.
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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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
TING
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
STEERING SYSTEM STEERING SYSTEMSTEERING SYSTEM STEERING SYSTEM
STEERING SYSTEM
1. Hard steeringLess fluid in the power steering • Get the fluid topped up to
tankcorrect level
Air in the system • Get the air removed by bleeding
the system
Loose pump belt • Get the belt correctly adjusted
ELECTRICAL ELECTRICALELECTRICAL ELECTRICAL
ELECTRICAL
1. No lights on the dash board after Battery terminal got disconnected• Get the battery properly
turning on the ignition key Battery completely dead connected
• Get the battery charged
• Get the alternator & charging
circuit checked
• Check for parking lamp fuse
2. Non functioning electricalBlown fuse in the circuit • Replace the fuse if blown
accessories such as powerLoose connectors • Get the connection properly
windows, head lamps, fueltightened
tank flap, wiper and washer etc. Circuit relay loose • Tighten the relay correctly
in the mounting
Defective components • Get the defective component
replaced from Authorised
Workshop
PRELIMINARY TROUBLE SHOOTING
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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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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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