2015 TATA SAFARI engine

136
( 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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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 ESER SERSER SER
SER
VICE SCHEDULE VICE SCHEDULEVICE SCHEDULE VICE SCHEDULE
VICE SCHEDULE
ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS :
A.. Driving in conditions such as Patrolling, Taxi, Pickup Van, Vehicle Towing, with Trailer Towing
B. Driving on Dusty / Sandy roads
C. More than 50% (in terms of kms) driving in heavy city traffic
D. Frequently operating in mountainous area
ITEMINTERVAL CONDITION
AB CD
1. Engine Oil & Oil Filter Change every 7500 kms.
z zz z
z
z zz z
z
z zz z
z
z zz z
z
2. Air Filter Element Clean at every 7500 kms. &
z zz z
z
replace at 30,000 kms.
3. Front (for 4X4) & Rear Axle Change First at 15000 kms
z zz z
z
z zz z
z
z zz z
z
z zz z
z
Oil Change & thereafter at 45,000 kms.
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
ELECTRICALS ELECTRICALSELECTRICALS ELECTRICALS
ELECTRICALS
1 Check headlamp focussing & functioning of other electrical equipment 15,000 km x x x x x x x
2 Check specific gravity of battery electrolyte 30,000 km x x x
HV HVHV HV
HV
A AA A
A
C CC C
C
1 Check the HVAC System for Satisfactory Performance & attend if required Every Service x x x x x x x x
WHEELS & WHEELS & WHEELS & WHEELS &
WHEELS &
T TT T
T
YRES YRESYRES YRES
YRES
1 Tyre rotation15,000 km x x x x x x x
* Under severe driving conditions, additional maintenance is required. Please Refer to “Additional Maintenance Schedule under severe driving conditions”:
P PP P
P
r rr r
r
ec ecec ec
ec
autions t autions tautions t autions t
autions t
o b o bo b o b
o b
e tak e take tak e tak
e tak
en while cleaning engine c en while cleaning engine cen while cleaning engine c en while cleaning engine c
en while cleaning engine c
ompar omparompar ompar
ompar
tmen tmentmen tmen
tmen
t : t :t : t :
t :
I I I I
I
t is r t is rt is r t is r
t is r
ec ecec ec
ec
ommended t ommended tommended t ommended t
ommended t
o use dr o use dro use dr o use dr
o use dr
y lo y loy lo y lo
y lo
w pr w prw pr w pr
w pr
essur essuressur essur
essur
e air e aire air e air
e air
.. ..
.
D D D D
D
o not use pr o not use pro not use pr o not use pr
o not use pr
essur essuressur essur
essur
ised isedised ised
ised
w ww w
w
a aa a
a
t tt t
t
er erer er
er
.. ..
.
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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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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
L LL L
L
Limited Slip Differential 82
Lubricants 9 3
Load consciouse pressure
reducing valve 117
M MM M
M
Middle Seat 57
Mirror (Inside) 63
Mirror (Motorised) 60
Mirror Demister 39
MP3/DVD player 67
Music System 66
O OO O
O
Odometer 47
Operating Switch 38
P PP P
P
Panel Lights 47
Parking Brake 32
Power Steering Fluid 115
Power Windows 55
Preparing to drive 77
Prior to driving – Check List 71
R RR R
R
Rear Seat 5 7
Rear Windshield Demister 39
Rear Windshield Wash & Wipe 39
Remote bypass valve 1 1 8
Relays 131
Reverse Guiding System 65
Roof Lights 63
Roof Mounted A.C. 54
Roof Rail 88
RPM Meter 49
Running in Period 77
S SS S
S
Seat Adjustment 58
Seat belt 1 6
Seat belt precautions 1 9
Service Schedule 144
Spare Wheel 1 2 5
Speedometer 4 8
Starting / Stopping the engine 7 6
Steering Lock 29
Steering Wheel Position Adjustment 38
Sunvisors 6 5
T TT T
T
Tail lamp 67
Technical Specifications 97
Temperature Gauge 50
Towing the vehicle 88
Transfer case 4X4 operation 82
Transfer case Electric Shift Switch 36
Transfer case oil 1 1 1
Trouble Shooting 136
Turbo Charger 133
Tyre 120,123
Tyre Rotation 124
V VV V
V
Vehicle Care 126
Vehicle Record Sheet 1 4 9
Vehicle Specifications 9 7
W WW W
W
Warranty-Terms & Condition 10
Wheels & Tyres 120
Wheel Alignment 123
Wheel Balancing 123
Wiper Care 127
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Chassis No. ......................................
Engine No. .......................................
Gear Box No. ...................................
Rear Axle No. ..................................
At 30,000 - 30,500 km OR 24 months whichever earlier
please bring your vehicle for this service as per details
given in the Service Schedule.
WORK DONE WORK DONE WORK DONE WORK DONE
WORK DONE
T TT T
T
O MY SA O MY SAO MY SA O MY SA
O MY SA
TISF TISFTISF TISF
TISF
A AA A
A
CTION CTIONCTION CTION
CTION
Sign. of Customer ......................................
Speedo Reading ........................................ Km. seal O.K. / Broken
R.O. No. ..................................................... Date ............................
Dealer's / Authorised Service Centre's
Stamp & Signature .........................................................................
3 33 3
3
FREE FREEFREE FREE
FREE
LABOUR LABOURLABOUR LABOUR
LABOUR
L - L -L - L -
L -
1 11 1
1
FREE FREEFREE FREE
FREE
LABOUR LABOURLABOUR LABOUR
LABOUR
L - L -L - L -
L -
2 22 2
2
FREE FREEFREE FREE
FREE
LABOUR LABOURLABOUR LABOUR
LABOUR
L - L -L - L -
L -
PDI PDIPDI PDI
PDI
FREE FREEFREE FREE
FREE
LABOUR LABOURLABOUR LABOUR
LABOUR
L - L -L - L -
L -
T TT T
T
a aa a
a
ta S ta Sta S ta S
ta S
afar afarafar afar
afar
i (DIC i (DICi (DIC i (DIC
i (DIC
OR) OR)OR) OR)
OR)
Chassis No. ......................................
Engine No. .......................................
Gear Box No. ...................................
At 15,000 - 15,500 km OR 12 months whichever earlier
please bring your vehicle for this service as per details
given in the Service Schedule.
WORK DONE WORK DONE WORK DONE WORK DONE
WORK DONE
T TT T
T
O MY SA O MY SAO MY SA O MY SA
O MY SA
TISF TISFTISF TISF
TISF
A AA A
A
CTION CTIONCTION CTION
CTION
Sign. of Customer ......................................
Speedo Reading ........................................ Km. seal O.K. / Broken
R.O. No. ..................................................... Date ............................
Dealer's / Authorised Service Centre's
Stamp & Signature .........................................................................
T TT T
T
a aa a
a
ta S ta Sta S ta S
ta S
afar afarafar afar
afar
i (DIC i (DICi (DIC i (DIC
i (DIC
OR) OR)OR) OR)
OR)
At the time of delivery of vehicle please ensure
pre-delivery inspection has been carried out as per details
given in the Service Schedule
.. ..
.
Chassis No. ......................................
Engine No. .......................................
Gear Box No. ...................................
WORK DONE WORK DONE WORK DONE WORK DONE
WORK DONE
T TT T
T
O MY SA O MY SAO MY SA O MY SA
O MY SA
TISF TISFTISF TISF
TISF
A AA A
A
CTION CTIONCTION CTION
CTION
Sign. of Customer ......................................
Speedo Reading ........................................ Km. seal O.K. / Broken
R.O. No. ..................................................... Date ............................
Dealer's / Authorised Service Centre's
Stamp & Signature .........................................................................
T TT T
T
a aa a
a
ta S ta Sta S ta S
ta S
afar afarafar afar
afar
i (DIC i (DICi (DIC i (DIC
i (DIC
OR) OR)OR) OR)
OR)
T TT T
T
a aa a
a
ta S ta Sta S ta S
ta S
afar afarafar afar
afar
i (DIC i (DICi (DIC i (DIC
i (DIC
OR) OR)OR) OR)
OR)
Chassis No. ......................................
Engine No. .......................................
At 1,000-1,500 km OR 1 month whichever earlier
please bring your vehicle for this service as per
details given in the Service Schedule.
WORK DONE WORK DONE WORK DONE WORK DONE
WORK DONE
T TT T
T
O MY SA O MY SAO MY SA O MY SA
O MY SA
TISF TISFTISF TISF
TISF
A AA A
A
CTION CTIONCTION CTION
CTION
Sign. of Customer ......................................
Speedo Reading ........................................ Km. seal O.K. / Broken
R.O. No. ..................................................... Date ............................
Dealer's / Authorised Service Centre's
Stamp & Signature .........................................................................
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4 44 4
4
FREE FREEFREE FREE
FREE
LABOUR LABOURLABOUR LABOUR
LABOUR
L - L -L - L -
L -
5 55 5
5
FREE FREEFREE FREE
FREE
LABOUR LABOURLABOUR LABOUR
LABOUR
L - L -L - L -
L -
T TT T
T
a aa a
a
ta S ta Sta S ta S
ta S
afar afarafar afar
afar
i (DIC i (DICi (DIC i (DIC
i (DIC
OR) OR)OR) OR)
OR)
Chassis No. ......................................
Engine No. .......................................
Gear Box No. ...................................
Rear Axle No. ..................................
At 45,000-45,500 km OR 36 months whichever earlier
please bring your vehicle for this service as per
details givenin the Service Schedule.
WORK DONE WORK DONE WORK DONE WORK DONE
WORK DONE
T TT T
T
O MY SA O MY SAO MY SA O MY SA
O MY SA
TISF TISFTISF TISF
TISF
A AA A
A
CTION CTIONCTION CTION
CTION
Sign. of Customer ......................................
Speedo Reading ........................................ Km. seal O.K. / Broken
R.O. No. ..................................................... Date ............................
Dealer's / Authorised Service Centre's
Stamp & Signature .........................................................................
T TT T
T
a aa a
a
ta S ta Sta S ta S
ta S
afar afarafar afar
afar
i (DIC i (DICi (DIC i (DIC
i (DIC
OR) OR)OR) OR)
OR)
Chassis No. ......................................
Engine No. .......................................
Gear Box No. ...................................
Rear Axle No. ..................................
At 60,000-60,500 km OR 48 months whichever earlier
please bring your vehicle for this service as per
details givenin the Service Schedule.
WORK DONE WORK DONE WORK DONE WORK DONE
WORK DONE
T TT T
T
O MY SA O MY SAO MY SA O MY SA
O MY SA
TISF TISFTISF TISF
TISF
A AA A
A
CTION CTIONCTION CTION
CTION
Sign. of Customer ......................................
Speedo Reading ........................................ Km. seal O.K. / Broken
R.O. No. ..................................................... Date ............................
Dealer's / Authorised Service Centre's
Stamp & Signature .........................................................................
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VEHICLE IDENTIFIC VEHICLE IDENTIFICVEHICLE IDENTIFIC VEHICLE IDENTIFIC
VEHICLE IDENTIFIC
A AA A
A
TION & TION & TION & TION &
TION &
VEHICLE REC VEHICLE RECVEHICLE REC VEHICLE REC
VEHICLE REC
ORD ORDORD ORD
ORD
Owner’s Name :
Address :
Selling Dealer Code :
Date of Delivery :
Date of Registration :
Registration No.:
Chassis No.:
Engine No.:
Gear Box No.:
Transfercase No.:
Rear Axle No.:
Front Axle No.:
THE THE THE THE
THE
W WW W
W
ARR ARRARR ARR
ARR
ANT ANTANT ANT
ANT
Y ON Y ON Y ON Y ON
Y ON
THIS THIS THIS THIS
THIS
VEHICLE IS VEHICLE IS VEHICLE IS VEHICLE IS
VEHICLE IS
V VV V
V
ALID ONL ALID ONLALID ONL ALID ONL
ALID ONL
Y Y Y Y
Y
WHEN ABOVE WHEN ABOVEWHEN ABOVE WHEN ABOVE
WHEN ABOVE
INFORMA INFORMAINFORMA INFORMA
INFORMA
TION IS FILLED TION IS FILLEDTION IS FILLED TION IS FILLED
TION IS FILLED
,, ,,
,
SIGNED AND ST SIGNED AND ST SIGNED AND ST SIGNED AND ST
SIGNED AND ST
AMPED BY AMPED BY AMPED BY AMPED BY
AMPED BY
THE SELLING DEALER THE SELLING DEALERTHE SELLING DEALER THE SELLING DEALER
THE SELLING DEALER
DEALER DEALERDEALER DEALER
DEALER
’S SIGNA ’S SIGNA’S SIGNA ’S SIGNA
’S SIGNA
TURE AND ST TURE AND STTURE AND ST TURE AND ST
TURE AND ST
AMP AMPAMP AMP
AMP
Following items are provided in your Following items are provided in yourFollowing items are provided in your Following items are provided in your
Following items are provided in your
T TT T
T
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a
ta S ta Sta S ta S
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i : i :i : i :
i :
1. 1.1. 1.
1. Owner’s Manual & Service Book
2. 2.2. 2.
2. Battery Warranty Card
3. 3.3. 3.
3. First Aid Kit
4. 4.4. 4.
4. Advance Warning Triangle
5. 5.5. 5.
5. Jack and Handle
6. 6.6. 6.
6. Spare Headlamp bulbs - 2 Nos
7. 7.7. 7.
7. Spare Fuses - (Provided in fuse box)
8. 8.8. 8.
8. Tool Kit
a. Wheel Spanner
b. Screw Driver
c. Ring spanner (8-9)
d. Socket Handle
(Part No. 2654 5890 35 24)
9. 9.9. 9.
9. Manufacturer’s manual for
a. Music System (if fitted)
b. Immobiliser (if fitted)
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