brake TATA SAFARI 2015 Owner's Guide

119
B BB B
B
A AA A
A
T TT T
T
TER TERTER TER
TER
Y YY Y
Y
,, ,,
,
ST ST ST ST
ST
AR ARAR AR
AR
TING TING TING TING
TING
THE ENGINE THE ENGINE THE ENGINE THE ENGINE
THE ENGINE
WITH JUMP LEADS WITH JUMP LEADSWITH JUMP LEADS WITH JUMP LEADS
WITH JUMP LEADS
The use of a wrench to loosen and remove cables from the
terminals should be made. Always disconnect the negative
(-ve) cable first and reconnect it last. Clean the battery
terminals with a terminal cleaning tool or wire brush.
Reconnect and tighten the cables, coat the terminals with
petroleum jelly. If you need to connect the battery to a
charger, disconnect both cables to prevent damage to the
vehicle’s electrical system.
NOTICE NOTICENOTICE NOTICE
NOTICE
Charging the battery with the cables connected can
seriously damage your vehicle’s electronic controls.
Detach the battery cables before connecting battery to
a charger.
* Swallowing electrolyte can cause fatal poisoning if
immediate action is not taken.
Starting the Engine with Jump Leads Starting the Engine with Jump LeadsStarting the Engine with Jump Leads Starting the Engine with Jump Leads
Starting the Engine with Jump Leads
Your Safari with a discharged battery may be started by
transferring electrical power from a battery in another vehicle.
This may be dangerous as any deviation from the following
instructions could lead to personal injury or damage
resulting from battery explosion, as well as the damage to
the electrical systems in both vehicles.• Never expose the battery to open flames or sparks.
• Do not allow battery electrolyte to come in contact with
eyes, skins, fabrics or painted surfaces. The fluid
contains sulphuric acid which can cause injuries and
damage in the event of direct contact.
• To lessen the risk of injury wear eye protection when
working near any battery.
• Make sure that battery providing the jump start has the
same voltage as the battery in your vehicle (12 V). Its
capacity must not be substantially lower than that of the
discharged battery. The voltage and capacity are given
on the batteries.
• Do not disconnect the discharged battery from the vehicle.
• Switch off all unnecessary electrical loads.
• Do not lean over the battery during jump starting.
• Do not allow the terminals of one lead to touch those of
the other lead.
• Apply hand brake. Place gear shift lever to neutral.
Connect Leads in the Order as shown Connect Leads in the Order as shownConnect Leads in the Order as shown Connect Leads in the Order as shown
Connect Leads in the Order as shown
on next page on next page on next page on next page
on next page
•Do not connect lead to negative terminal of discharged
battery.
•The connection point should be as far away from the
discharged battery as possible.
M A I N T E N A N C E
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ST STST ST
ST
AR ARAR AR
AR
TING TING TING TING
TING
THE ENGINE THE ENGINE THE ENGINE THE ENGINE
THE ENGINE
WITH JUMP LEADS, WITH JUMP LEADS,WITH JUMP LEADS, WITH JUMP LEADS,
WITH JUMP LEADS,


WHEELS & WHEELS & WHEELS & WHEELS &
WHEELS &
T TT T
T
YRES YRESYRES YRES
YRES
•Route the leads so that they cannot catch on rotating parts in
the engine compartment.
•The engine of the vehicle providing the jump start can be allowed
to run during starting.
Attempts to start the engine of the vehicle with the discharged
battery
should be made at intervals of one minute and should not last longer
than 15 seconds. After starting, allow both engines to idle for
approximately 3 minutes with the leads still connected.
W WW W
W
heels & heels & heels & heels &
heels &
T TT T
T
yr yryr yr
yr
es eses es
es
Always use only recommended size of wheel rims and tyres. Use of
rims and tyres not recommended by us may have adverse effect on
vehicle safety and further more could infringe on vehicle regulations.
If you have a flat tyres If you have a flat tyresIf you have a flat tyres If you have a flat tyres
If you have a flat tyres
1) Reduce vehicle speed gradually keeping it is a straight line.
Move cautiously off the road to safe place away from traffic.
Park the vehicle on a level and firm ground. Apply parking brake
& engage 1st gear.
2) Turn on Hazard warning switch. Keep advance-warning triangle
at least 50 meters behind the vehicle as an indication of
breakdown.
3) Take out Jack from vehicle which is below the right hand side
rear jump seat whose access is by opening the tail gate.
M A I N T E N A N C E
JUMP ST JUMP STJUMP ST JUMP ST
JUMP ST
AR ARAR AR
AR
T B T BT B T B
T B
A AA A
A
T TT T
T
TER TERTER TER
TER
Y YY Y
Y
OF ANOTHER CAR OF ANOTHER CAROF ANOTHER CAR OF ANOTHER CAR
OF ANOTHER CAR
DISCHAR DISCHARDISCHAR DISCHAR
DISCHAR
GED B GED BGED B GED B
GED B
A AA A
A
T TT T
T
TER TERTER TER
TER
Y YY Y
Y
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Maintaining the car when not in extended use : Maintaining the car when not in extended use :Maintaining the car when not in extended use : Maintaining the car when not in extended use :
Maintaining the car when not in extended use :
Park the car in covered, dry and if possible well-ventilated
premises.
Engage a gear.
Remove the cables from the battery terminals (first remove
the cable from the negative terminal).
Make sure the handbrake is not engaged.
Clean and protect the painted parts using protective wax.
Clean and protect the shiny metal parts using commercially
available special compounds.
Sprinkle talcum powder on the rubber windscreen wiper and
rear window wiper blades and lift them off the glass.
Slightly open the windows.
Cover the car with a cloth or perforated plastic sheet. Do
not use sheets of imperforated plastic as they do not allow
moisture on the car body to evaporate.
Inflate the tyres to 0.5 bar above the normal specified
pressure and check it at regular intervals.
Check the battery charge every six weeks.
Do not drain the engine cooling system.
VEHICLE C VEHICLE CVEHICLE C VEHICLE C
VEHICLE C
ARE AREARE ARE
ARE
Wiper Care : Wiper Care :Wiper Care : Wiper Care :
Wiper Care :
Wiper blade attack angle on windshield glass should be 90
0
i.e. perpendicular.
Remove wiper blade and root wiper arm on windshield glass
in the centre position. Check the gap between arm strip
and glass.
Adjust by twisting wiper arm as shown in the figure.
OK OKOK OK
OK FOR CHA FOR CHAFOR CHA FOR CHA
FOR CHA
T TT T
T
TERING & NOISY PR TERING & NOISY PRTERING & NOISY PR TERING & NOISY PR
TERING & NOISY PR
OBLEMS OBLEMSOBLEMS OBLEMS
OBLEMS
NO NONO NO
NO
T OK T OKT OK T OK
T OK Windshield
GlassVIE VIEVIE VIE
VIE
W W W W
W
WITHOUT WITHOUT WITHOUT WITHOUT
WITHOUT
WIPER BL WIPER BLWIPER BL WIPER BL
WIPER BL
ADE ADEADE ADE
ADE
M A I N T E N A N C E
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VEHICLE C VEHICLE CVEHICLE C VEHICLE C
VEHICLE C
ARE AREARE ARE
ARE
W WW W
W
A AA A
A
XING : XING :XING : XING :
XING :
Waxing and polishing is recommended to maintain the gloss
and wet-look appearance of your paint finish.
1. Use a good quality polish and wax for your vehicle.
2. Re-wax your vehicle when the water does not slip off the
surface and collects over the surface in patches.
Further tips for the care of your new vehicle finish : Further tips for the care of your new vehicle finish :Further tips for the care of your new vehicle finish : Further tips for the care of your new vehicle finish :
Further tips for the care of your new vehicle finish :
If your vehicle is washed in an automatic car wash, please
remember that the paint can be scratched by type of brushes,
unfiltered washing water or the washing process itself.
Scratching reduces paint durability and gloss, especially on
darker colours. It is suggested to wash the vehicle by hand with
cool and clean water using a soft cloth or sponge. Please do not
use soap but a car shampoo recommended by your dealer.
Please take the following precautions : Please take the following precautions :Please take the following precautions : Please take the following precautions :
Please take the following precautions :
1. Always wash your vehicle in shade, avoiding direct exposure
to sunlight during washing.
2. Dry wiping your vehicle may lead to the formation of
scratches and hence always use a soft cloth and clean water
while wiping your vehicle.
3. Always keep your vehicle parked in a well ventilated shade.
Exposure to heat with entrapped moisture promotes corrosion.4. Avoid driving on gravel roads, as the possibility of paint
chip off due to the impact of stones is high. If you are
driving on freshly tarred road, check immediately
afterwards for any stains & clean them.
5. External contamination in the form of sap or industrial
fall-out may mar or develop spots on a new finish. Hence
avoid parking your vehicle near trees, which are known
to drop sap, or near factories, which give out heavy smoke.
6. The acid content in bird droppings may damage the newly
painted finish and hence any bird dropping must be
immediately washed off.
7. The paint finish is susceptible to damage in case petrol,
brake fluid, liquid from car battery, oil, antifreeze,
transmission fluid or windshield solvent spills onto the
painted surface. In case of such a spillage immediately
rinse the affected area with water. Avoid wiping the area
far as possible, however if wiping is required, ensure that
you wipe the area gently with soft cotton cloth.
8. Avoid using sharp objects to scrap off tar or mud from a
painted surface as it may develop scratches or may peel
off the paint.
M A I N T E N A N C E
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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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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
REAR AXLE, LIVE FRONT AXLE REAR AXLE, LIVE FRONT AXLEREAR AXLE, LIVE FRONT AXLE REAR AXLE, LIVE FRONT AXLE
REAR AXLE, LIVE FRONT AXLE
1. Loss of lubricant (Oil) Breather hole clogged
•Clean the breather hole on the
axle housing
Differential cover gasket torn
•Get replaced
Pinion oil seal damaged
•Get replaced
2. Differential housing overheatingInsufficient oil
•Get the oil filled
Incorrect lubricant used
•Drain, flush and get correct
lubricant filled
BRAKES BRAKESBRAKES BRAKES
BRAKES
1. Poor brakes Insufficient brake fluid.
•Get the brake fluid filled
Air in the system
•Bleed the system
Malfunction of automatic
•Check & rectify auto adjuster
adjustermechanism or replace
Vacuum leakage
•Rectify the leakage
Brake fluid contamination
•Replace the brake fluid
Brake fluid, grease, oil or water
•Replace the leaking line, bleed
on pad /drum the system. Clean pad/lining.
replace seals if leaking
Worn brake lining/pad
•Get the liners/pad replaced
Excessive worn drums at rear
•Replace rear drums
soft or weak hose
•Check & replace
2. Spongy pedalAir in the system
•Bleed the system
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
3 . Brake pulling to one side Oil on the lining/pad•Clean the pad lining
One side shoe (pad) worn
•Get the shoe pad replaced
Loose brake anchor plate
•Tighten the bolts
Wheel adjustment disturbed
•Adjust
Unequal tyre pressure
•Adjust
One side brake pipe clogged
•Get the brake line cleaned &
bleed the system
4. Brake grab Improperly adjusted parking brake
•Get correctly adjusted
Brake fluid container breather hole
•Clean the hole on the container
clogged
No brake pedal free play/brake pedal
•Adjust brake pedal
not returning fully
Defective tandem master cylinder
•Replace/rectify tandem master
cylinder
5. Brake Squeal Defective brake lining/pad
•Replace
Glazed lining/pad
•Clean or replace lining/pad
Loose rivets
•Install rivets properly
Wrong lining/pad
•Install correct lining/pad
Shoe return spring broken
•Replace
Front pads /Antisqueal shims rubbing
•Get corrected
on the disc
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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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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