lock TATA SAFARI 2015 Service Manual

117
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 EWHEELS & WHEELS & WHEELS & WHEELS &
WHEELS &
T TT T
T
YRES YRESYRES YRES
YRES
Location of Jack 4) Take out Spare wheel cover. Pull the cover from top side and
then side way to remove from spare wheel.
5) Remove the spare wheel-mounting nut by wheel spanner
(provided in tool kit). Remove the spare wheel cover mounting
bracket and then spare wheel.
6) Block the wheel, which is diagonally opposite to the flat tyre.
Take out wheel cover and loosen the wheel nut of flat tyre (Do
not remove the nut at this stage).
7) Set the jack properly at correct jack point as shown in fig. and
slowly lift the vehicle with the help of jack handle.
8) Remove wheel-mounting nuts and take out flat tyre.
9) Roll the spare wheel into position and align the holes in the
wheel with studs. Then reinstall the wheel nuts (taper end
inward) and tighten them as much as you can by hand.
10) Lower the jack completely then tighten the wheel nuts one by
one. Put the wheel cover back.
11) Restore all the tools and jack at their respective location.
12) Place the flat tyre at spare wheel location, put spare wheel cover
mounting bracket and tighten the mounting nuts properly. For
assembling spare wheel cover, push the cover on the tyre and
then press at centre of cover to lock cover on to the bracket.
Ensure that the cover is locked on to the spare wheel cover
mounting bracket (the sound is heard during assembly).
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M A I N T E N A N C EFUSES FUSESFUSES FUSES
FUSES
Fuse Box - Cabin
Fuse Box - Engine Compartment
Fuses FusesFuses Fuses
Fuses
All the electrical circuits in your vehicle have fuses to protect them
from a short circuit or overload. These fuses are located in 2 fuse boxes.
The interior fuse box is below the dash board on driver’s side. Remove
the fuse box lid by grabbing and pulling down the slot.
The under bonnet fuse box is located in engine compartment on LHS.
Checking and Replacing Fuses Checking and Replacing FusesChecking and Replacing Fuses Checking and Replacing Fuses
Checking and Replacing Fuses
If any electrical unit in your vehicle has stopped functioning, the fuses
should be checked first.
1. Turn the ignition key to lock position.
2. Remove the cover of the fuse box.
3. Check each fuse and look for burnt wire inside the fuse. If it is burnt,
replace it with one of the spare fuses of same rating or lower.
4. If the replacement fuse of same rating burns out in short time, there
is probably a serious electrical problem. Get the vehicle attended at
nearest Authorised Workshop.
NOTICE NOTICENOTICE NOTICE
NOTICE
Ensure that the replaced fuses have the same rating as indicated on
the sticker.
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AIR CONDITIONING AIR CONDITIONING AIR CONDITIONING AIR CONDITIONING
AIR CONDITIONING
Air Conditioning Air ConditioningAir Conditioning Air Conditioning
Air Conditioning
The Air Conditioning is a sealed system. Any major maintenance
should be done by Authorised Workshop.
There are couple of things which can be done by you to ensure proper
working of Air conditioning / Heating.
Periodically check the engine’s radiator and air conditioning
condensers for leaves, insects and dirt stuck in front surface.
These block the air flow and reduce the cooling efficiency. Use a light
water spray from a hose or a soft brush to remove them.
NO NONO NO
NO
TICE TICETICE TICE
TICE
Use only low pressure spray or soft bristle brush to clean condenser
and radiator fins.
Run the air conditioning at least once a week during winter season.
Run it at least for ten minutes with vehicle at steady speed and engine
at normal operating condition. This circulates lubrication oil in the
compressor.
For any complaint on A.C. and Heating get it attended at Authorised
Workshop.
NO NONO NO
NO
TICE TICETICE TICE
TICE
The system is charged with R 134 (a) - ‘Non C.F.C.’ refrigerant. Do
not top up with any other refrigerant.
M A I N T E N A N C E
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PRELIMINARY TROUBLE SHOOTINGPRELIMINAR 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
5 . Poor pickup Loose contact of connectors•Get defect rectified.
Blocked fuel filter
•Clean/replace fuel filter element
Clogged air filter
•Clean / replace the element
EGR malfunctioning
•Get checked & corrected
•Check for loose pipes &
connections.
6. Does not accelerate Accelerator pedal module defective
•Get defect rectified
7. Belt squeal Loose belt
•Get belt tension adjusted
Belt glazed
•Get belt replaced
CL CLCL CL
CL
UT UTUT UT
UT
CH CHCH CH
CH
1. Clutch does not get disengagedAir in the hydraulic system
•Bleed the system
Less fluid in the master cylinder
•Get the clutch fluid filled
2 . Clutch pedal goes too low Air in the hydraulic system
•Bleed the system
Less fluid in the master cylinder
•Get the clutch fluid filled
3. Clutch pedal return sluggishBlocking of vent in clutch fluid
•Open the cap from the bottle
bottle & clean the breather hole, if
clogged
GEAR BO GEAR BOGEAR BO GEAR BO
GEAR BO
X XX X
X
1. Hard gear shifting / Clutch does not disengage
•Get the clutch hydraulic system
crash engagementproperly attended
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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
ANTI-LOCK BRAKING SYSTEM ANTI-LOCK BRAKING SYSTEMANTI-LOCK BRAKING SYSTEM ANTI-LOCK BRAKING SYSTEM
ANTI-LOCK BRAKING SYSTEM
1. ABS warning lamp stays ‘ON’ ABS unit faulty
No supply to ABS unit • Check wiring connections &
battery condition.
Electrical circuit problem : • Check wiring harness
Intermittent contact, Wiring connections
connections / connections loose/
faulty
Component and sensor failure : • Check gap between sensor &
RPM sensors/toner rings fitting toner ring
loose, gap disturbances, Sensor
signal that deviates from the specified
levels
Circuit / bulb failure • Replace bulb
Leakage from hydraulic unit ports • Eliminate leakage by tightening
Hydraulic unit fluid level low • Check reservoir fluid level and
bleed properly.
Unusual response and malfunction • Check sensor condition &
in the actuators replace if necessary.
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
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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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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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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