maintenance TATA SAFARI 2015 Owners Manual

3
13 . Fuel, Coolants & Lubricants 91
14 . Vehicle Specifications 97
15 . Maintenance 103
16 . Preliminary Trouble Shooting 136
17. Special Instructions 144
18 . Service Schedule 146
19. Alphabetical Index 155
20 . Service Set up Addresses A-1
1 . Foreword 5
2 . Important information for owners 6
3 . Environmental Protection 8
4 . Warranty 10
5 . Location of Chassis & Aggregate
Identification Numbers 12
6 . Getting into the vehicle 13
7 . Your Safety 15
8 . Driving Controls 27
9 . Indicators and Instruments 41
10 . Comfort and Convenience 51
11 . Prior to driving 69
12 . Driving 75
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CONTENTS
ProCarManuals.com

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Thank you for selecting Tata Safari - the vehicle of your choice
We welcome you to the world of advanced automotive engineering in a form especially
suited to your operating conditions.
This book gives you all the information necessary for making your ownership of this
vehicle a thoroughly satisfying experience.
To assist you in maintaining your vehicle as per recommended schedule, we have a
widespread network of dealers and service centres. The list is included in this book for
your convenience.
Should you need any special assistance, please call on our Regional / Zonal level offices
which are also listed in this book.
Please note that by adhering to the correct operating procedures and by availing the
scheduled maintenance services at our authorised service centres, you can obtain the
maximum performance from your vehicle.
We request you to go through the book and derive many miles of motoring pleasure.
FOREWORD
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. is committed to produce the vehicles
using environmentally sustainable technology. A number of
features have been incorporated in Tata Motors passenger
vehicles which have been designed to ensure environmental
compatibility throughout the life cycle of the vehicle. We would
like to inform you that your vehicle meets emission norms and
this is being regularly validated at the manufacturing stages.
As a user you too can protect the environment by operating
your vehicle in a proactive manner. A lot depends on your
driving style and the way you maintain your car. We have
given few tips below for your guidance.
DRIVING DRIVINGDRIVING DRIVING
DRIVING
¾Avoid frequent and violent accelerations.
¾Do not carry any unnecessary weight on the vehicle as
it overloads the engine. Avoid using devices requiring
high power consumption during slow city traffic
condition.
¾Monitor the vehicle’s fuel consumption regularly and if
showing rising trend get the vehicle immediately
attended at the Company’s Authorised Service Outlets.
ENVIR ENVIRENVIR ENVIR
ENVIR
ONMENT ONMENTONMENT ONMENT
ONMENT
AL PR AL PRAL PR AL PR
AL PR
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TECTION TECTIONTECTION TECTION
TECTION
¾Switch off the engine during long stops at traffic jams
or signals. If you need to keep the engine running, avoid
unnecessary revving it up or stopping and starting.
¾It is not necessary to rev up the engine before turning
it off as it unnecessarily burns the fuel.
¾Shift to higher gears as soon as it is possible. Use each
gear upto 2/3rd of it’s maximum engine speed. A chart
indicating gear shifting speeds is given in this book.
MAINTENANCE MAINTENANCEMAINTENANCE MAINTENANCE
MAINTENANCE
¾Ensure that recommended maintenance is carried out
on the vehicle regularly at the Authorised Service
Outlets.
¾As soon as you see any leakages of oil or fuel in the
vehicle we recommend to get it attended immediately.
¾Use only recommended grades and quantity of
lubricants and clean/uncontaminated and correct fuels.
¾Get your vehicle checked for emission periodically by
authorised dealer
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ENVIR ENVIRENVIR ENVIR
ENVIR
ONMENT ONMENTONMENT ONMENT
ONMENT
AL PR AL PRAL PR AL PR
AL PR
O OO O
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TECTION TECTIONTECTION TECTION
TECTION
¾Ensure that fuel filter, oil filter and breather are checked
periodically and replaced, if required, as recommended
by Tata Motors.
¾Do not pour the used oils or coolants into the sewage
drains, garden soil or open streams. Dispose the used
filters and batteries in compliance with the current
legislation.
¾Do not allow unauthorised person to tamper with
engine settings or to carry modifications on the vehicle.
¾Never allow the vehicle to run out of fuel.
¾Parts like brake liners, clutch disc should be vacuum
cleaned. Do not use the compressed air for cleaning
these parts which may spread the dust in the
atmosphere.
¾While carrying out the servicing or repairs of your While carrying out the servicing or repairs of yourWhile carrying out the servicing or repairs of your While carrying out the servicing or repairs of your
While carrying out the servicing or repairs of your
vehicle you should pay keen attention to some of vehicle you should pay keen attention to some ofvehicle you should pay keen attention to some of vehicle you should pay keen attention to some of
vehicle you should pay keen attention to some of
the important engine aggregates and wiring the important engine aggregates and wiringthe important engine aggregates and wiring the important engine aggregates and wiring
the important engine aggregates and wiring
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components are :- components are :-components are :- components are :-
components are :-
1. 1.1. 1.
1.
Fuel injection equipments : pump, rail,Injectors, Fuel injection equipments : pump, rail,Injectors,Fuel injection equipments : pump, rail,Injectors, Fuel injection equipments : pump, rail,Injectors,
Fuel injection equipments : pump, rail,Injectors,
Nozzles and high pressure pipes. Nozzles and high pressure pipes.Nozzles and high pressure pipes. Nozzles and high pressure pipes.
Nozzles and high pressure pipes.2. 2.2. 2.
2.
Air Intake & Exhaust system especially for Air Intake & Exhaust system especially forAir Intake & Exhaust system especially for Air Intake & Exhaust system especially for
Air Intake & Exhaust system especially for
leakages. leakages.leakages. leakages.
leakages.
3. 3.3. 3.
3.
Cylinder head for valve leakage. Cylinder head for valve leakage.Cylinder head for valve leakage.
Cylinder head for valve leakage.
Cylinder head for valve leakage.
4. 4.4. 4.
4.
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ers such as air ers such as airers such as air ers such as air
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oil & fuel filt
ers (check ers (checkers (check ers (check
ers (check
periodically). periodically).periodically). periodically).
periodically).
5. 5.5. 5.
5.
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vacuum hoses. vacuum hoses.vacuum hoses. vacuum hoses.
vacuum hoses.
6. 6.6. 6.
6.
EGR System & components. EGR System & components.EGR System & components. EGR System & components.
EGR System & components.
7. 7.7. 7.
7.
Electrical connections Electrical connectionsElectrical connections Electrical connections
Electrical connections
8. 8.8. 8.
8.
‘Service’ lamp contineously glows, please take ‘Service’ lamp contineously glows, please take‘Service’ lamp contineously glows, please take ‘Service’ lamp contineously glows, please take
‘Service’ lamp contineously glows, please take
the vehicle to Service Station. the vehicle to Service Station.the vehicle to Service Station. the vehicle to Service Station.
the vehicle to Service Station.
9. 9.9. 9.
9.
Catalytic Convertor Catalytic ConvertorCatalytic Convertor Catalytic Convertor
Catalytic Convertor
10. 10.10. 10.
10.
EMS wiring harness i.e. electrical connections to EMS wiring harness i.e. electrical connections toEMS wiring harness i.e. electrical connections to EMS wiring harness i.e. electrical connections to
EMS wiring harness i.e. electrical connections to
all sensors and actuators. all sensors and actuators.all sensors and actuators. all sensors and actuators.
all sensors and actuators.
This owner’s manual contains further information on driving
precautions and maintenance care leading to environment
protection. Please familiarise yourself with these aspects
before driving.
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WARRANTYTERMS AND CONDITIONS TERMS AND CONDITIONSTERMS AND CONDITIONS TERMS AND CONDITIONS
TERMS AND CONDITIONS
We

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vehicles & parts thereof
manufactured by us to be free from
defect in material and workmanship,
subject to the following terms &
conditions :
1. This warranty shall be for 24 months
OR 75000 kms, whichever is earlier
from the date of sale of the vehicle,
However, for the vehicles used for
commercial applications (including
those used for hire or reward viz
those operating with a yellow
number plate), the warranty shall be
limited to 24 months or 50,000 kms,
whichever occurs earlier.
2. Our obligation under this warranty
shall be limited to repairing or
replacing, free of charge, such parts
of the vehicle which, in our opinion,
are defective, on the vehicle being
brought to us or to our dealers
within the warranty period. The
parts so repaired or replaced shall
also be warranted for quality and
workmanship but such warranty
shall be co-terminus with this
original warranty.3. Any part which is found to be
defective and is replaced by us
under the warranty shall be our
property.
4. As for such parts as tyres, batteries,
transfer case, rubber parts, electrical
equipment and fuel injection
equipment, power steering
equipment, A.C. equipment not
manufactured by us but supplied by
other parties, this warranty shall not
apply, but buyers of the vehicle shall
be entitled to, so far as permissible
by law, all such rights as we may
have against such parties under their
warranties in respect of such parts.
Our Dealers/TASC’s will assist the
purchaser in taking up the
complaint with the respective
manufacturers and their decision on
the warranty will be final.
5. This warranty shall not apply if the
vehicle or any part thereof is
repaired or altered otherwise than
in accordance with our standard
repair procedure, or by any person
other than our sales or serviceestablishments, our authorised
dealers or service centres or service
points in any way so as, in our
judgement which shall be final and
binding, to effect its reliability, nor
shall it apply if, in our opinion which
shall be final and binding the vehicle
is subjected to misuse, negligence,
improper or inadequate
maintenance or accident or loading
in excess of such carrying capacity
as certified by us, or such services as
prescribed in our Owner’s Manual
and Service Book are not carried out
by the buyer through our sales or
service establishments, our
authorised dealers or service centres
or service points.
6. This warranty shall not cover normal
wear and tear or any inherent
normal deterioration of the vehicle
or any of its parts arising from the
actual use of the vehicle or any
damage due to negligent or
improper operation or storage of
the vehicle. This warranty shall not
apply to normal maintenance
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Y O U R S A F E T YAIR BAGS (IF FITTED) AIR BAGS (IF FITTED)AIR BAGS (IF FITTED) AIR BAGS (IF FITTED)
AIR BAGS (IF FITTED)
Air bag warning light : Air bag warning light :Air bag warning light : Air bag warning light :
Air bag warning light :
The diagnostic system continually monitors the readiness of the
SRS AIR BAG while the vehicle is being driven. The air bag warning
light on the instrument panel will illuminate for approximately
5 seconds when the ignition is switched on. This is normal and
indicates the system is performing a self check. The following
components are monitored by the indicator.
• •• •
•Airbag control module - ECU
• •• •
•Driver airbag
• •• •
•Passenger air bag (If fitted)
• •• •
•Retractor Pre-tensioners.
• •• •
•All related wiring.
Air bag maintenance and servicing : Air bag maintenance and servicing :Air bag maintenance and servicing : Air bag maintenance and servicing :
Air bag maintenance and servicing :
If the warning light does not illuminate when ignition is
switched on, or remains illuminated after the initial check
period of 5 seconds or flashes during driving, indicates fault
with air bag and seat belt pre-tensioner and it should be
checked by an authorized
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immediately.
• •• •
•The air bag warning light does not illuminate when the
ignition key is turned on.
• •• •
•The air bag warning light illuminates while driving.If the air bag system is not attended to when a warning
is given, it will not function properly in the event of
collision, or it may deploy unexpectedly. The air bag
system fitted to your vehicle does not require regular
maintenance.
NOTE : NOTE :NOTE : NOTE :
NOTE :
1. 1.1. 1.
1.
Any maintenance on or near the SRS components must be
performed only by an authorized
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ORS dealer. Do
not permit anyone else to do service, inspection,
maintenance or repair on any SRS components or wiring.
Similarly, no part of the SRS system should ever be handled
or disposed of by anyone except an authorized
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ORS ORS ORS ORS
ORS dealer. Improper work on the SRS system will result
inadvertent deployment of the air bag or could render the
SRS system inoperative. This could also lead to personal injury.
2. 2.2. 2.
2.Do not modify your steering wheel or any other SRS
components, For example replacement of steering wheel
or modifications to the steering column, front bumper, body
or frame structure can adversely affect the SRS performance
and lead to possible injury.
3. 3.3. 3.
3.If your vehicle has received any front end damage, you
should have the SRS system inspected by an authorized
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ORS ORS ORS ORS
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order.
SRS SRSSRS SRS
SRS
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INDICATORS AND INSTRUMENTSGA GAGA GA
GA
UGES UGESUGES UGES
UGES
Speedometer
Display for Trip - B
Mode Selector Mode SelectorMode Selector Mode Selector
Mode Selector
Knob KnobKnob Knob
Knob
Display for Trip - A
Odometer OdometerOdometer Odometer
Odometer
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or Intensity level of
panel illumination panel illuminationpanel illumination panel illumination
panel illumination
Set SetSet Set
Set
Knob KnobKnob Knob
Knob
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CD) : CD) :CD) : CD) :
CD) :
The speedometer indicates the car speed in km/hr. The odometer records
the total distance the car has been driven. The tripmeter can be used to
measure the distance travelled on each trip or between fuel fillings.
CAUTION CAUTIONCAUTION CAUTION
CAUTION
Keep track of the odometer reading & follow the maintenance
schedule regularly for meeting service requirements.
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instrument panel (LCD) : instrument panel (LCD) :instrument panel (LCD) : instrument panel (LCD) :
instrument panel (LCD) :
The instrument panel has an LCD to display the following :
Main Odometer (Non- resettable) - Counts upto 999999 kms
Tripmeter A (Resettable)- Counts upto 1999.9 kms
Tripmeter B (Resettable)- Counts upto 1999.9 kms
Ambient display and Digital Clock display
Intensity level of instrument panel illumination - selection among preset
levels.
LCD has two line display.The first line displays the Odometer count.The
second line displays either of Tripmeter A, Tripmeter B, Intensity level of
panel illumination, Ambient temperature and Digital clock display.
The selection and control of functions are done through 'MODE' and
'SET' push buttons (knobs) provided on either side of the LCD.
The 'MODE' knob is used to select one of Tripmeter A, Tripmeter B Ambient
temperature , Digital clock display and Intensity level of panel illumination.
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FUEL, LUBRICANTS & COOLANTS
Lubricants and Oils Lubricants and OilsLubricants and Oils Lubricants and Oils
Lubricants and Oils
Recommended lubricants conform to the following
specifications :
1. 1.1. 1.
1.
Engine oil Engine oilEngine oil Engine oil
Engine oil -API-CH4 + MB 228.3 or higher
grade engine oil
2. 2.2. 2.
2.
Gear Box oil Gear Box oilGear Box oil Gear Box oil
Gear Box oil - 75W90 GL-4
3. 3.3. 3.
3.
Power Steering Power SteeringPower Steering Power Steering
Power Steering - ATF Type A, Suffix A
and and and and
and
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ase asease ase
ase
4. 4.4. 4.
4.
Rear & Front axle Rear & Front axleRear & Front axle Rear & Front axle
Rear & Front axle -M/Grade oil SAE 85W 140 GL5
Angolmol AG043 oil
* * * *
* Friction modifier 40819 (2-5%) to be added to oil for
Limited Slip Differential
5. 5.5. 5.
5.
Chassis and wheel Chassis and wheelChassis and wheel Chassis and wheel
Chassis and wheel -SS6805 bearing grease
bearing
bearingbearing bearing
bearing
Please use only recommended grades for good Please use only recommended grades for goodPlease use only recommended grades for good Please use only recommended grades for good
Please use only recommended grades for good
performance. performance.performance. performance.
performance.
DO NOT DO NOT DO NOT DO NOT
DO NOT mix grease of different brands and optional grades.
Replace old grease completely.
The oil change periods recommended in maintenance
schedule should be adhered to.
L LL L
L
UBRIC UBRICUBRIC UBRIC
UBRIC
ANT ANTANT ANT
ANT
S SS S
S
Engine EngineEngine Engine
Engine
Qty : 7.5 Litres Qty : 7.5 Litres Qty : 7.5 Litres Qty : 7.5 Litres
Qty : 7.5 Litres
Recommended grades of engine oil for range of ambient
temperature :
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mbien
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Engine Oil Grade Engine Oil GradeEngine Oil Grade Engine Oil Grade
Engine Oil Grade
- 5 and above SAE 15W/40
- 10 to 0 SAE 5W30
- 20 and -10 SAE 0W30
Front live axle and rear axle oil (Spicer axles) Front live axle and rear axle oil (Spicer axles)Front live axle and rear axle oil (Spicer axles) Front live axle and rear axle oil (Spicer axles)
Front live axle and rear axle oil (Spicer axles)
Use Multigrade oil SAE 85W 140 Angolmol A6043 oil
Capacity : Capacity :Capacity : Capacity :
Capacity :
For Rear axle For Rear axleFor Rear axle For Rear axle
For Rear axle
- 2.2 litres - 2.2 litres- 2.2 litres - 2.2 litres
- 2.2 litres
For Front axle For Front axleFor Front axle For Front axle
For Front axle
- 1.2 litres - 1.2 litres- 1.2 litres - 1.2 litres
- 1.2 litres
Gear Box oil : Gear Box oil :Gear Box oil : Gear Box oil :
Gear Box oil :
Qty : 1.6 Litres Qty : 1.6 LitresQty : 1.6 Litres Qty : 1.6 Litres
Qty : 1.6 Litres
75W90, (Synthetic oil GL4)
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MAINTENANCE
• •• •
•Engine Compartment Engine CompartmentEngine Compartment Engine Compartment
Engine Compartment
• •• •
•Air filter Air filterAir filter Air filter
Air filter
• •• •
•Cooling system Cooling systemCooling system Cooling system
Cooling system
• •• •
•Engine oil & oil filter Engine oil & oil filterEngine oil & oil filter Engine oil & oil filter
Engine oil & oil filter
• •• •
•Changing fuel filter Changing fuel filterChanging fuel filter Changing fuel filter
Changing fuel filter
• •• •
•Changing gear box oil Changing gear box oilChanging gear box oil Changing gear box oil
Changing gear box oil
• •• •
•Changing transfer case oil Changing transfer case oilChanging transfer case oil Changing transfer case oil
Changing transfer case oil
• •• •
•Changing front axle & rear axle oil Changing front axle & rear axle oilChanging front axle & rear axle oil Changing front axle & rear axle oil
Changing front axle & rear axle oil
• •• •
•Head lamp & head lamp focus adjustment Head lamp & head lamp focus adjustmentHead lamp & head lamp focus adjustment Head lamp & head lamp focus adjustment
Head lamp & head lamp focus adjustment
• •• •
•Clutch & brake fluid Clutch & brake fluidClutch & brake fluid Clutch & brake fluid
Clutch & brake fluid
• •• •
•Power steering Power steeringPower steering Power steering
Power steering
• •• •
•L LL L
L
CR CRCR CR
CR
V (if fitt V (if fittV (if fitt V (if fitt
V (if fitt
ed) ed)ed) ed)
ed)
• •• •
•Battery BatteryBattery Battery
Battery
• •• •
•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
• •• •
•Wheels & tyres Wheels & tyresWheels & tyres Wheels & tyres
Wheels & tyres
• •• •
•V VV V
V
ehicle c ehicle cehicle c ehicle c
ehicle c
ar arar ar
ar
e ee e
e
• •• •
•Fuses & Relays Fuses & RelaysFuses & Relays Fuses & Relays
Fuses & Relays
• •• •
•Catalytic Converter Catalytic ConverterCatalytic Converter Catalytic Converter
Catalytic Converter
• •• •
•EGR system EGR systemEGR system EGR system
EGR system
• •• •
•T TT T
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urb
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char charchar char
char
ger gerger ger
ger
• •• •
•Air Conditioning Air ConditioningAir Conditioning Air Conditioning
Air Conditioning
• •• •
•Belts tension Belts tensionBelts tension Belts tension
Belts tension
Your TATA SAFARI is designed to give you long trouble free service for
thousands of kilometres/miles. However with proper maintenance
care you can get optimum performance from your vehicle. We have
indicated some of the important maintenance operations to be
carried out on the vehicle. Please read the procedure carefully and
get it attended at Authorised Workshop.
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Changing of Engine Oil and Oil Filter Changing of Engine Oil and Oil FilterChanging of Engine Oil and Oil Filter Changing of Engine Oil and Oil Filter
Changing of Engine Oil and Oil Filter
Change the oil and oil filter at specified service intervals. (Engine oil and
oil filter may be changed earlier inline with recommendation given for
additional maintenance schedule under severe driving condition)
Changing of oil and oil filter requires access from underneath the vehicle.
Vehicle should be raised on a hydraulic lift of a service station or should
be on a service pit.
1 . Run the engine until it reaches normal operating temperature. Then
shut it off.
2. Remove oil sump guard.
3. Open the bonnet and remove engine oil filler cap. Remove the drain
plug of the oil sump from the bottom of the engine. Drain the oil into
an appropriate container.
4. Remove the oil filter with the help of special wrench. The removed
oil filter should not be reused and hence should be destroyed to
avoid recycling of the same. Used filter and oil should be disposed
in compliance with the current legislation.
5. Ensure cooler is tightened to it’s position.
6. Smear a little fresh engine oil on rubber gasket of new engine oil
filter. Hand tighten the engine oil filter fully and further 3/4 turn with
special tool.
Do not over tighten engine oil filter as this may damage oil filter and
oil may leak out.
7. Before filling in fresh oil in the engine, clean the drain plug..
ENGINE OIL & OIL FIL ENGINE OIL & OIL FILENGINE OIL & OIL FIL ENGINE OIL & OIL FIL
ENGINE OIL & OIL FIL
TER TERTER TER
TER
1. Engine Oil Filling Neck
2. Dip Stick
1. Oil Sump Drain Plug
2. Engine Oil Filter
M A I N T E N A N C E
2 22 2
21 11 1
1
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