torque TATA SAFARI 2015 Owners Manual

82
Automatic Hub Locks Automatic Hub LocksAutomatic Hub Locks Automatic Hub Locks
Automatic Hub Locks
While driving in 2H mode this mechanism on the front axle
hub allows the hub to free wheel. This avoids the unnecessary
spinning of front drive components and results in fuel saving,
reduced noise and longer component life.
As soon as 4H or 4L mode is selected the hub gets
automatically connected to front drive line to increase the
traction.
Limited Slip Differential Limited Slip DifferentialLimited Slip Differential Limited Slip Differential
Limited Slip Differential
(Standard on 4x4 and optional on others)
A standard differential delivers torque equally to each wheel.
In case one wheel loses traction and begins to spin, the
differential distributes the rotary speed unequally but with
same torque. This can cause the wheel with good traction to
slow down or stop while the wheel which lost traction rotates
with increased speed. Such a situation can prevent the vehicle
from moving.
The limited slip differential provided in the rear axle takes
care of such situations. The clutch lock arrangement provided
internally, ensures that in case one wheel loses traction and
begins to slip, a locking action takes place which prevents
differential action and both wheels turn at the same speed.
D R I V I N GTR TRTR TR
TR
ANSFER C ANSFER CANSFER C ANSFER C
ANSFER C
ASE ASEASE ASE
ASE
,, ,,
,
AUT AUT AUT AUT
AUT
OMA OMAOMA OMA
OMA
TIC HUB L TIC HUB LTIC HUB L TIC HUB L
TIC HUB L
OCK & LIMITED SLIP DIFFERENTIAL OCK & LIMITED SLIP DIFFERENTIALOCK & LIMITED SLIP DIFFERENTIAL OCK & LIMITED SLIP DIFFERENTIAL
OCK & LIMITED SLIP DIFFERENTIAL
T TT T
T
r rr r
r
ansf ansfansf ansf
ansf
er C er Cer C er C
er C
ase and ase and ase and ase and
ase and
T TT T
T
r rr r
r
ansf ansfansf ansf
ansf
er C er Cer C er C
er C
ase S ase Sase S ase S
ase S
elec elecelec elec
elec
t tt t
t
or E or Eor E or E
or E
lec leclec lec
lec
tr trtr tr
tr
ic S ic Sic S ic S
ic S
wit witwit wit
wit
ch chch ch
ch
(If fitted) (If fitted)(If fitted) (If fitted)
(If fitted)
On four wheel drive vehicles transfer case is fitted after the
gear box for driving front live axle along with rear axle.
The following 3 selector positions are provided on the knob.
2H - 2H -2H -
2H -
2H - Only two rear wheels are driven and transfer case
operates at 1:1 ratio.
4H - 4H -4H - 4H -
4H - All four wheels are driven and transfer case operates
at 1:1 ratio.
4L - 4L -4L - 4L -
4L - All four wheels are driven and transfer case operates
at 2.48:1 speed reduction ratio.
Automatic Hub Lock4X4 Selector Switch
For driving in 2H mode keep the selector knob in 2H position.
(*For 4 WD model only)
ProCarManuals.com

83
D R I V I N GLIMITED SLIP DIFFERENTIAL AND FOUR LIMITED SLIP DIFFERENTIAL AND FOUR LIMITED SLIP DIFFERENTIAL AND FOUR LIMITED SLIP DIFFERENTIAL AND FOUR
LIMITED SLIP DIFFERENTIAL AND FOUR
WHEEL DRIVING WHEEL DRIVINGWHEEL DRIVING WHEEL DRIVING
WHEEL DRIVING
Thus unnecessary spinning of one wheel is avoided and torque
is transmitted to both wheels, thus assisting the vehicle to traverse
loose terrain. However during normal driving, the differential
action takes place in the same manner as in a standard differential.
1. 1.1. 1.
1.
Four Wheel Drive Operation Four Wheel Drive OperationFour Wheel Drive Operation Four Wheel Drive Operation
Four Wheel Drive Operation
In 2-H mode, only the rear two wheels of the vehicle are
powered by the engine and the front wheels are merely
pushed. By shifting to four wheel drive mode (4H or 4L)
the rear as well as the front axles get geared to the engine
through transfer case and transmit the engine power to all
four wheels. This gives the vehicle increased traction.
In 4H mode, the transmitted engine torque and vehicle
speed remain the same as in 2H. However, when you shift
to 4L mode engine torque is multiplied and vehicle moves
at low speed in the same gears with increased traction. 4L
mode is provided for negotiating sharp gradients or driving
through loose soil/sand.
2. 2.2. 2.
2.
Shifting from 2H to 4H Shifting from 2H to 4HShifting from 2H to 4H Shifting from 2H to 4H
Shifting from 2H to 4H
Turn the selector knob from 2H to 4H position. 4H indicator
on instrument panel will light up. Changing from 2H to 4H
can be done at any speed upto 65 km/h (40 mph). No
pressing of clutch pedal is required.3. 3.3. 3.
3.
Shifting from 4H to 2H Shifting from 4H to 2HShifting from 4H to 2H Shifting from 4H to 2H
Shifting from 4H to 2H
Turn the selector knob from 4H to 2H position. 4H indicator
on instrument panel will go off. Changing from 4H to 2H
can be done at any speed upto 65 km/h (40 mph). No
pressing of clutch pedal is required.
Free Wheeling of Front Hub Free Wheeling of Front HubFree Wheeling of Front Hub Free Wheeling of Front Hub
Free Wheeling of Front Hub
After shifting from 4H to 2H, for effecting free wheeling of front
wheels, direction of vehicle motion needs to be changed. If
the vehicle was moving forward in 4H then bring it to halt and
engage reverse gear of main gear box. (If it was moving reverse
in 4H mode then stop it, and then engage forward gear of
main gear box.) After stopping and changing the gear the
vehicle must travel in opposite direction for a minimum of three
meters, before free wheeling takes place.
4. 4.4. 4.
4.
Shifting from 4H to 4L Shifting from 4H to 4LShifting from 4H to 4L Shifting from 4H to 4L
Shifting from 4H to 4L
Stop the vehicle. Press clutch pedal. Turn the selector knob
from 4H to 4L position. 4L indicator light on instrument panel
will blink few times and remain on.
5. 5.5. 5.
5.
Shifting from 4L to 4H Shifting from 4L to 4HShifting from 4L to 4H Shifting from 4L to 4H
Shifting from 4L to 4H
Stop the vehicle. Press clutch pedal. Turn the selector knob
from 4L to 4H position. 4H indicator light on instrument panel
will blink few times and will remain on.
ProCarManuals.com

98
1.0 1.01.0 1.0
1.0
ENGINE : ENGINE :ENGINE : ENGINE :
ENGINE :
Model : TATA 2.2 L DICOR
Type : 16 valve, Water cooled, Direct
injection, commonrail , Turbo-
charged, intercooledDiesel
Engine with cranck case
breather and relief valve.
Exhaust gas recirculation
system.
No. of cylinders : 4 inline
Bore/Stroke : 85 mm x 96 mm
Capacity :2179 cc
Max. engine output : 103 kw at 4000 rpm
Max. Torque : 320 Nm at 1700-2700 rpm
as per CMVR / TAP-115/116
Firing order: 1-3-4-2
Engine oil capacity : Max.7.5 litres / Min.5.5 litres
VEHICLE SPECIFICATIONSENGINE ENGINEENGINE ENGINE
ENGINE
,, ,,
,
CL CL CL CL
CL
UT UTUT UT
UT
CH & GEAR BO CH & GEAR BOCH & GEAR BO CH & GEAR BO
CH & GEAR BO
X XX X
X
2.0 2.02.0 2.0
2.0
CL CLCL CL
CL
UT UTUT UT
UT
CH : CH :CH : CH :
CH :
CLUTCH : Single plate dry friction
diaphragm type
Outside diameter of :240 mm
clutch lining
Friction area : 452 sq.cm. (approx.)
3.0 3.03.0 3.0
3.0
GEAR BOX : GEAR BOX :GEAR BOX : GEAR BOX :
GEAR BOX :
Model :G-76-5/4.1 with overdrive
Type : Synchromesh on all gears
No. of gears : 5 Forward 1 Reverse
Gear ratios : 1st 4.10
2nd 2.2 2
3rd 1.37
4th 1.00
5th 0.7 7
Rev. 3.75
ProCarManuals.com

109
FUEL FIL FUEL FILFUEL FIL FUEL FIL
FUEL FIL
TER & FUEL SY TER & FUEL SYTER & FUEL SY TER & FUEL SY
TER & FUEL SY
STEM STEMSTEM STEM
STEM
6. Refit the drain plug using a new sealing washer. Tighten
drain plug to 5 mkg. torque.
7. Fill, recommended quantity of fresh engine oil in the crank
case and secure the oil filler cap in its place.
8. Start the engine and run for a few minutes. The engine oil
pressure indicator lamp should go ‘off ’ after starting the
engine.
9. Check for engine oil leakages.
10. Stop the engine and recheck engine oil level after a few
minutes. If necessary add oil to bring the level to the upper
mark on the dipstick.
NOTICE NOTICENOTICE NOTICE
NOTICE
Use of reclaimed oil is not recommended
Priming Pump Priming PumpPriming Pump Priming Pump
Priming Pump
Priming pump is used for priming the fuel manually after
overhauling of the engine or after refitment of fuel lines. Pump
the fuel by means of priming pump until all air in the fuel line is
removed. Before cranking the engine ensure that there is no air
in the fuel system.
NOTICE NOTICENOTICE NOTICE
NOTICE
Please do not loosen/remove high pressure pipes and injectors
for air bleeding in the fuel.
M A I N T E N A N C E
F FF F
F
uel & F uel & Fuel & F uel & F
uel & F
ilt iltilt ilt
ilt
er D er Der D er D
er D
r rr r
r
aining ainingaining aining
aining
Loosen drain plugs by 1-2 turn and drain out water and other
sediments from fuel filter bowls depending on operating
conditions to ensure that no water is allowed to enter the fuel
system.
S SS S
S
edimen edimenedimen edimen
edimen
t tt t
t
er er er er
er
W WW W
W
a aa a
a
t tt t
t
er D er Der D er D
er D
r rr r
r
aining ainingaining aining
aining
Water sedimenter is located near fuel tank at rear left hand side
of the vehicle.
Loosen drain plug by 1-2 turns and drain out water and other
sediments from sedimenter when water level indicator lamp
glows in instrument cluster to ensure that no water is
allowed to enter the fuel system.
Sedimenter
ProCarManuals.com

110
Gear Box Oil Gear Box OilGear Box Oil Gear Box Oil
Gear Box Oil
C CC C
C
heck heckheck heck
heck
ing of Oil L ing of Oil Ling of Oil L ing of Oil L
ing of Oil L
e ee e
e
v vv v
v
el elel el
el
1. Clean the oil level plug and surrounding area.
2 . Remove the oil level plug and check whether oil is dripping out.
Oil level must not be below the filler plug. Add oil to bring it to
the level.
3. Tighten oil level plug to 2-3 mkg. torque.
C CC C
C
hanging Oil in G hanging Oil in Ghanging Oil in G hanging Oil in G
hanging Oil in G
ear B ear Bear B ear B
ear B
o oo o
o
x xx x
x
1. Let the engine idle for about 5 min. in neutral, so that the gear box
oil is warmed up.
2. Clean the oil level plug, drain plug and surrounding area.
3. Place a container under gear box to collect the oil.
4. Remove the drain plug and let the oil drain out.
5. Also remove the oil level plug.
6. Tighten the oil drain plug and fill new recommended oil through oil
level plug and tighten the oil drain plug oil level plug to 2-3 mkg.
torque.
GEAR BO GEAR BOGEAR BO GEAR BO
GEAR BO
X OIL X OILX OIL X OIL
X OIL
1. Gear Box Oil Filler Plug / Level Plug
2. Gear Box Drain Plug
1
2
M A I N T E N A N C E
ProCarManuals.com

111
TRANSFER CASE OIL TRANSFER CASE OILTRANSFER CASE OIL TRANSFER CASE OIL
TRANSFER CASE OIL
C CC C
C
heck heckheck heck
heck
ing Oil L ing Oil Ling Oil L ing Oil L
ing Oil L
e ee e
e
v vv v
v
el of el of el of el of
el of
T TT T
T
r rr r
r
ansf ansfansf ansf
ansf
er C er Cer C er C
er C
ase asease ase
ase
NO NONO NO
NO
TICE TICETICE TICE
TICE
Before checking or removing the oil, warming up of the transfer
case is necessary. This should be done by driving the vehicle for
some time in 4x4 mode.
Checking of Oil levels Checking of Oil levelsChecking of Oil levels Checking of Oil levels
Checking of Oil levels
1. Clean the oil level plug and surrounding area.
2 . Remove the oil level plug and check whether oil is dripping out.
3 . If oil is not dripping out, oil level must be below the required
level. Add oil to bring it to the level when it starts dripping out.
4. Tighten oil level plug. Tightening torque of oil level plug is 2 to
3 mkg.
C CC C
C
hanging of hanging of hanging of hanging of
hanging of
T TT T
T
r rr r
r
ansf ansfansf ansf
ansf
er C er Cer C er C
er C
ase Oil ase Oilase Oil ase Oil
ase Oil
1. Clean the oil level plug, drain plug and surrounding area.
2. Place a container to collect oil, under transfer case.
3. Remove the drain plug and let the oil drain out.
4. Remove the oil level plug.
5. Tighten oil drain plug and fill new recommended oil through oil
level plug, till it begins to drip out.
6. Tighten oil level plug. Tightening torque of oil drain plug is 2 to 3 mkg.
1. Transfer case Oil Filler Plug / Level Plug
2. Transfer case Oil Drain Plug
1
2
M A I N T E N A N C E
ProCarManuals.com

112
Checking Oil Level in Front/Rear Axle Checking Oil Level in Front/Rear AxleChecking Oil Level in Front/Rear Axle Checking Oil Level in Front/Rear Axle
Checking Oil Level in Front/Rear Axle
1 . Clean the oil level plug and surrounding area.
2. Remove the oil level plug and check whether oil is dripping
out. Oil level must be below the required level. Add oil to bring
it to the level, when it starts dripping out.
3 . Tighten oil level plug to 2 to 3 mkg. torque.
Changing Oil in Front Axle/Rear Axle Changing Oil in Front Axle/Rear AxleChanging Oil in Front Axle/Rear Axle Changing Oil in Front Axle/Rear Axle
Changing Oil in Front Axle/Rear Axle
1 . Clean the oil level plug, drain plug and surrounding area.
2 . Place a container under Front/Rear axle to collect the oil.
3 . Remove the drain plug and let the oil drain out.
4 . Also remove the oil level plug.
5 . Tighten the oil drain plug and fill new recommended oil through
oil level plug till it begin to drip.
6 . Tighten oil drain and oil level plugs to 2 to 3 mkg. torque.
FRONT AXLE AND REAR AXLE OIL FRONT AXLE AND REAR AXLE OILFRONT AXLE AND REAR AXLE OIL FRONT AXLE AND REAR AXLE OIL
FRONT AXLE AND REAR AXLE OIL
1. Front Axle Oil Filler Plug / Level Plug
2. Front Axle Oil Drain Plug
1
2
M A I N T E N A N C E
ProCarManuals.com

125
R RR R
R
epair epairepair epair
epair
ing a ing a ing a ing a
ing a
T TT T
T
yr yryr yr
yr
e ee e
e
•Mark suitability the tyre position (if original colour dot mark is
not visible) with reference to valve stem hole to ensure that the
tyre is refitted in original location.
•Ensure that balancing weights are not disturbed during removal
of tyres.
•Check the balance weight prior to removal of tyre if found loose,
mark its location on rim & refit properly. Balance the wheel after
every dismantling and assembly of tyre on wheel rim.
•Tightening torque of wheel nut is 12-15 mkg.
•While fitting wheels on vehicle ensure that wheel bolts are free
from dust, scratches, dirt, dents, etc.
•Do not apply any oil on the wheel nut or bolt. Wipe off if present.
T TT T
T
YRES YRESYRES YRES
YRESM A I N T E N A N C E
ProCarManuals.com

133
TURBO CHARGER (IF FITTED) TURBO CHARGER (IF FITTED)TURBO CHARGER (IF FITTED) TURBO CHARGER (IF FITTED)
TURBO CHARGER (IF FITTED)
V VV V
V
ar arar ar
ar
iable iable iable iable
iable
T TT T
T
urbine urbine urbine urbine
urbine
T TT T
T
echnolo echnoloechnolo echnolo
echnolo
g gg g
g
y- y- y- y-
y-
VT VTVT VT
VT
T T T T
T
T TT T
T
urb urburb urb
urb
o oo o
o
char charchar char
char
ger : ger :ger : ger :
ger :
Your vehicle is fitted with a turbocharger having variable
turbine technology ( VTT ). Turbocharger is an efficient
supercharging device used in our engine. It makes optimal
use of thermal energy of engine exhaust gases to run a
turbine which in turn drives a compressor to force air under
pressure into the inlet manifold. This turbocharger is
optimized for higher power output flat torque across large
engine speed range and better fuel consumption.
L LL L
L
ubr ubrubr ubr
ubr
ic icic
ic
ic
a aa a
a
tion of tion of tion of tion of
tion of
T TT T
T
urb urburb urb
urb
o oo o
o
char charchar char
char
ger : ger :ger : ger :
ger :
The turbocharger rotor assembly is supported by two fully
floating bearing bushes in the bearing housing. These
bearing bushes are lubricated with finely filtered engine
oil from the lubrication system of the engine.
Idle the engine for a while (30 seconds) after starting the
engine and before stopping the engine to ensure adequate
lubricating oil supply to the turbocharger.
T TT T
T
urb urburb urb
urb
o oo o
o
char charchar char
char
ger C ger Cger C ger C
ger C
onnec onneconnec onnec
onnec
tions : tions :tions : tions :
tions :
All turbocharger connections must be leak-proof. Check air
inlet, air outlet, exhaust gas inlet and exhaust outlet
connections as well as oil inlet and outlet connections to
the turbocharger and tighten the connections where
required.Proper maintenance of air filter, oil filter as well as use of
correct grade of oil and adherence to oil change intervals is
essential for proper functioning of the turbocharger.
If you suspect any malfunctioning of the turbocharger, take
the vehicle to the nearest dealer. Do not remove the
turbocharger yourself.
M A I N T E N A N C E
Turbocharger ( VTT )
ProCarManuals.com