turbo TATA SAFARI 2015 Owners Manual

75
D R I V I N G
• •• •
•S SS S
S
tar tartar tar
tar
ting & st ting & stting & st ting & st
ting & st
opping the engine opping the engineopping the engine opping the engine
opping the engine
• •• •
•Preparing to drive Preparing to drivePreparing to drive Preparing to drive
Preparing to drive
• •• •
•Running-in period Running-in periodRunning-in period Running-in period
Running-in period
• •• •
•Gear change Gear changeGear change Gear change
Gear change
• •• •
•Brakes (Anti-lock brake system) Brakes (Anti-lock brake system)Brakes (Anti-lock brake system) Brakes (Anti-lock brake system)
Brakes (Anti-lock brake system)
• •• •
•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
• •• •
•Fuel economy Fuel economyFuel economy Fuel economy
Fuel economy
• •• •
•Four wheel driving system Four wheel driving systemFour wheel driving system Four wheel driving system
Four wheel driving system
• •• •
•Limited slip differential Limited slip differentialLimited slip differential Limited slip differential
Limited slip differential
• •• •
•Driving in adverse conditions Driving in adverse conditionsDriving in adverse conditions Driving in adverse conditions
Driving in adverse conditions
• •• •
•Driving Safety Driving SafetyDriving Safety Driving Safety
Driving Safety
This section gives you important tips on how to start the engine, how
to take care of turbo charger, operation of transmission and transfer
case. It also includes important tips on safe driving in adverse
conditions and difficult terrains.
The information on topics listed above would certainly help you in
safe and carefree driving.
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D R I V I N GST STST ST
ST
AR ARAR AR
AR
TING AND ST TING AND STTING AND ST TING AND ST
TING AND ST
OPPING OPPING OPPING OPPING
OPPING
THE ENGINE THE ENGINETHE ENGINE THE ENGINE
THE ENGINE
Starting the Engine Starting the EngineStarting the Engine Starting the Engine
Starting the Engine
Before starting
1. Apply parking brake.
2. Ensure gear lever in neutral.
A. Insert the key in steering cum ignition lock and turn it to ‘ON’ position.
B. Press the clutch pedal fully.
C. Now crank the engine.
D. If the engine does not start turn the key to off position and try after
30 seconds.
NOTICE NOTICENOTICE NOTICE
NOTICE
After starting run the engine in low idle speed for at least 30 seconds.
Do not press accelerator pedal while starting the engine to avoid
damage to turbocharger..
Stopping the Engine Stopping the EngineStopping the Engine Stopping the Engine
Stopping the Engine
Before switching off the engine, run the engine idle for atleast 30 seconds
and then switch off. This will allow the engine oil to lubricate the
turbocharger, till its speed is fully reduced and also allow the unit to cool
down.
Above precautions will ensure satisfactory life and performance from
the turbocharger.1. Parking Brake Lever 2. Release Button
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FUEL, LUBRICANTS & COOLANTSBRANDED LUBRICANTS, COOLANTS & ADHESIVES BRANDED LUBRICANTS, COOLANTS & ADHESIVESBRANDED LUBRICANTS, COOLANTS & ADHESIVES BRANDED LUBRICANTS, COOLANTS & ADHESIVES
BRANDED LUBRICANTS, COOLANTS & ADHESIVES
PLEASE USE ONL PLEASE USE ONLPLEASE USE ONL PLEASE USE ONL
PLEASE USE ONL
Y FOLL Y FOLLY FOLL Y FOLL
Y FOLL
O OO O
O
WING GENUINE OILS, WING GENUINE OILS,WING GENUINE OILS, WING GENUINE OILS,
WING GENUINE OILS,


C CC C
C
OOL OOLOOL OOL
OOL
ANT ANTANT ANT
ANT
S , S ,S , S ,
S ,
L L L L
L
UBRIC UBRICUBRIC UBRIC
UBRIC
ANT ANTANT ANT
ANT
S , S ,S , S ,
S ,
ANTI R ANTI R ANTI R ANTI R
ANTI R
UST & SOUND DEADENING UST & SOUND DEADENINGUST & SOUND DEADENING UST & SOUND DEADENING
UST & SOUND DEADENING
C CC C
C
O OO O
O
A AA A
A
T TT T
T
S, S,S, S,
S,


WINDSCREEN SEAL WINDSCREEN SEALWINDSCREEN SEAL WINDSCREEN SEAL
WINDSCREEN SEAL
ANT ANTANT ANT
ANT
,, ,,
,
ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BR
ADHESIVES & FUEL ADDITIVES BR
ANDED BY ANDED BY ANDED BY ANDED BY
ANDED BY
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 F ORS FORS F ORS F
ORS F
OR OPTIMUM OR OPTIMUMOR OPTIMUM OR OPTIMUM
OR OPTIMUM
PERFORMANCE OF PERFORMANCE OF PERFORMANCE OF PERFORMANCE OF
PERFORMANCE OF
Y YY Y
Y
OUR OUR OUR OUR
OUR
T TT T
T
A AA A
A
T TT T
T
A Saf A SafA Saf A Saf
A Saf
ari DICOR ari DICORari DICOR ari DICOR
ari DICOR
... ......
...
...
ITEM COMPANY BRAND QTY
ENGINE OIL ENGINE OILENGINE OIL ENGINE OIL
ENGINE OIL
CASTROL CASTROLCASTROL CASTROL
CASTROL
Castrol GTX (Diesel) Castrol GTX (Diesel)Castrol GTX (Diesel) Castrol GTX (Diesel)
Castrol GTX (Diesel)
HPCL HPCLHPCL HPCL
HPCL
HP MIL HP MILHP MIL HP MIL
HP MIL
CY CY CY CY
CY
TURBO PL TURBO PLTURBO PL TURBO PL
TURBO PL
US USUS US
US
7.5 Litres 7.5 Litres7.5 Litres 7.5 Litres
7.5 Litres
COOLANT COOLANTCOOLANT COOLANT
COOLANT
SUNST SUNSTSUNST SUNST
SUNST
AR ARAR AR
AR
Golden Cruiser Premium 1400 M Golden Cruiser Premium 1400 MGolden Cruiser Premium 1400 M Golden Cruiser Premium 1400 M
Golden Cruiser Premium 1400 M
HPCL HPCLHPCL HPCL
HPCL
HP HP HP HP
HP
T TT T
T
handa R handa Rhanda R handa R
handa R
aja P aja Paja P aja P
aja P
Approx 13 Litres Approx 13 LitresApprox 13 Litres Approx 13 Litres
Approx 13 Litres
CASTROL CASTROLCASTROL CASTROL
CASTROL
Radicool
RadicoolRadicool Radicool
Radicool
GEAR BOX (G-76) GEAR BOX (G-76)GEAR BOX (G-76) GEAR BOX (G-76)
GEAR BOX (G-76)
HPCL HPCLHPCL HPCL
HPCL
HP Gear Oil XP 75W90 HP Gear Oil XP 75W90HP Gear Oil XP 75W90 HP Gear Oil XP 75W90
HP Gear Oil XP 75W90
CASTROL CASTROLCASTROL CASTROL
CASTROL
Castrol Syntro 75W90 GL4 Castrol Syntro 75W90 GL4Castrol Syntro 75W90 GL4 Castrol Syntro 75W90 GL4
Castrol Syntro 75W90 GL4
1.6 Litres 1.6 Litres1.6 Litres 1.6 Litres
1.6 Litres
TRANSFERCASE TRANSFERCASETRANSFERCASE TRANSFERCASE
TRANSFERCASE
HPCL HPCLHPCL HPCL
HPCL
HP-A HP-AHP-A HP-A
HP-A
ut utut ut
ut
oma omaoma oma
oma
tic tic tic tic
tic
T TT T
T
r rr r
r
ansmission F ansmission Fansmission F ansmission F
ansmission F
luid luid luid luid
luid
T TT T
T
yp ypyp yp
yp
e A e Ae A e A
e A
1.2 Litres 1.2 Litres
1.2 Litres 1.2 Litres
1.2 Litres
CASTROL CASTROLCASTROL CASTROL
CASTROL
C CC C
C
astr astrastr astr
astr
ol ol ol ol
ol
T TT T
T
r rr r
r
ansp anspansp ansp
ansp
o oo o
o
w ww w
w
er er er er
er
T TT T
T
Q QQ Q
Q
POWER STEERING OIL POWER STEERING OILPOWER STEERING OIL POWER STEERING OIL
POWER STEERING OIL
HPCL HPCLHPCL HPCL
HPCL
HP-A HP-AHP-A HP-A
HP-A
TF D TF DTF D TF D
TF D
e ee e
e
x II x IIx II x II
x II
1.4 Litres 1.4 Litres1.4 Litres 1.4 Litres
1.4 Litres
CASTROL CASTROLCASTROL
CASTROL
CASTROL
C CC C
C
astr astrastr astr
astr
ol ol ol ol
ol
T TT T
T
QD QDQD QD
QD
REAR AXLE, LIVE FRONT AXLE, REAR AXLE, LIVE FRONT AXLE,REAR AXLE, LIVE FRONT AXLE, REAR AXLE, LIVE FRONT AXLE,
REAR AXLE, LIVE FRONT AXLE,
HPCL HPCLHPCL HPCL
HPCL
HP AXLE OIL 85W140 HP AXLE OIL 85W140HP AXLE OIL 85W140 HP AXLE OIL 85W140
HP AXLE OIL 85W140
2.2 2.2 2.2 2.2
2.2
(Rear) (Rear)(Rear) (Rear)
(Rear) 1.2 1.2 1.2 1.2
1.2(Front (Front(Front (Front
(Front) )) )
)
CASTROL CASTROLCASTROL CASTROL
CASTROL
Castrol Long Drain 85W140 Castrol Long Drain 85W140Castrol Long Drain 85W140 Castrol Long Drain 85W140
Castrol Long Drain 85W140
BR BRBR BR
BR
AKE / CL AKE / CLAKE / CL AKE / CL
AKE / CL
UT UTUT UT
UT
CH FL CH FLCH FL CH FL
CH FL
UID UIDUID UID
UID
HP CL HP CLHP CL HP CL
HP CL
Super Duty Brake Fluid DOT - 3 Super Duty Brake Fluid DOT - 3Super Duty Brake Fluid DOT - 3 Super Duty Brake Fluid DOT - 3
Super Duty Brake Fluid DOT - 3
As required As requiredAs required As required
As required
CASTROL CASTROLCASTROL CASTROL
CASTROL
Universal Brake Fluid DOT 3 Universal Brake Fluid DOT 3Universal Brake Fluid DOT 3 Universal Brake Fluid DOT 3
Universal Brake Fluid DOT 3
WHEEL BEARING & CHASSIS WHEEL BEARING & CHASSISWHEEL BEARING & CHASSIS WHEEL BEARING & CHASSIS
WHEEL BEARING & CHASSIS
HPCL HPCLHPCL HPCL
HPCL
HP Multipurpose Grease-2 HP Multipurpose Grease-2HP Multipurpose Grease-2 HP Multipurpose Grease-2
HP Multipurpose Grease-2
As required As requiredAs required As required
As required
CASTROL CASTROLCASTROL CASTROL
CASTROL
Castrol AP2 Castrol AP2Castrol AP2 Castrol AP2
Castrol AP2
ANTI R ANTI R ANTI R ANTI R
ANTI R
UST
UST UST UST
UST
TREA TREATREA TREA
TREA
T TT T
T
MENT MENTMENT MENT
MENT
DINITROL DINITROLDINITROL DINITROL
DINITROL
Dinitrol DinitrolDinitrol Dinitrol
Dinitrol
— —— —
—
& SOUND DEADENING & SOUND DEADENING & SOUND DEADENING & SOUND DEADENING
& SOUND DEADENING
WUERTH WUERTHWUERTH WUERTH
WUERTH
Wuerth WuerthWuerth Wuerth
Wuerth
3M 3M3M 3M
3M
3M 3M3M 3M
3M
— —— —
—


WIND SCREEN SEAL WIND SCREEN SEALWIND SCREEN SEAL WIND SCREEN SEAL
WIND SCREEN SEAL
ANT ANTANT ANT
ANT
WUERTH WUERTHWUERTH WUERTH
WUERTH
Wuerth WuerthWuerth Wuerth
Wuerth
— —— —
—
3M 3M3M 3M
3M
3M 3M3M 3M
3M
— —— —
—
Car System Car SystemCar System Car System
Car System
Car System Car SystemCar System Car System
Car System— —— —
—
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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
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AIR FIL AIR FILAIR FIL AIR FIL
AIR FIL
TER TERTER TER
TER
Air Filter Air FilterAir Filter Air Filter
Air Filter
The air filter element should be cleaned as per service schedule .
Replace the air filter element with a new one when the service
indicator shows red band even after cleaning in vehicle operations.
Always use genuine air filter element.
Replacement of Air Filter Element Replacement of Air Filter ElementReplacement of Air Filter Element Replacement of Air Filter Element
Replacement of Air Filter Element
a) Disconnect air filter from hose. Unscrew top cover of the air
filter.
b) Remove the cover of the air filter.
c) Remove the air filter element.
d) Clean the air filter element with pressurised air. Do not tap or
hammer the element on ground.
e) Check element for puncture or pin holes by light source.
f ) If found OK install paper filter element. Fit the cover and tighten air
filter screws at the place.
g) Clean the hose connecting the air filter to turbocharger pipe.
Reset the indicator by pressing the rubber cap, red band will disappear
from Service Indicator.
M A I N T E N A N C E
1. Service Indicator 2. Air filter
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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 )
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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
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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