TATA Motors SUMO GOLD Owner'S Manual & Service Book Download Page 7

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CONTENTS

VEHICLE MAINTENANCE

Engine Compartment - CR-4

Engine Compartment - 4SPTC

Changing Engine Oil

Changing Oil Filter

Engine Air Filter

Fuel Filter & Priming CR-4

Fuel Filter & Priming 4SPTC

Fan Belt Tension Adjustment

Brake Clutch System Bleeding

Cooling System

Brake System

Brake Adjustment

Wheels & Tyres

Wheel Change

Wheel Alignment

Tyre Pressure

Wheel Balancing

Replacing Tyre / Tube

Replacing Tyre / Rim

Tyre Rotation

Headlamps

Head Lamp Adjustment

Head Lamp Bulb Replacement

Bulb Specification

Fuses

Vehicle Care

FUEL, LUBRICANTS & COOLANTS

Fuel

Lubricants

Coolants

Recommended Oils, Lubricants

TECHNICAL SPECIFICATIONS

SPECIAL INSTRUCTIONS

SERVICE SCHEDULE

101

RECORD OF SERVICE
PERFORMED

105

RECORD OF REPAIRS
CARRIED OUT

107

ALPHABETICAL INDEX

108

ABBREVIATIONS

110

Summary of Contents for SUMO GOLD

Page 1: ...OLD A SUMO GOLD A SUMO GOLD A SUMO GOLD A SUMO GOLD CR 4 BS IV 4SPTC BS III Owner s Manual Service Book Mumbai Pune The contents given in this book are not binding subject to change without notice and are for illustration purpose only ...

Page 2: ...r Manual 12 Tool Kit a Wheel Spanner b Screw Driver c Ring Spanner 8 9 d Socket Handle You are also entitled for Free Services as per details given in your Owner s manual and service book at any TATA MOTORs Dealership or TATA MOTORS Authorised Service Centre TASC or Tata Motors Authorised Service Point TASP On the spot settlement of warranty as per terms and conditions given in this book We welcom...

Page 3: ...uld request you to get acquainted with the details in this owner s manual which will enable you to derive optimum performance from your Tata Sumo gold We look forward to having you as a satisfied customer and hope to have you retain us as your first choice for any of your motoring needs We are privileged to have you as our customer DO YOU KNOW ...

Page 4: ...4 DO YOU KNOW ...

Page 5: ...h the book and drive many miles of motoring pleasure We provide safe high quality high performance vehicles In order to maintain the level of performance and reliability in the vehicle it is important that only Tata motors genuine accessories are to be fitted Any accessory that is fitted or modification that is carried out without authorisation can hamper the safety and performance of the vehicle ...

Page 6: ...th USB Blue Tooth 41 Antenna 41 Micro Phone 41 Engine Compartment Lamp 41 Tail Lamp 42 Registration Plate lamp 42 High Mounted Stop Lamp 42 Interior Roof Lamps 43 Headlamp Leveling Switch 44 Accessory Switches 45 Power Socket 47 Mobile Holder 47 Grab Handle 48 Glove Box with Cup Holder 48 Gear Shift lever 49 Parking Brake 49 Bonnet Opening Closing 50 Fuel Filling Cap Opening 50 Spare Wheel 52 Vehi...

Page 7: ...eels Tyres 83 Wheel Change 83 Wheel Alignment 83 Tyre Pressure 83 Wheel Balancing 84 Replacing Tyre Tube 84 Replacing Tyre Rim 84 Tyre Rotation 85 Headlamps 85 Head LampAdjustment 85 Head Lamp Bulb Replacement 86 Bulb Specification 87 Fuses 88 Vehicle Care 89 FUEL LUBRICANTS COOLANTS Fuel 92 Lubricants 93 Coolants 93 Recommended Oils Lubricants 94 TECHNICAL SPECIFICATIONS 95 SPECIAL INSTRUCTIONS 9...

Page 8: ...tre Switch off the engine during long stops at traffic jams or signals If the situation demands that engine be kept running avoid frequent revving up of the engine Also avoid frequent stopping and restarting if uncalled for It is not necessary to rev up the engine before turning it off as it unnecessarily burns the fuel Shift to higher gears as soon as possible Use each gear upto 2 3rd of its maxi...

Page 9: ...ld pay keen attention to some of the important aggregates which greatly affect emission These components are 1 Fuel injection pump Injectors Nozzles 2 Air intake Exhaust system especially for leakages 3 Cylinder head for valve leakage 4 All filters such as air oil and fuel filters check periodically 5 Turbocharger and intercooler if fitted 6 Catalytic converter if fitted 7 EGR System and component...

Page 10: ...le 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 standar...

Page 11: ... or otherwise expressed or implied and all other obligations or liabilities on our part and we neither assume nor authorise any person to assume on our behalf any other liability arising from the sale of the vehicle or any agreement in relation thereto 9 The buyer shall have no other rights except those set out above and have particular no right to repudiate the sale or any agreement or to claim a...

Page 12: ...keep the cooling system pressurised and to maintain coolant level Always use genuine radiator cap only of 1 0 kg cm2 14 PSI for replacement 8 Check tyres for damage from time to time and remove any foreign bodies embedded in treads In case of tyre replacement or repairs due to puncture have the wheel balanced Keep grease oil and fuel away from the tyres In case of uneven tyre wear get the vehicle ...

Page 13: ...n case of emergency parking or breakdown on road push the hazard warning switch to flash all the blinker lights to warn other road users 19 Release parking brake before driving off 20 Release the ignition key as soon as engine starts 21 Retighten wheel mounting nuts after 100 km of every wheel change Tightening Torque 12 15 mkg 22 Use only recommended FUSES and always keep spare fuses in the box 2...

Page 14: ...windows rolled up when AC system is working 3 If you feel irritation in the eyes due to smoke or during long drive stop A C and ventilate for half a minute by winding down door glasses or use fresh air mode provided with HVAC system 4 Before stopping the engine first switch OFF A C and then the blower 5 During off season operate the air conditionerafewtimeseverymonth to lubricate components Do s ...

Page 15: ... do not stop the engine at once allow it to run at idling speed for atleast 1 minute Also do not accelerate engine till the engine oil pressure has built up 7 Do not cause heating of A C pipe where fitted while welding brazing in its viscinity 8 Do not disturb the fast idling control device actuator setting where fitted 9 Do not open any hose pipe points of A C system where fitted 10 Do not put yo...

Page 16: ...ON OF CHASSIS AGGREGATE SERIAL NUMBERS 1 Chassis number plate 4SPTC BS III 2 Body Shell Cab no plate 4SPTC BS III FIP number Chassis number on frame 1 Chassis number plate CR 4 BS IV 2 Body Shell Cab no plate CR 4 BS IV ...

Page 17: ...17 HANDLING LOCATION OF CHASSIS AGGREGATE SERIAL NUMBERS Rear axle number Tata Motors Gear box number Engine number ...

Page 18: ...or further details of operations and features Key Your vehicle comes with two identical keys With this key you can operate 1 Door Locks 2 Steering Lock cum Ignition switch 3 Tail gate Lock 4 Glove Box 5 Fuel Flap lock if fitted It is advisable to keep one of the keys in a safe place for use in case of an emergency CAUTION Do not use a locally made key but obtain a duplicate through your TATA MOTOR...

Page 19: ...cking system is provided if you lock unlock the driver door with the key the remaining three doors get locked unlocked at a time The tail gate door is not part of the central locking provision To open the door from the outside use the swing handle 1 After unlocking the door with the key pull the swing handle upward The swing handles are provided on each door To open the door from the inside pull h...

Page 20: ...tive However the rear windows can be operated by the switches on the console Illumination on rear window switches goes OFF in locked position press down the lock button to unlock Express power down on driver and co driver windows are provided Individual window winding switches have been provided only on the rear doors Switches on the central console for operating the door glasses Individual Switch...

Page 21: ...isors are provided inside the cab to prevent sun glare Lower the sun visors to protect the eyes from bright sunlight The sun visors also moves sideways towards the door Avanity mirror has been provided on the co driver s sun visor Vanity Mirror Sun Visors ...

Page 22: ...sions the same rear view mirror is also provided on co driver s door Outside Rear View Mirror 1 Inner rear view mirror 2 Operating Knob 1 2 Inner Rear view mirror Inner rear view mirror is also fitted inside the cab between sun visors In few versions an additional adjustable anti glare rear view mirror is provided inside the cab Provision has been made for two positions 1 Normal position 2 Anti gl...

Page 23: ... support 3 to give you maximum driving comfort To achieve correct position for proper driving lift the handle 2 and slide the seat either forward or backward Once the desired position is achieved push down the handle to lock the seat Turn the lever 1 to adjust backrest to the desired position Release the lever to lock it Do not adjust seat while driving 1 Seat backrest inclination adjustment lever...

Page 24: ... the folded middle seat can be somersaulted further For fixing the rear seat back upright just push back the seat in position It will get locked by itself Seats at rear Two rows of seats single or double are provided at rear for passengers Fig 4 on previous page These seats can be folded for carrying bulkier baggage as per procedure given below 1 Lift the seat squab and hold against backrest 2 Eng...

Page 25: ...ckle Belt adjustment When the vehicle is at rest adjust the length of the belt to suit convenience Insert belt tongue in buckle A positive click indicates correct assembly Adjust length of the belt to suit you and fasten The lap section should be comfortably tight the diagonal sections should be adjusted so that a flat hand will pass between the chest and the strap To tighten shorten the belt Pull...

Page 26: ...ith the instructions and no excessive slackness in the belt should be evident Avoid twisting the straps during use Webbing must not be allowed to chafe against sharp edges on seat or bodywork Do not make any alterations or additions to the belt If in doubt consult the authorised service outlet The belt that have been cut frayed damaged or have been stressed through impact should be replaced To cle...

Page 27: ...e fittedwithadjustable headrestraint Headrestraint can help to protect you from whiplash and other injuries For best protection adjust the top of the headrestraint as shown in the figure The headrestraint can be adjusted by using release button as shown in figure Release Button for Head rest height adjustment ...

Page 28: ...Steering Wheel 5 Instrument Cluster 6 Headlamp leveling Switch 7 Horn Pad 8 Accelerator Pedal 9 Brake Pedal 10 Clutch Pedal 11 Parking Brake 12 Power Window Switch 13 Gear Shifting Lever 14 Music System 15 Facia Switches 16 A C Controls Driving Controls Sumo Gold DRIVING CONTROLS ...

Page 29: ...ING INSTRUMENT PANEL INSTRUMENT PANEL CR 4 BS IV All indicators may not be provided on some instrument cluster and may not be applicable to all models ca 5 4 2 3 7 20 21 8 1 6 9 10 11 12 13 14 15 16 17 18 19 22 ...

Page 30: ...LING INSTRUMENT PANEL All indicators may not be provided on some instrument cluster and may not be applicable to all models ca INSTRUMENT PANEL 4SPTC BS III 5 4 2 3 7 20 18 1 6 9 10 11 12 13 14 15 17 19 21 22 ...

Page 31: ...d 21 Cumulative Odometer 22 Service Indicator Immobiliser Warning Indicator This system disables engine starting if original key is not used The user has to use original key for authentification and unlocking the car Refer to Immobiliser section for details Lamp Blink Car is in immobilised condition when key is not inserted Lamp OFF Normal condition Authenticated user and engine will start Lamp On...

Page 32: ...he parking brakes is applied and goes off when parking brake is released It also lights up when brake fluid level is low When ignition key is turned to IGN position this indicator lights up and goes off when engine starts in normal condition If it continueously ON while engine is running get the problem attended to an Authorised Service Outlet Water In Fuel Indicator This indicator indicates exces...

Page 33: ... MIL This symbol comes ON when the ignition is turned ON and goes OFF once the engine is cranked NOTICE This symbol will remain ON for any engine related fault which may cause increase in emission levels of the car beyond the regulatory limit Take your car to a TATA Authorized service centre On Board Diagnostic OBD System On board Diagnostics or OBD is an automotive term referring to a vehicle s s...

Page 34: ...y also be checked by the traffic police using specific devices OBD II Connector Location HANDLING INDICATORS GAUGES Odometer and Trip meter on LCD The odometer records the total distance the vehicle has been driven The trip meter can be used to measure the distance traveled on each trip or between fuel fillings Keep track of the odometer reading follow the maintenance schedule regularly for meetin...

Page 35: ...is display returns to Trip meter A after a few seconds of intensity level selection if left in this mode NOTICE Main odometer and trip meter A indication will remain on display even if the ignition key is removed IntensityLevelIndicator LCD has two line display The first line displays the Odometer count The second line displays either of Trip meter A Trip meter B Intensity level of panel illuminat...

Page 36: ...perature of the engine coolant The red zone at H indicates temperature higher than the normal Avoid driving when the pointer is in the red zone It indicates engine overheating which may be due to insufficient coolant in the radiator or due to any other defect At this stage take the car to the nearestAuthorised Service outlet for necessary attention CAUTION Never remove the radiator pressure cap fr...

Page 37: ... switch After withdrawing the key from the switch ensure that steering is locked by turning steering wheel clockwise and anticlockwise To unlock the steering insert the key into the switch and turn it clockwise If any difficulty arises in unlocking turn the steering wheel a little clockwise or anticlockwise while turning the key ACC By turning the key to ACC position power supply to accessories is...

Page 38: ... for few seconds and switches OFF automatically As a safety feature glow plugs are automatically switched OFF after a lapse of certain time if the engine is not started to conserve battery In this case to start the engine repeat the operation by first going to ACC or LOCK position START Turn the key further clockwise to start position spring loaded to operate starter motor As soon as the engine st...

Page 39: ...39 HANDLING COMBI SWITCH COMBI SWITCH ...

Page 40: ...F Press side knob for wash Rotate selector to set delay timing for intermit tent wipe A Head lamp OFF position B Position lamp ON C Position lamp head lamp ON D Push down the lever for high beam E Pull up the lever spring return for high beam flash F Lane change left self cancelling G Side Indicator LH H Lane change right self cancelling I Side Indicator RH LIGHTS CONTROL LEVER RIGHT ...

Page 41: ...enna Music System with 1 USB Connector 2 Blue tooth Connector Micro phone Antenna TheAntenna is loacated on the RH side of front windshield glass on the A piller Please refer the music system User s Manual provided in the vehicle for understanding it s function Micro phone Micro phone is located on roof between sunvisors and above inner rear view mirror Engine Compartment Lamp To operate engine co...

Page 42: ...ing Rear stop lamp 3 Reverse light 4 Reflex reflecor 5 Fog lamp Registration Plate Lamp Two concealed lamps are provided for illumination of the rear registration plate High Mounted Stop Lamp High mounted stop lamp is incorporated on the tail gate from inside and it glows whenever service brake is applied 1 2 3 4 5 High Mounted Stop Lamp Registration Plate Lamp ...

Page 43: ... operate these lamps Lamp positions Interior Roof lamp POSITION FUNCTION The lamp will remain ON at all times irrespective of whether any of the doors is open The lamp will come ON only when any of the five doors are opened For GX version In this mode the lamp will come ON only when driver s door is opened For EX version The lamp will remain OFF irrespective of whether any of the five doors are op...

Page 44: ...ition Marks assigned Unladen One person in Driver seat Driver Co Driver Driver Co driver all the Seats 0 farthest to rear occupied All the seats occupied Laden AllseatsoccupiedLuggageinbootspace 1 to achieve permissible load on the rear axle Driver Evenly distributed load in the boot to 2 obtain permissibleloadoncorrespondingaxle Since the leveling switch takes care of focus patern under different...

Page 45: ... till the parking lamp is switched OFF The rear fog lamps can also be switched ON even if only headlights are ON NOTICE Useonlyduringfoggyconditionsorheavyrainsifrequired Rear Windshield Wash and Wipe unlatched switch if fitted Push and hold the switch knob for the operation of the wash function for the desired duration for rear visibility through glass The function indicator lights up when wash f...

Page 46: ...d at the side of the road or vehicle being operated in adverse condition This can be operated without Ignition ON Press hazard warning switch to switch ON All outside turn signal lights and indicators on cluster will flash simultaneously to warn the other road users about hazardous condition of the vehicle Depress the switch to switch OFF the hazard function CAUTION Ensure that all turn signal ind...

Page 47: ...g loads upto 10Amaximum To use this socket remove the cap first CAUTION Always keep this socket covered with the cap when not in use Mobile Holder A mobile holder is provided on the central console below music system and beside of power socket Place your mobile inside the mobile holder for charging purpose while driving Power Socket Mobile Holder ...

Page 48: ...ompartment for comfortable positioning of passengers during journey Glove Box with Cup Holder The glove box is located on the dash board in front of the codriver s seat The glove box can be locked with the ignition key Cup holders are provided on the inner face of glove box flap CAUTION Do not use the cup holders while the vehicle is in motion Grab Handle Glove Box with Cup Holder ...

Page 49: ... highways Parking brake The parking brake is mounted on floor console between driver s seat and co driver s seat To apply the parking brake pull lever UP To release it pull the lever up slightly press the release button and push the lever DOWN Ensure parking brake is released before driving the vehicle Indication is given on instrument cluster Gear Shift Lever 1 Parking Brake Lever 2 Release Butto...

Page 50: ...bonnet lock can be opened by inserting a screw driver from the top centre position of grill through a slot provided behind it on the sheet metal and by pressing the lock plate towards your left Push upward the additional lock lever at your right and lift the bonnet while the lock plate is kept pressed with the help of screw driver Fuel filling Cap The fuel filling cap is located at the rear on the...

Page 51: ...e may be under pressure and may spray out suddenly causing injury To remove the fuel filler cap turn it anti clockwise Turn the cap slowly to allow any residual pressure to escape In few version mechanical remote fuel lid opener is used The fuel lid is located on the left rear side of the vehicle ...

Page 52: ...of spare wheel 3 Using the wheel spanner the spare wheel can be raised by rotating the wheel winch screw in anticlockwise direction 4 Align one of the wheel mounting screw hole with the locating pin on frame while raising the spare wheel 5 Continue to rotate the wheel winch screw in anticlockwise direction until spare wheel is raised completely Spare wheel Spare wheel winch grommet Loosening Tight...

Page 53: ...CLE JACK TOOLS Vehicle Jack Tools Vehicle tool bag jack and handle is kept below driver s seat Jack is mounted on floor over studs by wing nuts screwed on them Jack tools location Below driver s seat Locking Wing Nuts ...

Page 54: ...s than 0 25 Use of any other diesel fuel can increase the pollutants WARNING Avoidparkingthevehicleoverinflammablematerials such as dry leaves grass etc as the exhaust system is hot enough to initiate FIRE TAKING CARE OF ENVIRONMENT Your vehicle is equipped with the EGR Exhaust Gas Recirculation System HANDLING CATALYTIC CONVERTOR EGR SYSTEM EGR System The 497SPTC engine has an Exhaust Gas Recircu...

Page 55: ...t every 20 000 km if fitted 3 It is advisable to run the engine at idle speed for about one minute after starting and before stopping the engine This ensures adequate lubricating oil supply to the turbocharger Turbocharger Lubrication of Turbocharger The rotor assembly of the turbocharger is supported by two floating lead bronze sleeve bearings in the bearing housing These bearings are lubricated ...

Page 56: ...reservoir 2 Check for any leakage in the system and if noticed take corrective action 3 Start the engine and steer the vehicle from full left to full right turn 3 4 times Add fluid if necessary to maintain the level up to the filter top 4 With the engine at steady speed check for bubble foaming in the fluid If present it indicates that air is getting sucked into the system Check the suction line f...

Page 57: ... of the belt for cracks or fraying Check the tension of the belt by pushing on it with your thumb Alternator Power Steering belt as shown in Figure The belts should have deflection of 8 to 10 mm X If the belt tension is not proper get it attended at the nearest Authorised service outlet Power Steering Pump Belt Adjustment Nut ...

Page 58: ...ree four speed blower The blower speeds can be regulated to any one of the following speeds by operating the knob B at the centre of the control panel LOW MEDIUM HIGH VERY HIGH C Air Direction Control Knob The air flow can be changed by turning the switch C to the desired direction Towards face Towards face and feet Towards feet Towards feet and windshield Recommended for clearing fogging on winds...

Page 59: ...ving in dusty condition To avoid traffic pollution To get quick cooling heating as required Whenever discomfort is felt switch air circulation mode to fresh NOTICE 1 The A C can be switched ON only if the blower is ON and engine is running WhenA C is switched ON engine idling RPM increases marginally to adjust to the A C compressor load When desired temperature is achieved A C trips OFF automatica...

Page 60: ... C position to Face mode In high humidity areas if cold air continues to flow over windshield it may cause sudden fogging on outside surface of windshield Defrosting For vehicles fitted with HVAC unit In low temperature areas to clear frost formation outside the windshield glass this setting is used First start the engine Maximum hot position accelerate to warm up Knob A Knob B Very High Knob C To...

Page 61: ...IGH MED LOW and OFF The switch is located on left hand side on the roof A C Air flow direction can be adjusted by adjusting the air vents The roof A C can be switched ON provided the front A C is ON However the blower of the roof A C unit can be operated independently HANDLING AIR CONDITIONING Roof AC ...

Page 62: ...e only the genuine company branded oils 3 Coolant level With the engine cool check the coolant in the auxiliary tank The levelshouldbebetweenthe FULL and MIN mark top up with the recommended coolant Bring the level upto the FULL mark The level must not exceed the FULL mark If the coolant level drops within a short time after replenishing there may be a leak in the system Rectify the leakage and to...

Page 63: ...uid in plastic container Top up if necessary Do not overfill Use only genuine company branded brake fluid 9 Check level of clutch fluid in plastic container Top up if necessary Do not overfill as this would result in spillage during clutch operation Use only genuine company branded clutch fluid NOTICE Always use genuine radiator cap only of 1 0 kg cm2 14 psi if required to be replaced 4 Ensure bat...

Page 64: ...k level of water in Windshield washer reservoir Top up with clean water if required Use good quality cleaning solvent available in the market in the ratio as specified by its manufacturer 11 Check oil level in power steering hydraulic tank where applicable 12 Check and correct tyre inflation pressure In cold condition ...

Page 65: ...SERVE THAT LOW OIL PRESSURE INDICATOR LIGHTGOES OFF BATTERY CHARGING INDICATOR LIGHTGOES OFF ENSURE THAT PARKING BRAKE IS RELEASED INDICATOR LAMP OFF VEHICLE IS NOW READY FOR A DRIVE DO NOT ALLOW VEHICLE TO ROLL BACK ON GRADIENTS During running in period i e first 2 000 km of operation Do not exceed the following vehicle speeds Gear Min Max 1st 20 2nd 15 35 3rd 25 55 4th 35 75 5th 45 95 Avoid rapi...

Page 66: ...h pedal and engage the reverse gear BRAKING While braking on turns apply brakes gently Before driving down a long steep gradient reduce vehicle speed by changing to lower gear Do not ride the brakes as they may overheat and their performance may be impaired Do not use half engaged clutch to hold the vehicle on up gradient as this will result in premature clutch failure After driving through pocket...

Page 67: ...f vehicle control Driving on Sandy or Muddy Roads Theextentofmuddy sandy conditions and the traction available is difficult to judge and the vehicle can get bogged down deeply Operation should be done at slow speed only If possible get down and check the path conditions before proceeding In case the traction on the wheels is sufficient you may be able to proceed it is better to select the lower ge...

Page 68: ...checked Never venture to drive through water when it flows over guard stones Engine may get seriously damagedifattemptedtocrossover through deep water If at all the situation demands that you have to drive through water then Keep engine in fast idling and crawl the vehicle in low gear After driving through water apply brakes several times to dry Driving on a Rainy Day Check brakes steering and win...

Page 69: ... select the appropriate gear so that gear changing in the middle of the climb is not required Changing gears in the middle of the climb can cause loss of momentum and engine stalling Shifting to lower gear has to be done cautiously to avoid loss of traction Under no conditions should the vehicle be moved diagonally across a hill The danger is in loss of traction and sideways slippage possibly resu...

Page 70: ...nging or clutch disengagement is not involved while descending the gradient Towing the Vehicle For towing the vehicle the best way is to use a recovery van Alternatively use a rigid tow bar Avoid using flexible cable or rope as your vehicle may crash into towing vehicle when it stops suddenly Switch ON Hazard warning switch to warn the other road users Keep the engine in idling so that power steer...

Page 71: ...and increase the risk of injury to yourself and others Mobile phones Avoid using mobile phones while driving a car This could divert your attention from the road and result in an accident Fatigue Rest Revive survive Do not attempt driving when you feel tired sleepy Long distance driving can tire you very much and fatigue can dull your reflexes and judgment Take rest and get refreshed at regular in...

Page 72: ...eservoir Do not drive the car when brake warning lamp is ON Tyres Check the condition of tyres for any abnormalities Maintain correct tyre pressure it is very important particularly when subjected to extreme conditions such as high speed high load and high outside temperature Do not use worn or bald tyres especially on the front wheels First Aid Kit A first aid kit is provided in your car This is ...

Page 73: ...ch Fluid Reservoir 3 Engine Compartment Lamp 4 Battery 5 Air Filter 6 Dip Stick 7 Radiator Cap 8 Engine Oil Filler Cap 9 Engine Coolant Tank 10 Windshield washer Fluid Container 11 Power Steering Fluid Reservoir 12 Fuse Box ENGINE COMPARTMENT CR 4 4 12 10 11 1 2 3 5 6 8 7 9 ...

Page 74: ...h Fluid Reservoir 3 Engine Compartment Lamp 4 Battery 5 Fuse Box 6 Air Filter 7 Dip Stick 8 Radiator Cap 9 Engine Oil Filler Cap 10 Windshield washer Fluid Container 11 Power Steering Fluid Reservoir 12 Engine Coolant Tank ENGINE COMPARTMENT 4SPTC 3 1 2 4 12 6 7 8 10 11 9 5 ...

Page 75: ...he new oil filter with fresh engine oil Smear a little engine oil on rubber gasket of new engine oil filter Hand tighten the filter fully and tighten it a further half turn with a special tool Do not overtighten engine oil filter as this may damage oil filter and oil may leak out Before filling in fresh oil in the engine refill the sump drain plug using a new sealing washer Tighten drain plug to 4...

Page 76: ...inues to show red band replace the paper filter element with new one and reset the service indicator For air filter please refer respective Engine Compartment pages Page 73 74 Fuel Filter Draining CR 4 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 Priming Pu...

Page 77: ...element at specified intervals and FIP side filter element Assemble fuel filter and fit it on mounting bracket Priming fuel system 4SPTC Unscrew fuel lift pump plunger knob Pull and push it 10 14 times 30 40 times if fuel tank has been completely emptied Tighten fuel lift pump plunger knob Start engine and check for smooth running If erratic fuel supply is still felt check for air suction in fuel ...

Page 78: ...cks or fraying Check the tension of the belt by pushing on it with your thumb for A C compressor belt andAlternator Power Steering belt as shown in figure The belts should have deflection of 8 to 10 mm If the belt tension is not proper get it attended at the nearest Authorisedserviceoutlet Belt Arrangement Engine with AC compressor and power steering pump ...

Page 79: ...be end holding the jar just above the bleed screw level c Pump clutch pedal twice or thrice slowly throughout its stroke and by holding clutch pedal in depressed condition loosen bleed screw on slave cylinder Watch for air bubbles in glass jar d Retighten bleed screw on slave cylinder and repeat the process until air bubbles cease to appear at the end of tube in glass jar allowing only fluid to fl...

Page 80: ... engine coolant auxiliary tank upto FULL mark Changing of coolant in the cooling system a Drain the cooling system and flush it with clean water b Pourthegenuineco brandedcoolantintotheradiatoruntilitis full c Start the engine Top up the radiator with coolant d Fill the auxiliary tank upto FULL mark e Ensure no leakage in the system For Engine Coolant Tank location please refer respective Engine C...

Page 81: ...81 VEHICLE MAINTENANCE BRAKE SYSTEM ...

Page 82: ...ake shoes have been properly adjusted 1 Put chocks on front wheels 2 Jack up the rear axle 3 Loosen check nut 2 Pull parking brake lever upto second notch 4 Tighten the parking brake adjustment nut 1 till rear wheels start jamming and cannot be rotated 5 Release the parking brake and ensure that wheels are rotating freely thentighten check nut 2 Operate parking brake a few times to ensure proper o...

Page 83: ... provided with the vehicle Jack should be placed below chassis long member behind front wheel for changing front tyres and before rear wheel as shown Wheel alignment If uneven tyre wear is noticed get the vehicle examine and attended by TATA MOTORS authorised workshop Periodically check and maintain correct tyre pressure to obtain longer tyre life Recommended tyre pressures with cold tyres For 215...

Page 84: ...ube and replacing the tyre or rim Repairing a tyre tube Mark suitably the tyre position If original colour dot mark is not visible with respect to valve stem hole to ensure that tyre is refitted in original location Ensure that the balancing VEHICLE MAINTENANCE WHEELS TYRES weights are not disturbed during removal of tyres Check the balance weight prior to removal of tyre if found loose mark its l...

Page 85: ...d lamp also incorporates a parking lights The head lamps must be properly aligned in order to obtain maximum road safety proper road illumination and reduced glare to oncoming traffic It is recommended to check alignment of headlamp beams periodically and whenever headlamp bulbs are replaced by means of a headlamp aligner or with the help of a screen as shown in figure on the following page Adjust...

Page 86: ...f vehicle lines and horizontal lines It is possible that high beams may not be exactly symmetrical but for this reason headlamps should not be realigned Preferably the alignment should be done in the dark No masking of headlamps with black paint is required If done this will reduce the intensity of light Head lamp focusing should be carried out in the level O position where head lamp leveling swit...

Page 87: ... Side Repeater Side Panels W 5 W 12 V 5 W 2 Front Fog Lamps Front Bumper H 3 12 V 55 W 2 Rear Fog Lamps Tail lamp BA 15 S 12 V 21 W 2 Roof Lamp Cab Roof 12 V 10 W 2 Engine Compartment Lamp Engine Compartment BA 15 S 12 V 21 W 1 TELLTALESYMBOLS Turn indicators Instrument Panel T 5 12 V 1 4 W 2 Oil Pressure T 5 12 V 1 4 W 1 Battery T 10 12 V 3 W 1 Low Brake fluidl Parking brake T 5 12 V 1 4 W 1 Seat...

Page 88: ... Amps 6 Fuse link Green 30 Amps 7 Fuse link Orange 40 Amps 8 Fuse Link Trasparent 80 Amps While fitting fuse box cover ensure that cover knob rests in the slot provided inside the fuse box Spare fuse links are provided inside the fuse box Always use fuses of correct rating Do not use wire in place of fuse Flasher with short circuit protection If flasher circuit is short circuited or overloaded mor...

Page 89: ...neutral detergent mixed with warm water Apply solution with a sponge or soft cloth and let it soak for a few minutes to loosen dirt Wipe the surface with a clean damp cloth to remove dirt and soap solution If some dirt still remains on the surface repeat the procedure Carpets Remove dirt as much as possible by using a vacuum cleaner Rub the stained area with clean cloth made damp with soap to abso...

Page 90: ... wash off with running hose water After rinsing wipe the body lightly with wet chamois or cloth and allow the body to dry it in the shade Warning After washing check that the brakes are dry If brakes are not dry dry them by gently repeatedly applying while driving at low speeds Washing the vehicle exterior After washing the vehicle waxing and polishing are recom mended to protect and beautify the ...

Page 91: ... doors and body Checkthefloorcoveringsfordampness Carpetsandfloor mats remain damp for a long time especially in winter This can eventually cause the floor panels to corrode Use a high pressure spray to clean the underside of your vehicle This is especially important in areas near chemical and other industries Have corrosion preventive coatings done on the underside of your vehicle using Tata Moto...

Page 92: ... 50 50 Care should be taken that diesel and supplementary fuel are thoroughly mixed before filling WARNING Do not mix gasoline OR alcohol with diesel This mixture can cause explosion NOTICE Where oxidation catalytic converter is fitted It is mandatory to use Diesel fuel with sulphur contents as under Use of any other diesel fuel can increase the pollutants Sulphur Content 0 035 BS IV 0 05 BS III C...

Page 93: ... above SAE 15W 40 20 TO above SAE 10W 30 or SAE 5W 20 Hub bearing grease Tata Motors axles front hub Use Lithium base multipurpose grease Quantity 25 gms per hub Rear Brake and clutch fluid Brake fluid conforming to IS 8654 DOT 3 is recommended Spicer propeller shaft where applicable Lubricate slip joint with Multipurpose grease 2 grade grease Lubrication of steering spindle ball joint Lubricate s...

Page 94: ... BS IV 80W90 with 7 ANGLOMOL BS III POWERSTEERING OIL HPCL HP ATF 1 6 Litres CASTROL CASTROL Transpower TQ REAR AXLE HPCL HP Gear Oil XP 85W140 GL5 2 2 Litres CR 4 CASTROL CASTROL Extreme Pressure 85W140 1 9 Litres 4SPTC BRAKE CLUTCH FLUID HP CL HP Super Duty Brake Fluid DOT 3 As required CASTROL CASTROL Universal Brake Fluid DOT 3 WHEELBEARING CHASSIS HPCL HP Multipurpose Grease 2 As required Pro...

Page 95: ...5 litres Weight of engine 315 kg Dry Radiator frontal area 2205 sq cm Capacity of cooling System 12 Litres ENGINE 4SPTC BS III Model TATA 497 SPTC 43 Type Turbo charged Water cooled Direct injection diesel engine No of cylinders 4 inline Bore Stroke 97 mm x 100 mm Capacity 2956 cc Max engine output 50 52 kw at 3000 rpm as per MOST CMVR TAP 115 116 Max torque 223 N m at 1600 2200 rpm as per MOST CM...

Page 96: ...ting axle shafts Ratio 3 36 CR 4 3 73 4SPTC FRONT AXLE Independently suspended STEERING Type Power Steering Victa type steering Ratio 18 2 1 EX GX FX 32 5 1 to 36 5 1 LX CX Steering wheel 420 mm dia LX CX 380 mm dia EX GX FX BRAKES Service brakes Vacuum assisted independent hydraulic brakes on front and rear Vacuum pump mounted on alternator Front 262 dia disc brake Rear 282 dia auto adjusted drum...

Page 97: ... Capacity CR 4 117Amps GX EX LX 75Amps CX 4SPTC 75 Amps All 40Amps Optional CX LX Battery CR 4 12V 75 Ah 4SPTC 12V MF 70 Z PERFORMANCE Max speed at rated GVW 120 km hr Max gradeability at rated GVW 32 Grade Restartability 32 CR 4 26 4SPTC PASSENGER CAPACITY Option I Driver 6 Option II Driver 8 Main Chassis Dimensions As per ISO 612 in mm Nominal Tolerances as per INTEREUROPE STVZO Wheel base 2425 ...

Page 98: ... Complete vehicle kerb 1820 FAW 997 RAW 823 weight as per ISO 1176 For AC HVAC With spare wheel tool 1800 FAW 987 RAW 813 For Non AC Gross Vehicle weight 2600 FAW 1080 RAW 1520 Max Permissible FAW 1100 Max Permissible RAW 1560 TECHNICALSPECIFICATION ...

Page 99: ...nside cover page 4 These services can be satisfactorily performed only by one of our Authorised Dealers TASC s TASP s Workshops in India irrespective of the dealer who sold the vehicle provided the vehicle is sent to them at the kilometerages specified and that this service book is produced before them The vehicle is entitled to pre delivery service with free labour After the delivery of the vehic...

Page 100: ...rised Dealer s TASC s TASP s Workshop for servicing 7 All our Authorised Dealer s TASC s Workshops have been equipped with special tools and are manned by technical personnel trained by us Besides they have adequate stocks of genuine spare parts for replacement purposes should the need arise Our Authorised Workshops are therefore in a position to render you any expert advice and service your vehic...

Page 101: ...pening lever Every 15000 km z z z z z z z lock plate tailgate hinges door lock inner ratchet ENGINE 3 0 CR4 1 Check coolant level Top up if necessary 15000 km z z z z z z z 2 Change coolant in cooling system 60000km z 3 Change engine oil oil filter cartridge with oil conforming to API CH4 and MB 228 3 15000 km OR 1 year z z z z z z z specifications whichever is earlier 4 Clean engine breather 1500...

Page 102: ...00 km z z z z z z z Every 15000 km OR 1 Year whichever is earlier 3 Check All accessory Drive belts adjust tension if required change if damaged Every Service z z z z z z z z Replace every 2 year OR 45000 kms whichever is earlier 4 Drain water from fuel pre filter Every Service z z z z z z z z 5 Change fuel filter 1st 15000 km z z z z z z z 6 Change fuel filter 1st 2nd 30000km z z z 7 Check adjust...

Page 103: ...he following replace if necessary 1 Top wishbone 45000 km z z 2 Lower wishbone 3 Anti roll bars 4 Leaf Spring 5 Check shock absorber its bushes replace if necessary 30000 km z z z 6 Grease steering spindle and sleeve 30000 km z z z 7 Check adjust front wheel bearing play Change grease in front hubs 45000 km z z 8 Check steering gearbox oil level top up if necessary only for mechanical steering 450...

Page 104: ... Schedule under severe driving conditions Precautions to be taken while cleaning engine compartment It is recommended to use dry low pressure air Do not use pressurised water ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS A Driving in conditions such as Patrolling Taxi Pickup Van Vehicle Towing with Trailer Towing B Driving on Dusty Sandy roads C More than 50 in terms of kms drivi...

Page 105: ...ure and km No Stamp At km PDI 5 000 15 000 30 000 45 000 60 000 75 000 90 000 1 05 000 1 20 000 1 35 000 Recommended Odometer Repair Servicing Dealer s Service Date reading Order Signature and km No Stamp 1 50 000 1 65 000 1 80 000 1 95 000 2 10 000 2 25 000 2 40 000 2 55 000 2 70 000 2 85 000 3 00 000 Chassis No ...

Page 106: ...106 RECORD OF REPAIRS CARRIED OUT Date Odometer Repair Particulars of Repair Servicing Dealer s Signature reading km Order No Stamp ...

Page 107: ...107 RECORD OF REPAIRS CARRIED OUT Date Odometer Repair Particulars of Repair Servicing Dealer s Signature reading km Order No Stamp ...

Page 108: ...Do s 10 Driver s Co driver s Seat 23 Driving Controls 28 Driving inAdverse Conditions 67 DrivingInstruction 65 Driving Safety 71 E EGRSystem 54 EngineAir Filter 76 Engine Compartment 4SPTC 74 Engine Compartment CR 4 73 EngineCompartmentLamp 41 EnvironmentProtection 6 F FanBeltTensionAdjustment 78 Foreward 5 Fuel Filter Priming 4SPTC 77 Fuel Filter Priming CR 4 77 Fuel Economy 66 Fuel Filling Cap O...

Page 109: ...RecommendedOils Lubricants 94 Record of Repairs Carried Out 107 Record of Service Performed 105 RegistrationPlatelamp 42 Replacing Tyre Rim 84 Replacing Tyre Tube 84 RoofAC 61 S SafetyChecks 72 SeatBelt 25 Seats at Rear 24 Service Schedule 101 Spare Wheel 52 SpecialInstructions 99 SteeringLockCumIgnitionSwitch 37 Sun Visors 21 T Tail Lamp 42 TechnicalSpecification 95 Towing the Vehicle 70 Turbocha...

Page 110: ...ur LH Left Hand Max Maximum MD Main Dealer Min Minimum mkg Meter per Kilogram mm Millimeter Mtg Mounting No Number Nm Newtonmeter PVBU Passenger Vehicle Business Unit PDI Pre delivery Inspection PSI Pounds per Square Inch PUC Pollution Under Control RAW Rear Axle Weight RCSM Regional Customer Support Manager RH Right Hand RM Regional Manager RPM Revolution Per Minute Sec Seconds Sq cm Square Centi...

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TATA Motors SUMO GOLD, Owner'S Manual & Service Book

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