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

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TATA Motors SUMO GRANDE Owner'S Manual & Service Book Download Page 81

8181

AXLE & BRAKE

Preliminary Trouble shooting

REAR AXLE

  1.

Loss of lubricant (Oil)

Breather hole clogged

• Clean the breather hole on the

axle housing

Differential cover gasket torn

• Get replaced

Pinion oil seal damaged

• Get replaced

  2.

Differential housing overheating

Insufficient oil

• Get the oil filled

Incorrect lubricant used

• Drain, flush and get correct

lubricant filled

BRAKES

 1.

Poor brakes

Insufficient brake fluid.

• Get the brake fluid filled

Air in the system

• Bleed the system

Malfunction of automatic adjuster

• Check & rectify auto adjuster

mechanism or replace

Vacuum leakage

• Rectify the leakage

Brake fluid contamination

• Replace the brake fluid

Brake fluid, grease, oil or water

• Replace the leaking line, bleed

on pad /drum

the system. Clean pad/lining.
replace seals if leaking

Worn brake lining/pad

• Get the liners/pad replaced

Excessive worn drums at rear

• Replace rear drums

soft or weak hose

• Check & replace

SR. NO.

SR. NO.

SR. NO.

SR. NO.

SR. NO.

PROBLEM OBSERVED

PROBLEM OBSERVED

PROBLEM OBSERVED

PROBLEM OBSERVED

PROBLEM OBSERVED

CAUSE

CAUSE

CAUSE

CAUSE

CAUSE

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CTION 

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O BE 

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Ofrecido por www.electromanuales.com

Summary of Contents for SUMO GRANDE

Page 1: ...E SUMO GRANDE SUMO GRANDE SUMO GRANDE Owner s Manual Service Book Passenger Car Business Unit PCBU Mumbai Pune This owner s manual should be considered as a permanent part of the vehicle and must remain with the vehicle Ofrecido por www electromanuales com ...

Page 2: ... not be fitted on your vehicle but they are applicable for other versions of Sumo Grande Q C Copyright 2004 TATAMOTORS Q All rights reserved The material in this manual may not be reproduced or copied in whole or in part in any form without written permission from TATAMOTORS Q The information and specifications given in this book are valid as on the date of printing TATA MOTORS Limited reserves th...

Page 3: ...nded 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...

Page 4: ... if the warning is ignored You are informed what you must or must not do in order to avoid or reduce the risk of damage to your vehicle and its equipment WARNING Indicates a strong possibility of severe personal injury or death if the instructions are not followed Safety symbol In this manual you will also see a circle with a slash This means Do not Do not do this or Do not let this happen IMPOR I...

Page 5: ...Wheel 69 Spare Wheel Limp Home Mode 70 Starting The Engine with Jump Leads 71 Know your Sumo Grande 6 Environmental Care 8 Sumo Grande At A Glance Driving Controls 10 Instrument Cluster 12 Steering Lock cum Ignition Switch 18 Combi Switch 23 Head Lamp Leveling 24 Transfer case Switch 26 Music System Antenna Clock 27 Heating Ventillation Air Conditioning 28 Grab Handle Cigarette lighter 29 Lamps 34...

Page 6: ...rvice Schedule 115 Service Maintenance Schedule 117 Record of Services Performed 123 Record of Repairs Carried Out 125 Towing the Vehicle 72 Routine Service 73 Preliminary Trouble shooting 74 Electrical Maintenance Fuses Relays 80 Bulb Specification 82 Bulb Replacement 83 Vehicle Care Washing Cleaning 85 General Precautions 87 Maintenance Opening Closing The Bonnet 88 Engine Compartment 89 Air Fil...

Page 7: ...nde ideal for operating in both urban as well as rural areas This vehicle is powered by a new generation 2 2L DICOR BS III engine which is in turn mated to a 5 speed fully synchromesh gearbox with overdrive for excellent fuel efficiency and tubeless tyres for better road holding and grip Your Sumo Grande s 2 2L DICOR engine is a refined power plant employing a sophisticated common rail fuel system...

Page 8: ... is via parabolic springs This suspension setup ensures good road holding and stability An ergonomically designed cab with added features like collapsible power steering central locking power windows highly effective HVAC for comfort music system state of art headlamp and rear lamps good all found visibility and easy access to areas of daily maintenance is some of the other user friendly features ...

Page 9: ...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 ...

Page 10: ...erson 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 any reduction in the purchase price of the vehicle or to demand any damages or compensation for losses incidental or indirect or i...

Page 11: ...Do 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 Monitor the vehicle s fuel consumption regularly and if showing rising trend get the vehicle immediately attended at the Company s Authorised Service Outlets Switch off the engine during long stops at traffic jams or signals If you ne...

Page 12: ...se the compressed air for cleaning these parts which may spread the dust in the atmosphere While carrying out the servicing or repairs of your vehicle you should pay keen attention to some of the important engine aggregates and wiring harness which greatly affect emission These components are 1 Fuel injection equipments pump rail Injectors Nozzles and high pressure pipes 2 Air Intake Exhaust syste...

Page 13: ...S DRIVING CONTROLS DRIVING CONTROLS 1 Steering Wheel 2 Instrument Cluster 3 MirrorAdjustment Switch 4 Horn Pads 5 Operating Switches 6 Bonnet Opening Lever 7 Gear Shifting Lever 8 Parking Brake 9 Cigar Lighter Rear 10 Cigar Lighter Front 11 Music System 12 A C Controls 13 Glove Box 14 A C Air Vents 15 Analog Clock 16 Central Air Vents Ofrecido por www electromanuales com ...

Page 14: ...INSTR INSTR INSTR INSTR INSTRUMENT CL UMENT CL UMENT CL UMENT CL UMENT CLUSTER GX USTER GX USTER GX USTER GX USTER GX 10 9 13 12 11 14 16 23 15 24 19 20 17 18 22 21 1 2 3 4 6 7 8 9 All indicators may not be provided on some instrument cluster and may not be applicable to all models ca 5 Ofrecido por www electromanuales com ...

Page 15: ...EX Sumo Grande At a Glance Sumo Grande At a Glance Sumo Grande At a Glance Sumo Grande At a Glance Sumo Grande At a Glance 9 10 9 13 12 11 14 16 23 15 17 18 21 1 2 6 7 8 All indicators may not be provided on some instrument cluster and may not be applicable to all models ca 24 3 4 5 Ofrecido por www electromanuales com ...

Page 16: ...tor Amber If fitted 7 High Water level Indicator in Sedimenter Amber 8 Glow Plug ON Indicator Amber If fitted 9 Direction Indicator Green 10 Head Lamp Main Bean Indicator Blue 11 Low Engine Oil Pressure Indicator Red 12 Battery Charging Indicator Red 13 Brake Fluid Level Check Parking Brake Indicator Red 14 Seat Belt Indicator Red 15 Trip Odometer 16 Cumulative Odometer 17 Mode Selector Knob Odome...

Page 17: ...ment cluster illumination lamps when the position lamps are ON Position lamps can be used as parking lamps Malfunction Indicator Lamp MIL if installed This indicator comes ON when the ignition is turned on and goes OFF once the engine is cranked The indicator remains on for any engine sensor related fault due to which emissions of the vehicle may cross the regulatory limit CAUTION MIL illuminates ...

Page 18: ...utton of the corresponding vehicle remote It will blink when vehicle is immobilised condition Unlock with remote and start vehicle Turn Signal Turn signal lamps can be operated only when the ignition supply is ON and by using the turn indicator switch on the combi switch The direction indicator arrow LHS and RHS on the instrument cluster flashes along with external indicator lights as selected Hig...

Page 19: ... but the indicator continues to remain ON NOTE NOTE NOTE NOTE NOTE Battery Indicator Symbol lights up when the IGN is turned ON and should go OFF after the engine starts If it remains ON while the engine is running It indicates that the battery is not getting charged Switch off all unnecessary electrical equipment and get the problem attended to at an Authorised Service outlet Parking Brake Indica...

Page 20: ...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 the Trip meter A Trip meter B OR Intensity level of panel illumination Switching among the above three functions can be done by pressing the knob The SET knob is used to control the chosen function Pressing the knob for a few seconds resets the chosen trip meter and ...

Page 21: ...igher 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 nearest Authorised Service outlet for necessary attention Caution Never remove the radiator pressure cap from the radiator when the engine is hot Do not restart the engine until ...

Page 22: ...N The demister will switch off automatically after 15 minutes Rear Wind Shield Demister will work effectively when battery is fully charged NOTICE Clean the rear windshield glass carefully from inside to avoid damage to demister heater element Hazard Warning Switch Hazard warning is used in case of breakdown especially during night and vehicle has to be parked at the side of the road or vehicle be...

Page 23: ...ched on with parking lamp and front fog lamps ON and can be remain ON till the parking lamp is switched OFF The rear fog lamps can also be switched ON even if only headlights are ON NOTICE Use only during foggy conditions or heavy rains if required Front Fog Lamps Unlatched switch The fog lamps are provided on front bumper to improve the visibility in foggy weather or during heavy rains The front ...

Page 24: ...when the key is removed WARNING Do not remove the key while driving It will lock the steering and can cause loss of control Remove the key only when the vehicle is parked OFF key IN By turning key to OFF key in position KEY IN driven load like music system will be ON IGN All electricals and accesories ON START Turn the key further clockwise to the START position spring loaded to start the engine A...

Page 25: ...Grande At a Glance Sumo Grande At a Glance Sumo Grande At a Glance Sumo Grande At a Glance C C C C COMBINA OMBINA OMBINA OMBINA OMBINATION SWIT TION SWIT TION SWIT TION SWIT TION SWITCH CH CH CH CH Ofrecido por www electromanuales com ...

Page 26: ...ne only when vehicle is stationary NOTICE Since the leveling switch takes care of headlamp focus pattern under varying load conditions it is advisable to select the correct position before starting a trip depending on load 2 Light stalk Outer rotary switch on right hand stalk is provided for selecting Position or Head lamp High Low beam It operates with Ignition switch in IGN position a Head Posit...

Page 27: ...m to High beam and vice versa For High beam flash pull the lever halfway For keeping the in High beam position pulls up the lever further up to latch 3 Light stalk Side Indicator Push the stalk upwards for changing lane or turning to Left and downwards for changing lane or turning to Right according to requirement It has three positions A Side indicator OFF B Lane change for Left or Right Turn Spr...

Page 28: ...em is provided on the facia the speakers are fitted on doors and tweeters on dashboard Music System stalk down for wipe and wash Pull towards driver for Flick Wipe spring return NOTICE After wash function is activated there will be three wipes of wiper There will be one more wipe after 5 seconds to clean traces of water on wind screen Analog Clock The vehicle is fitted with an analog clock on the ...

Page 29: ... a Glance Sumo Grande At a Glance HEATING VENTILATION AIR CONDITIONING Central Console A C Controls A B C D E A Air Direction Control Knob B Temperature Control Knob C Blower Speed Regulation Knob D A C ON OFF Switch E Air Recirculation Fresh Air Switch Ofrecido por www electromanuales com ...

Page 30: ...nob B on the control panel The temperature can be increased by rotating the knob towards the red segment and decreased by rotating it towards the blue segment C Blower Speed Regulation Knob The HVAC system has a four speed blower The blower speeds can be regulated to any one of the following speeds by operating the blower knob C centre of the control panel Towards face Towards face and feet Toward...

Page 31: ... In recirculation mode air inside the vehicle is circulated again and again In Fresh mode air is taken from atmosphere and circulated in the vehicle Recirculation mode can be used Q While driving in dusty condition Q To avoid traffic pollution Q To get quick cooling heating as required Whenever discomfort is felt switch air circulation mode to fresh NOTICE NOTICE NOTICE NOTICE NOTICE Q The A C can...

Page 32: ...de and temperature control switch in the maximum cooling Blue position At maximum cooling A C trips off automatically when the desired temperature is achieved Q In case you find reduction in air flow or foul smell in the passenger compartment clean the evaporator Demisting In rainy season or in areas of high humidity mist formation inside windshield glass is observed To clear mist dehumidified air...

Page 33: ...otary control knob at the vents on the dash board The air vents can be adjusted upward and downward NOTICE NOTICE NOTICE NOTICE NOTICE Refrigerant charged in the air conditioning circuit has been identified on the label over front body member Use only refrigerant as given in the label for topping up or recharge i e do not charge R12 CFC in the vehicle earlier charged with R134a Non CFC or vice ver...

Page 34: ...ngers When front AC is ON it will provide cool air from frontAC When front AC is OFF it can be used as blower supplying normal air RearAC switch is provided on roof and can be used to switch ON the blower and select the blower speed four adjustable air vents are provided on roof Air flow and direction can be adjusted on each air vent Ofrecido por www electromanuales com ...

Page 35: ...illuminates the road immediately ahead for short distance visibility It also contains side indicator lamp and a parking lamp Tail Lamp The tail lamp assembly incorporates the following 1 Reverse Lamp 2 Direction Indicator 3 Tail Brake Lamp Side Repeater Indicator Lamp F F F F Fr r r r ron on on on ont F t F t F t F t Fo o o o og Lamp g Lamp g Lamp g Lamp g Lamp R R R R Rear F ear F ear F ear F ear...

Page 36: ...arn the traffic coming from the rear that the door is open Door Puddle Lamp This is provided on the bottom side of the doors to assist the user for easy entry and exit during night Engine Compartment Lamp This lamp is provided for your convenience High Mounted Stop Lamp High Mounted Stop Lamp High Mounted Stop Lamp High Mounted Stop Lamp High Mounted Stop Lamp Registration Plate Lamps Registration...

Page 37: ...ately for the right and left reading lamps Rear roof lamp A roof mounted lamp is provided above the rear seat It has following three positions ON DOOR OFF The function of this switch is similar to front interior light LAMPS Left Right Middle Follow me home Headlamps After closing the door your car s headlights remain ON for approximately 30 seconds to help you reach your destination in the dark If...

Page 38: ...r A vanity Mirror has been provided on the back of the Co driver s sunvisor Roof Grab Handle These are provided on all seats except driver seat This helps in comfortable positoning of passengers during journey NOTE When not in use keep the sunvisors in their original position otherwise they may block the driver s vision Sunvisor Vanity Mirror Goggle Case A goggle case is provided near inner rear v...

Page 39: ...is her position 1 Move the main switch to L for adjusting left side mirror and R for adjusting right side mirror 2 Use the 4 positions of the knob to adjust the rear view mirrors to correct angles NOTE Manually adjusted outer rear view mirror are also available in few version Inner Rear View Mirror Antiglare mirror The antiglare mirror is fitted inside the cab Provision has been made for two posit...

Page 40: ...co driver s seat The glove box can be locked with the ignition key Cup holder Two cup holders are provided in the glove box lid for your convenience Cup holder Cup holder Cup holder Cup holder Cup holder Utility pocket box Utility pocket is provided to all the doors to keep magazines books etc Front utility pocket box Glove Box Glove Box Glove Box Glove Box Glove Box Rear utility pocket box Ofreci...

Page 41: ...ly when Engine is ON or Ignition key in ON position CAUTION Handle the lighter carefully to avoid personal injury If lighter does not pop out remove it to avoid overheating Avoid smoking inside the vehicle it may spoil inside ambience interiors upholstery etc Cigarette Lighter for front passengers Cigarette Lighter for Rear passengers B Cup Holder Two cup holders are provided in the floor console ...

Page 42: ... a push type switch located at the centre below the window switches It has two positions LOCK When switch is pressed UNLOCK When switch is released WARNING While raising the glass take care to avoid fingers hands getting trapped between glass and the frame Power window switch On Rear Doors Individual window winding switches have been provided only on the rear doors To close the door window glass p...

Page 43: ...o open the windows whenAC is ON This will adversely affect the AC performance Steering Wheel Position Adjustment You can adjust the steering wheel position to suit your convenience Adjust the steering wheel position as follows before you start driving 1 Adjust the seat to a comfortable position 2 The lever to tilt the steering wheel is under steering column Pull the lever up and hold in that posit...

Page 44: ...cle WARNING Fuel vapour is extremely hazardous Always stop the engine before refueling and never refuel near sparks or open flames CAUTION Remove the fuel filler cap slowly and wait for any hissing to stop then remove it The fuel may be under pressure may spray out causing injury if the cap is opened suddenly Fuel Flap Openning Lever Always use only original specification fuel cap or an approved e...

Page 45: ...d behind the gearshift lever To apply the parking brake pull the lever up fully The indicator light on the instrument panel will become ON To release it pull the lever up slightly press the release button and push the lever down The parking brake indicator on the instrument panel will go OFF when the parking brake lever is fully released 1 Release Button 2 Parking brake lever A Applied Condition B...

Page 46: ...odule BCM 3 Lock Indicator Warning on instrument cluster for indication of mode of the system Features Q Locking unlocking the vehicle from distant place Refer arm mode Q Immobilisation of vehicle and continuous flashing of turn indicators and hooting if theft is detected Refer Armed Panic Q Protection when user forgets to lock using remote Refer Auto Arm Mode Q Immobilisation of vehicle if theft ...

Page 47: ...Remote Unlearning Lost Remote Modes of the system State of Immobiliser Meaning Function of the state Disarmed Vehicle can be driven Armed Vehicle cannot be driven Immobiliser is sensing for unauthorised entry Armed Panic Vehicle cannot be driven Immobilised Fuel starter supply is cut and EMS interface state is inverted Auto Armed Vehicle cannot be driven Immobiliser is sensing for unauthorised ent...

Page 48: ...Distant Place Do not use Me chanical Key Press UNLOCK on User Remote Q Gives one flash on turn indicators Q Unlocks drivers door Press UNLOCK again to unlock other doors Q Lock Indicator on dashboard stops blinking Q The vehicle disarms User can drive the vehicle When Lock Indicator on dash board is blinking the vehicle cannot be driven Press UNLOCK to disarm the vehicle ARMED PANIC MODE InArmed M...

Page 49: ...icator on instrument cluster is blinking the vehicle cannot be driven Press unlock to disarm the vehicle CAR SEEK Used to find the vehicle Press LOCK on User Remote when the vehicle is locked Range 7 5 meters max Q Gives three flashes on turn indicators and remains armed CENTRAL DOOR LOCKING FEATURE All doors can be locked unlocked by manually locking unlocking the driver s door using mechanical k...

Page 50: ...within 5 seconds the system will remain in immobilised state and the left right indicators will not come ON as in point no 4 Close the driver s door and follow the step no 2 onwards 6 After step 5 the left and right indicators start flashing ON OFF for max 9 counts the user Must count the number of flashes and turn ignition ON as soon as this count matches the first digit of secret code The left a...

Page 51: ... remotes 8 Learning mode will be exited in 30 seconds if any of the remotes is not learnt during this time The learning process has to be repeated CHANGING OF SECRET CODE THIS PROCEDURE IS APPLICABLE IN CASE WHEN THE USER WANTS TO CHANGE THE SECRET CODE CHANGING OF PIN WILL BE POSSIBLE WHEN IMMOBILISER IS IN UNSETSTATE OR REMOTE KEY ENTRY IN UNLOCK STATE 1 Press UNLOCK button from the remote 2 Swi...

Page 52: ... the 4 digits of new secret code the left and right indicators stops flashing for 10 sec 13 If the new secret code entered twice is not matching then the flashing of side indicators will start for 5 sec To restart the procedure of entering new code steps from 12 onwards to be performed The left and right indicators starts flashing after 10 sec 14 If secret code entered twice is matching then the s...

Page 53: ...hen the vehicle can be driven Contact the dealer if the vehicle still could not be started Q Pressing UNLOCK LOCK does not UNLOCK LOCK the vehicle If the turn indicators are blinking pressing UNLOCK LOCK will stop the blinking of lamps The next UNLOCK LOCK press will actually unlock disarm the vehicle and the vehicle can be driven Q Battery Low Indication 1 Operating Distance has come down 2 LED o...

Page 54: ...ped on the plate attached to the key set Detach this plate and store at safe place Not in the vehicle This reference number is necessary while getting duplicate keys from your Authorised Dealer It advisable to keep another key at safe place for use in case of emergency NOTICE Do not use locally made keys get duplicate key through your authorized dealer Locking without a key from inside All the doo...

Page 55: ...ich has been locked cannot be opened from inside it can be opened only from the outside Tail gate Locking Unlocking Insert the key and turn it anti clockwise to open or clockwise to lock the door Pull the Door handle to open an unlocked door and just by closing the tail gate to its original position it gets locked DOOR LOCK CHILD LOCK Getting Started Location of door opening lever latch Tail gate ...

Page 56: ... slightly and raise the lever 2 Then lean back to the position you want and release it Make sure that lever return to its original position Moving the Seat Forward Backward To adjust the seat position lift the lever under the seat cushion front then slide the seat to the desired position and release the lever Once the desired position is achieved release the lever to lock the seat Make sure the se...

Page 57: ... press the unlock button push the head restraint down wards CAUTION Avoid driving the car with the head rest removed as it is a safety item Do not attempt to adjust the head rest while driving the vehicle SEAT FOLDING Getting Started Utility Tray Utility Tray Co driver Seat A Sliding tray is provided below co driver s seat Important papers documents can be kept inside Always ensure that this tray ...

Page 58: ...e for the third row seat passenger or for carrying extra luggage Folding of middle row seats from outside the vehicle Latches are provided on both seats on outer side for folding the seat backrest Operate the seat latch A to fold the seat back on seat base Pull the seat release strap B provided on seat base and tilt the seat base up so that it is vertical and touching front seat To unfold the seat...

Page 59: ...at is also front facing It can be accessed after folding one of the middle row seats Two adjustable neck restraints are provided on the third row seat This seat can be folded and also can be removed as and when required for more luggages Folding of third row seat Latch is provided on back rest for folding the seat backrest Open the tail gate to access the latch Pull the seat latch 1 to drop the se...

Page 60: ...middle row seat neck restraints This will hold the seat firmly Removal of third row seat Once the seat is folded it can be taken out from the vehicle Operate the levers to release the seat and care fully takes out seat from vehicle Seat Release Lever Ofrecido por www electromanuales com ...

Page 61: ...he height of the passenger wearing it The lap belt has one manually adjusted belt that fits across the hip bone It is similar to safety belt used in aeroplanes Make sure that your seat is adjusted to a good driving position and the back of the seat is upright 1 Pull the tongue across your body and insert it into the buckle 1 Seat Belt 3 Lock Buckle 2 Tongue 4 Lap Belt 2 1 3 4 2 Check and ensure th...

Page 62: ...could be crushed together and seriously injured Never use one belt for more than one person at a time 9 The belts are meant intended for adult occupants only 10 The belts if required should be replaced by Authorised personnel only 11 The belt should not be disassembled If required authorised personnel only should carry out disassembly and assembly 12 Clean the webbing with a mild soap solution rec...

Page 63: ...icle s seat belt Also use the seat belt while the child is in the rear seat According to accident statistics the child is safer when properly restrained in the rear seat than in the front seat Child restraint systems are available TATA MOTORS recommend the use of a type which fits to your vehicle Before installation always read the manufacturer s instructions Pregnant Woman TATA MOTORS recommends ...

Page 64: ... clean and unobstructed Remove dust frost snow or ice if any on these 6 All switches lamps are working 7 Check and ensure that all the gauges and indicators in the instrument cluster are working 8 Gear shift lever is in neutral position 9 Parking brake is released 10 Adjust steering wheel position SAFETY CHECKS Windshield wiper windshield washer Always keep windshield glass clean to avoid any dist...

Page 65: ...ecked for any disintegration and should be updated regularly Documents Always carry vehicle registration papers insurance validPUCcertificate and driving licence with you DRIVING SAFETY Seat Belt Seat belts are life saving equipment use of seat belt reduces the chance of injury and severity of injury in case of an accident It is strongly recommended that all the car occupants should always wear se...

Page 66: ... down and then acceleration which uses more fuel Fuel economy speeds Gear Speed kmph 1st 15 2nd 30 3rd 45 4th 60 5th 80 Driving FUEL SAVING TIPS NOTICE Always maintain clean air filter The amount of air supplied will reduce due to clogged air filter resulting in wastage of fuel due to incomplete combustion Avoid incorrect tyre pressures Under inflated tyres result in increased running resistance o...

Page 67: ...TING STOPPING THE ENGINE Driving Gear Km ph 1st 20 2nd 40 3rd 65 4th 90 5th 110 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 Running in Period Avoid rapid acceleration and prolonged high speed running of the engine while usin...

Page 68: ... engine when slowing down by shifting to a lower gear This can help you to maintain a safe speed and prevent your brakes from overheating while going down a steep hill CAUTION Avoid excessive revving up of engine rpm CAUTION Runing Engine under idle condition for long duration and also in high idle fly up rpm should be avoided Gear Shifting Gear Change Speeds during upshift Gear Change Speeds duri...

Page 69: ...ers for efficient energy absorption Q Load Sensing Proportionating Valve to avoid rear wheel locking in extreme load condition Q Auto adjusted rear brakes which are designed for trouble free performance The system is designed with an H circuit this has an advantage of providing minimum braking even if one circuit fails however the pedal will be harder to press and stopping CAUTION distance will in...

Page 70: ...ISED Workshop to check entry of water in cylinders It will also be necessary to replace lubricants of engine gearbox transfer case front axle and rear axle if water has entered Get the starter and alternator checked Driving on a Rainy Day Check brakes steering and windows Check tyres for wear and tyre pressure Check wiper blades for proper functioning Avoid harsh braking and sharp turns It may cau...

Page 71: ...iagonally across a hill The danger is in loss of traction and sideways slippage possibly resulting in tipping over If unavoidable choose as mild an angle as possible and keep the vehicle moving If the wheels start to slip within few feet of the end of the climb motion can be maintained by swinging the steered wheels left and right thereby providing increased grip If the vehicle stalls or losses he...

Page 72: ... if a bad hill top obscures the view Hazard Warning Switch Use Hazard Warring lights besides advance warning triangle in case of breakdown specially during night time and vehicle has to be parked at the side of the road or vehicle is being operated in adverse condition This can be operated without ignition ON Press the hazard warning switch red knob on the left side of the dash board all side indi...

Page 73: ...ation of breakdown Take out the tool kit jack and handle from the vehicle which is kept below driver seat Removal of Spare wheel Spare wheel is mounted below cab at rear side of vehicle Open the tail door Lift the carpet cutout covering the spare wheel winch screw hole Rotate the wheel winch screw in anti clockwise direction using the wheel spanner to lower the spare wheel Let the wheel touch the ...

Page 74: ... with the locating pin on the frame while raising the spare wheel Continue to rotate the wheel winch screw in anticlockwise direction until spare wheel is raised completely Changing the flat tyre Block the wheel which is diagonally opposite to the flat tyre Take out wheel cover If fitted and loosen the wheel mounting nuts of flat tyre Do not remove the flat tyre at this stage Set the jack properly...

Page 75: ...hange the flat tyre Do not carry any other work under the vehicle supported by jack otherwise personnel injury may occur Do not start or run the vehicle while supported by jack Remove wheel mounting nuts and take out flat tyre Roll the spare wheel into position and align the holes in the wheel with studs Then reinstall the wheel nuts taper end inward and tighten them as much as you can by hand Low...

Page 76: ...and brake Keep the gearshift lever in neutral Do not connect the lead to the negative terminal of the discharged battery The connection of the ve lead point should be as far away from the discharged battery as possible and close to the starter motor on engine transaxle Route the leads so that they cannot get caught by the rotating parts in the engine compartment The engine of the vehicle providing...

Page 77: ...ope as your vehicle may crash into the vehicle towing your car when it stops suddenly Switch ON the hazard warning signals of both the vehicle to warn other road users Where possible keep the engine idling so that power steering assistance and brake vacuum are available Limit the speed to 20 30 kmph In case of brake failure use the parking brake to control the vehicle Front and Rear Tow Hook Locat...

Page 78: ...We highly recommend that these items be inspected at least every week Engine Oil Level Engine coolant Level Brake Fluid Level Washer Fluid Level Battery Tyre inflation pressure Do it Yourself Service Improper or incomplete service may result in problems Several mantenance procedures can be done only by a qualified service technician with special tools Improper do it ourself maintenance during the ...

Page 79: ...battery connections Clean and tighten battery connections 2 Engine cranks but does not start Air in the fuel system Press pear pump for air removal Check leakages Service lamp should glow Get defect rectified EMS fuse blown Replace the fuse 3 Engine overheats Coolant level low Top up coolant check and correct leakages Hose collapse torn Get the hose replaced Low engine oil level Add oil Radiator c...

Page 80: ...luid in the master cylinder Get the clutch fluid filled 2 Clutch pedal goes too low Air in the hydraulic system Bleed the system Less fluid in the master cylinder Get the clutch fluid filled 3 Clutch pedal return sluggish Blocking of vent in clutch fluid Open the cap from the bottle bottle clean the breather hole if clogged GEAR BOX 1 Hard gear shifting Clutch does not disengage Get the clutch hyd...

Page 81: ...matic adjuster Check rectify auto adjuster mechanism or replace Vacuum leakage Rectify the leakage Brake fluid contamination Replace the brake fluid Brake fluid grease oil or water Replace the leaking line bleed on pad drum the system Clean pad lining replace seals if leaking Worn brake lining pad Get the liners pad replaced Excessive worn drums at rear Replace rear drums soft or weak hose Check r...

Page 82: ...iner clogged No brake pedal free play brake Adjust brake pedal pedal not returning fully Defective tandem master cylinder Replace rectify tandem master cylinder 5 Brake Squeal Defective brake lining pad Replace Glazed lining pad Clean or replace lining pad Loose rivets Install rivets properly Wrong lining pad Install correct lining pad Shoe return spring broken Replace Front pads Antisqueal shims ...

Page 83: ...the specified levels Circuit bulb failure Replace bulb Leakage from hydraulic unit ports Eliminate leakage by tightening Hydraulic unit fluid level low Check reservoir fluid level and bleed properly Unusual response and malfunction Check sensor condition in the actuators replace if necessary STEERING SYSTEM 1 Hard steering Less fluid in the power steering Get the fluid topped up to tank correct le...

Page 84: ... lamps fuel tightened tank flap wiper and washer etc Circuit relay loose Tighten the relay correctly in the mounting Defective components Get the defective component replaced from Authorised Workshop AIR CONDITIONING 1 Fan motor does not operate Blown fuse Replace fuse and correct any wiring short Faulty connection Properly connect poor connections Faulty motor Replace motor if no conductance SR N...

Page 85: ... blade is worn out 2 The wiper blade jumps across No proper contact of wiper blade Clean the wind shield If jumping the windshield and makes a lot with wind shield glass and wiper persists replace the blade of noise Un smooth operation blade does not move smoothly across the surface but vibrates noisily and bounces 3 The wipe leaves large un wiped Rubber deformed Replace the blade spots 4 The blad...

Page 86: ...86 FUSES RELAYS Electrical Maintenance Ofrecido por www electromanuales com ...

Page 87: ...87 87 FUSES RELAYS Electrical Maintenance Ofrecido por www electromanuales com ...

Page 88: ...15S White 12V 21 5W 2 Reverse lamp BA15S White 12V 21W 2 Rear fog lamp BA15S White 12V 21W 2 Cabin lamp Ist Row Festoon White 12V 10W 1 Spot lamp Ist Row Wedge base w 2 1 x 9 5d White 12V 5W 2 Cabin lamp IIst Row Wedge base w 2 1 x 9 5d White 12V 5W 1 Cabin lamp IIIrd Row Wedge base w 2 1 x 9 5d White 12V 5W 1 Engine lamp BA15S White 12V 10W 1 Puddle lamp All doors Wedge base w 2 1 x 9 5d White 12...

Page 89: ...RNING Handling Halogen Bulbs It is dangerous if a halogen bulb breaks These bulbs contain pressurized gas and if broken will explode and serious injuries could be caused by the flying glass Halogen bulbs can break if the glass portion is touched with bare hands body oil could cause the bulb to overheat and explode when lit Never touch the glass portion of the bulb with your bare hands and always w...

Page 90: ...bulb is located below the Headlamp bulb on the assembly 3 Pull the bulb holder from the socket 4 Carefully remove the parking bulb from the socket by pulling it straight back Fig 5 5 Replace the bulb 6 Install in the reverse order of removal Replacing Tail Lamp Bulb 1 Make sure lighting stalk is in OFF position 2 Open the tail gate 3 Remove the bolts 2 nos holding the tail lamp cluster using a siz...

Page 91: ...move the cover located on the inner side of tail gate Fig 4 3 Rotate and pull out the socket with bulb to be replaced Fig 5 4 Carefully remove the fused bulb from the socket by rotating and pulling it 5 Replace the bulb 6 Install in the reverse order of removal 1 2 3 4 5 Ofrecido por www electromanuales com ...

Page 92: ...hes that could allow corrosion to start Apply touch up paint where necessary Polishes Polishes and cleaners can restore shine to the painted surface that has oxidised and become dull They normally contain mild abrasives and solvents that remove the top layer of the finish coat Polish your Vehicle if the finish does not regain its original shine after using wax Cleaning of Carpets Vacuum clean the ...

Page 93: ... blade attack angle on windshield glass should be 900 i e perpendicular Remove wiper blade and root wiper arm on windshield glass in the centre position Check the gap between arm strip and glass FOLLOWING GUIDELINES WILL HELP YOU TO PROTECT YOUR VEHICLE FROM CORROSION EFFECTIVELY PROPER CLEANING In order to protect your vehicle from corrosion it is recommended that you wash your vehicle thoroughly...

Page 94: ...ehicle HAND WASH 1 Always wash your vehicle in shade and the surface is at room temperature 2 Wash with mild car wash soap like Car Shampoo and use a soft 100 cotton cloth to avoid scratches 3 To avoid scratches please wear soft gloves Remove finger rings nails wrist watch while washing 4 To remove stubborn stains and contaminants like tar use turpentine or cleaners like Stain remover which are sa...

Page 95: ...e do not use soap but a car shampoo recommended by your dealer Please take the following precautions 1 Always wash your vehicle in shade avoiding direct exposure to sunlight during washing 2 Dry wiping your vehicle may lead to the formation of scratches and hence always use a soft cloth and clean water while wiping your vehicle 3 Always keep your vehicle parked in a well ventilated shade Exposure ...

Page 96: ...otection treatments z Cheaper than other corrosion protection methods eg galvanizing anodizing z For decoration and identification Various Environmental Hazards affecting paints z Environmental hazards destroy your vehicle s finish z Even as your new vehicle rolls off the assembly line the paint is not protected The enemy Ultraviolet Rays Pollution Tree Sap Bird Droppings Car Wash Chemicals Road S...

Page 97: ...lever located under the bonnet centre 4 Lift the bonnet up Pull the bonnet stay rod from its clip and insert the free end into the slot in the bonnet slide stay rod outward to secure Closing 1 To close the bonnet disengage the stay rod clamp it properly 2 Lower the bonnet and drop it from a short height to shut CAUTION Bonnet release Lever Location of Bonnet release lever Ensure that the bonnet is...

Page 98: ...il Dipstick 4 Wind shield washer container 5 Glow Plug Interface Unit 6 Battery 7 ECU 8 Power steering reservoir 9 Radiator Pressure Cap 10 Auxiliary tank 11 Engine Oil Filling Cap 12 Service Indicator 13 Air Filter Maintenance ENGINE COMPARTMENT Ofrecido por www electromanuales com ...

Page 99: ...o greater intake resistance and result in increased fuel consumption Using low pressure compressed air blow off dust on the air cleaner element If the air cleaner element appears to be choked replace it with a new one ENGINE OIL LEVEL CHECKING Warm up the engine to normal operating temperature Turn it off and wait 5 minutes for the oil to return to the oil pan Be sure the Vehicle is on a level sur...

Page 100: ... are cool 2 Turn the radiator cap anti clockwise without pressing it until it stops This will relieve the pressure if any in the cooling system 3 Remove the radiator cap by pushing down and turning anti clockwise 4 The level of coolant should be upto the base of the filler neck Coolant should be added if it is low 5 Secure the radiator cap in its place 6 Add coolant into the auxiliary tank up to t...

Page 101: ... allow brake fluid to splash or spill on the paint surface as it will damage the paint In case of spillage wipe it off immediately Power steering reservoir The level of the power steering fluid must be between the min max marks on the side of the power steering fluid container If the level falls below the min mark add recommended fluid Refer chapter Fuels coolants lubricants In case of leakage or ...

Page 102: ... and in this condition under high pressure they have a tendency to skid The valve is installed in the line to the rear brake drum During heavy braking the valves limits the pressure to the rear wheels this allows rear wheels to keep turning instead of locking up and skidding If any alteration is done in Rear suspension the performance of this valve will be impaired The valve stem gap should be adj...

Page 103: ...rew the water sensor 7 Clip the hydraulic connector and the electric connector to the water sensor 8 Use hand primer Pear pump to refill the line before restarting chassis frame near fuel tank below the vehicle It is used in the fuel supplying system in order to reduce the water content in the fuel provided to the DICOR system A water sensor is fitted to the water sedimenter in order to indicate t...

Page 104: ...or sedimenter pump by means of priming pump pear pump until all air in the fuel line removed Before cranking the engine ensure that there is no air in the fuel system Fuel Filter Fuel filter separates dust particles from the fuel allows clean fuel in to the common rail system It also separates stores water Fuel Filter Fuel Filter Fuel Filter Fuel Filter Fuel Filter Priming Pear pump Priming Pear p...

Page 105: ...life and better fuel efficiency Over inflation of tyres makes the car ride bumpy and harsh Tyres aremorepronetounevenwearand damage from road hazards Under inflated tyres reduce your comfort in car handling and are prone to failures due to high temperature They also cause uneven wear and more fuel consumption Check for inflation and condition of your car tyres periodically Inflation Check the pres...

Page 106: ...sure that wheel pins are free from dust scratches dirt dents etc Ensure the tube being replaced has the correct valve CAUTION Recommended Tyre Pressures Bumps or bulges in the tread or the side of the tyre Replace the tyre if you find either of these conditions Cuts splits or cracks in the side of the tyre Replace the tyre if you notice this on the fabric or cord Excessive tread wear or non unifor...

Page 107: ...he vehicle with damaged rim may cause deflation of tyre and subsequent dislodging of tyre from rim 4 Maintain recommended inflation pressure Over inflation in particular may cause puncture or bursting of tyre NOTE Life and wear pattern of tyres depends on various parameters like tyre pressure wheel alignment wheel balancing tyre rotation etc It also largely depends on vehicle speed load carried us...

Page 108: ...mbalance for tyre with rim 250 gm cm max 2 Total balance weight should be within 140 gms on each side 3 Relocate the tyre if the weight required to balance is more than 140 gm 4 Balance weights are available from 10 gms to 140 gms in steps of every 10 gms and from 15 gms to 135 gms in steps of every 10 gms 5 Do not use more than one balance weight on one side Care for the Catalytic Converter The c...

Page 109: ... Clean the battery terminals with a terminal cleaning tool or wire brush Reconnect and tighten the cables coat the terminals with petroleum jelly Ensure that battery securely mounted If you need to connect the battery to a charger disconnect both cables to prevent damage to the vehicle s electrical system BATTERY During normal operation the battery generates gas which is explosive in nature a spar...

Page 110: ...lavis gauge to ensure recommended values as given below Alternator Power Steering Belt Alternator Power Steering Belt Alternator Power Steering Belt Alternator Power Steering Belt Alternator Power Steering Belt Arrangement Arrangement Arrangement Arrangement Arrangement A C Compressor Belt Arrangement A C Compressor Belt Arrangement A C Compressor Belt Arrangement A C Compressor Belt Arrangement A...

Page 111: ...yntro 75W90 GL4 CASTROL Castrol Syntro 75W90 GL4 1 6 Litres 1 6 Litres 1 6 Litres 1 6 Litres 1 6 Litres POWER STEERING OIL POWER STEERING OIL POWER STEERING OIL POWER STEERING OIL POWER STEERING OIL A A A A ATF TF TF TF TF T T T T Typ yp yp yp ype A e A e A e A e A HPCL HP A HPCL HP A HPCL HP A HPCL HP A HPCL HP ATF D TF D TF D TF D TF De e e e ex II x II x II x II x II 1 4 Litres 1 4 Litres 1 4 L...

Page 112: ... or aviation turbine fuel Ratio for mixing of supplementary fuel and diesel are shown in the table Do not mix gasoline or alcohol with diesel This mixture can cause explosion Recommended Fuel Specification for engines to be added Parameter Unit BS III 1 Cetane Number min CN 51 2 Sulphur content mg kg 350 3 Lubricity HFRR micon 460 Important Technical Information FUEL LUBRICANTS COOLANTS Ambient te...

Page 113: ... T T Temp emp emp emp emp 0 0 0 0 0 C C C C C Grade Grade Grade Grade Grade 5 and above SAE 15W 40 10 to 0 SAE 5W30 20 and 10 SAE 0W30 Front live axle and rear axle oil Front live axle and rear axle oil Front live axle and rear axle oil Front live axle and rear axle oil Front live axle and rear axle oil Spicer axles Spicer axles Spicer axles Spicer axles Spicer axles Use Multigrade oil SAE 85W 140...

Page 114: ...echnical Information OIL FILLING DRAIN POINTS GEARBOX G 76 A OIL LEVEL PLUG B DRAIN PLUG ENGINE OIL DRAIN PLUG REAR AXLE SPICER A OIL LEVEL PLUG B DRAIN PLUG ENGINE OIL FILLING CAP Ofrecido por www electromanuales com ...

Page 115: ...ngine Oil Capacity 5 5 Litre Min 7 5 Litre Max 2 CLUTCH Type Single plate dry friction diaphragm type Outside diameter 240 mm of clutch lining Friction area 503 sq cm Approximately 3 GEAR BOX Model GBS 76 5 4 1 with overdrive Type Double Synchromesh on all gears No of gears 5 forward 1 reverse Gear Ratios 1st 4 10 2nd 2 22 3rd 1 37 4th 1 00 5th 0 77 Rev 3 75 4 REAR AXLE Single Reduction Salisbury ...

Page 116: ...unted handle Cable Operated Mechanical Linkages Acting on Rear Wheels 8 FRAME Type Ladder Type Cranked Frame with Boxed Section Long Members bolted Welded Cross Members 9 SUSPENSION Front Double Wishbone Type coil spring Rear Parabolic Leaf Springs Shock Absorber Hydraulic Double Acting Telescopic Type at Both Front Rear Antiroll Bar At both Front and Rear 10 WHEELS TYRES Tyres 235 70 R 16 Tubeles...

Page 117: ...Overhang 834 Rear Overhang 1036 over bumper Overall Height Unladen laden 1910 1890 Minimum Turning Circle Dia 10 5 m Minimum Turning Clearance Circle Dia 11 5 m Ground Clearance 180 mm 16 WEIGHTS kg TOLERANCE AS PER INTEREUROPE STVZO Complete vehicle kerb weight asper ISO 1176 with sparewheel and tools 1950 FAW 1000 RAW 950 Gross Vehicle Weight 2625 FAW 1100 RAW 1525 Max Permissible FAW 1150 Max P...

Page 118: ...118 INFORMATION AT A GLANCE Dimensions Important Technical Information Ofrecido por www electromanuales com ...

Page 119: ...N OF AGGREGATE NUMBER Vehicle Identification REAR AXLE NUMBER SPICER GEARBOX NUMBER CHASSIS NUMBER PLATE ON LH FRONT DOOR B PILLER ENGINE NUMBER ENGINE NUMBER CHASSIS NUMBER ON FRAME Ofrecido por www electromanuales com ...

Page 120: ...120 LOCATATION OF AGGREGATE NUMBER Vehicle Identification Ofrecido por www electromanuales com ...

Page 121: ...x 9 Check for any Leakages of coolant 10 Drain water from fuel water separator 11 Check hose clamps pipes at all locations in cooling system 12 Check hose clamps pipes at all locations in air intake system 13 Check for leakages of gear box oil 14 Check for Proper fitment of gear shift level rubber boot 15 Check level of Clutch and brake fluid Acceptable if found between mid and max 16 Check for oi...

Page 122: ... locks latches and windows 36 Check for any complaints on cab fittings instrument paner glove box etc 37 Check and tighten hand loose fasteners 38 Check for any breakages bends failure of any component assembly unit 39 Check for any fouling between two components which may lead to leakages or other complaints Check for fouling of fuel lines brake pipes clutch pipes air intake pipe power steering h...

Page 123: ...se Fasteners hydraulic line connections Exhaust system FuelPipes EveryService x x x x x x x x for Damages Leakages if any Attend if necessary 6 Apply grease on door latches door lock door check stop striker bonnet opening lever lock Every Service x x x x x x x plate tailgatehinges doorlockinnerratchet 7 Check ensure normal working of engine using DiagnosticEquipment EveryService x x x x x x x x 2 ...

Page 124: ...nt 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...

Page 125: ... while cleaning engine c en while cleaning engine c en while cleaning engine c en while cleaning engine c en while cleaning engine compar ompar ompar ompar ompartmen tmen tmen tmen tment t t t t I I I I It is r t is r t is r t is r t is rec ec ec ec ecommended t ommended t ommended t ommended t ommended to use dr o use dr o use dr o use dr o use dry lo y lo y lo y lo y low pr w pr w pr w pr w pres...

Page 126: ...traffic D Frequently operating in mountainous area ITEM INTERVAL CONDITION A B C D 1 Engine Oil Oil Filter Change every 7500 kms z z z z z z z z z z z z z z z z z z z z 2 Air Filter Element Clean at every 7500 kms z z z z z replace at 30 000 kms 3 RearAxle Oil Change Change First at 15000 kms z z z z z z z z z z z z z z z z z z z z thereafter at 45 000 kms Service Schedule SERVICE OPERATIONS TO BE...

Page 127: ... reading Kms Repair Order No Servicing Dealer s Signature Stamp Recommended Service At km Date Odometer reading Kms Repair Order No Servicing Dealer s Signature Stamp 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 3 15 000 Record Of Service Performed Ofrecido por www electromanuales com ...

Page 128: ...3 30 000 3 45 000 3 60 000 3 75 000 3 90 000 4 05 000 4 20 000 4 35 000 4 50 000 4 65 000 4 80 000 Recommended Service At km Date Odometer reading Kms Repair Order No Servicing Dealer s Signature Stamp 4 95 000 5 10 000 5 25 000 5 40 000 5 55 000 5 70 000 5 85 000 6 00 000 6 15 000 6 30 000 6 45 000 Ofrecido por www electromanuales com ...

Page 129: ...129 129 Odometer Repair Servicing Dealer s Date reading km Order No Particulars of Repair Signature Stamp Chassis No Record Of Repairs Carried Out Ofrecido por www electromanuales com ...

Page 130: ...130 Record Of Repairs Carried Out Odometer Repair Servicing Dealer s Date reading km Order No Particulars of Repair Signature Stamp Chassis No Ofrecido por www electromanuales com ...

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