SAFARI
|
SAFARI |
1 |
|
TATA SAFARI |
1 |
|
1. GENERAL |
5 |
|
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS |
8 |
|
1.2. LIFTING AND JACKING POINTS |
12 |
|
1.3. TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
13 |
|
1.4. CHASSIS NUMBERING SYSTEM |
14 |
|
A. CHASSIS NUMBERING SYSTEM FOR DOMESTIC VEHICLES |
14 |
|
B. CHASSIS NUMBERING SYSTEM FOR EXPORT VEHICLES |
18 |
|
C. CHASSIS NUMBERING SYSTEM FOR CKD VEHICLES |
18 |
|
1.5. AGGREGATE NUMBERING SYSTEM |
19 |
|
1.6. TECHNICAL SPECIFICATIONS |
22 |
|
1.7. FILLING CAPACITIES |
26 |
|
1.8. FUEL, LUBRICANTS & COOLANTS |
26 |
|
A. FUEL |
26 |
|
B. LUBRICANTS |
27 |
|
C. COOLANTS |
27 |
|
D. GENUINE CO-BRANDED ITEMS |
28 |
|
1.9. SERVICE SCHEDULE |
29 |
|
2. ENGINE - 4 DLT |
33 |
|
2.1. TECHNICAL SPECIFICATION |
36 |
|
2.2. SCHEMATIC CIRCUITS OF VARIOUS SYSTEMS ON ENGINE |
37 |
|
A) LUBRICATION SYSTEM |
37 |
|
B) COOLING SYSTEM |
37 |
|
C) FUEL SYSTEM |
38 |
|
D) EGR SYSTEM |
38 |
|
E) ENGINE BREATHING SYSTEM / OIL SEPARATOR SECTIONAL VIEW |
39 |
|
2.3. VISCOUS FAN DRIVE |
40 |
|
2.4. SPECIAL TOOLS |
41 |
|
2.5. PRELIMINARY INSPECTION OF ENGINE |
42 |
|
2.6. REMOVAL OF ENGINE FROM VEHICLE |
44 |
|
2.7. ENGINE DISMANTLING PROCEDURE |
46 |
|
2.8. CHECKING VISCOUS FAN DRIVE |
47 |
|
2.9. CYLINDER HEAD DISMANTLING |
59 |
|
2.10. TIGHTENING TORQUES |
61 |
|
2.11. REPAIR DATA |
63 |
|
2.12. INSPECTION AND CLEANING |
69 |
|
2.13. SERVICE INSTRUCTION FOR ALUMINIUM RADIATORS |
71 |
|
2.14. CYLINDER BLOCK ASSEMBLY |
73 |
|
2.15. REMOVAL, INSTALLATION AND MACHINING OF CYLINDER LINER |
76 |
|
2.16. ENGINE ASSEMBLY PROCEDURE |
102 |
|
2.17. FIP TIMING SETTING PROCEDURE (MICO) |
113 |
|
2.18. FUEL INJECTION EQUIPMENT SCHEMATIC LAYOUT & FUNCTION (LUCAS) |
117 |
|
A) LUCAS DPC FIP - HYDRAULIC CIRCUIT |
118 |
|
B) LUCAS FIP EURO - III |
119 |
|
C) LUCAS DPC FIP - FEAUTRES |
120 |
|
D) AIR VENTING |
121 |
|
E) IDLE SPEED SETTING |
122 |
|
F) ANTISTALL SETTING |
123 |
|
G) FAULT DIAGNOSIS FUEL INJECTION SYSTEM |
124 |
|
H) FAULT DIAGNOSIS INJECTORS |
125 |
|
I) FAULT DIAGNOSIS SMOKE |
126 |
|
2.19. FIP TIMING SETTING PROCEDURE (LUCAS) |
127 |
|
2.20. FUEL TANK & HOSES |
129 |
|
2.21. TURBOCHARGER |
135 |
|
2.22. EXHAUST SYSTEM |
138 |
|
2.23. EGR SYSTEM (FOR EURO III) |
141 |
|
2.24. ACCELERATOR CABLE |
143 |
|
2.25. ENGINE TESTING |
145 |
|
2.26. TROUBLE SHOOTING |
146 |
|
3. ENGINE - 486 PETROL |
149 |
|
3.1. TECHNICAL SPECIFICATIONS |
152 |
|
3.2. SPECIAL TOOLS LIST |
152 |
|
3.3. UNIQUE FEATURES OF ENGINE |
153 |
|
3.4. TIGHTENING TORQUES |
154 |
|
3.5. BELT ARRANGEMENT |
155 |
|
3.6. SPARK PLUG |
155 |
|
3.7. BOSCH MOTRONIC ENGINE MANAGEMENT SYSTEM |
156 |
|
3.8. INTEGRATED ENGINE ELECTRONICS |
157 |
|
3.9. SENSORS IN MOTRONIC SYSTEM |
158 |
|
3.10. FOUR VALVE ENGINEERING |
160 |
|
3.11. HYDRAULIC TAPPETS |
161 |
|
3.12. CYLINDER HEAD BOLT TIGHTENING PROCEDURE |
161 |
|
3.13. EMISSION CONTROL SYSTEM |
162 |
|
3.14. IDLE SPEED ACTUATOR |
164 |
|
3.15. ENGINE DISASSEMBLY & ASSEMBLY |
165 |
|
3.16. TEST PROCEDURE FOR SYSTEM CHECK AFTER ENGINE ASSEMBLY |
218 |
|
3.17. REPAIR ADJUSTMENT DATA |
219 |
|
3.18. DIAGNOSTICS USING KTS-300 SYSTEM TESTER |
224 |
|
3.19. DIAGNOSTICS USING BLINK CODE METHOD |
229 |
|
3.20. TROUBLE SHOOTING CHART |
232 |
|
4. CLUTCH |
235 |
|
4.1. CONSTRUCTIONAL DETAILS |
239 |
|
4.2. FACTORS AFFECTING CLUTCH WEAR |
239 |
|
4.3. PRELIMINARY INSPECTION |
239 |
|
4.4. SPECIFICATIONS AND RECOMMENDATIONS |
241 |
|
4.5. REMOVAL OF CLUTCH FROM VEHICLE |
241 |
|
4.6. INSPECTION OF COMPONENTS |
242 |
|
4.7. INSTALLATION OF CLUTCH ON VEHICLE |
242 |
|
4.8. CLUTCH ACTUATION MECHANISM REMOVAL |
243 |
|
4.9. CLUTCH MASTER CYLINDER |
245 |
|
4.9A. DISMANTLING OF MASTER CYLINDER |
245 |
|
4.9B. INSPECTION AND ASSEMBLY OF MASTER CYLINDER |
245 |
|
4.10. CLUTCH SLAVE CYLINDER |
246 |
|
A. DISMANTLING OF CLUTCH SLAVE CYLINDER |
246 |
|
B. INSPECTION AND ASSEMBLY CLUTCH SLAVE CYLINDER |
246 |
|
4.11. INSTALLATION OF CLUTCH ACTUATION MECHANISM |
246 |
|
4.12. BLEEDING THE CLUTCH SYSTEM |
247 |
|
4.13. CLUTCH PEDAL LINKAGE ADJUSTMENT |
247 |
|
5. GEAR BOX |
248 |
|
5.1. CONSTRUCTION |
251 |
|
I. SECTIONAL VIEW |
251 |
|
II. EXPLODED ILLUSTRATED VIEW |
253 |
|
III. LIST OF PARTS |
254 |
|
5.2. TECHNICAL SPECIFICATIONS |
257 |
|
5.3. SPECIAL TOOLS LIST |
258 |
|
5.4. REMOVAL OF G-76 GEAR BOX FROM VEHICLE |
259 |
|
5.5. DISMANTLING OF GEAR BOX |
260 |
|
5.6. DISASSEMBLY |
267 |
|
I. DRIVE SHAFT |
267 |
|
II. MAIN SHAFT |
267 |
|
III COUNTER SHAFT |
270 |
|
IV. GEAR BOX HOUSING REAR HALF |
271 |
|
V. GEAR CASE COVER FRONT |
272 |
|
VI. GEAR CASE COVER REAR |
272 |
|
5.7. ASSEMBLY OF SUB-ASSEMBLIES |
273 |
|
I. GENERAL INSTRUCTIONS |
273 |
|
II. IDENTIFICATION PARAMETERS |
274 |
|
III. ENGAGING GEARS 1ST/2ND, 3RD/4TH, REV/5TH |
276 |
|
IV. MAIN SHAFT |
277 |
|
V. COUNTER SHAFT |
280 |
|
VI. DRIVE SHAFT |
280 |
|
5.8. MEASUREMENT OF CONTROL DIMENSIONS |
281 |
|
5.9. SUB- ASSEMBLY |
287 |
|
I. GEAR BOX HOUSING COVER FRONT |
287 |
|
II. GEAR BOX HOUSING COVER REAR |
287 |
|
III. SHIFTER AND SELECTOR SHAFTS |
288 |
|
IV. GEAR BOX HOUSING REAR HALF |
289 |
|
5.10. ASSEMBLY OF GEAR BOX |
290 |
|
5.11. ASSEMBLY OF GEAR SHIFT LINKAGE |
295 |
|
5.12. INSTALLATION OF GEAR BOX ON VEHICLE |
296 |
|
5.13. TROUBLESHOOTING |
297 |
|
5.14. G-76 IMPROVEMENTS -SUPPLEMENT |
298 |
|
6. TRANSFER CASE |
306 |
|
6.1. TECHNICAL SPECIFICATION |
309 |
|
6.2. SPECIAL TOOLS AND TORQUE TABLE |
310 |
|
6.3. CONSTRUCTION AND PARTS IDENTIFICATION |
311 |
|
6.4. TRANSFER CASE WORKING |
314 |
|
6.5. ELECTRONIC CONTROL UNIT & SELF DIAGNOSIS |
316 |
|
6.6. REMOVAL AND INSTALLATION |
319 |
|
6.7. DISASSEMBLY |
320 |
|
6.8. CLEANING & INSPECTION |
325 |
|
6.9. ASSEMBLY |
326 |
|
6.10. LUBRICATION |
334 |
|
6.11. TROUBLESHOOTING |
335 |
|
7. SUSPENSION (WHEELS AND TYRES) |
336 |
|
7.1. FRONT INDEPENDENT SUSPENSION |
340 |
|
7.1.1. CONSTRUCTIONAL DETAILS |
340 |
|
7.1.2. SPECIFICATIONS AND RECOMMENDATIONS |
340 |
|
7.1.3. SPECIAL TOOLS |
342 |
|
7.1.4. REMOVAL/DISMANTLING PROCEDURE |
342 |
|
A. REMOVAL OF FRONT WHEELS |
342 |
|
B. REMOVAL OF FRONT ANTIROLL BAR |
342 |
|
C. REMOVAL OF FRONT SHOCK ABSORBER |
342 |
|
D. REMOVAL OF TORSION BAR |
344 |
|
E. REMOVAL/DISMANTLING OF UPPER WISHBONE |
344 |
|
F. REMOVAL/DISMANTLING OF LOWER WISHBONE |
346 |
|
7.1.5. INSPECTION OF PARTS |
346 |
|
7.1.6. ASSEMBLY/INSTALLATION PROCEDURE |
346 |
|
A. ASSEMBLY/INSTALLATION OF LOWER WISHBONE |
346 |
|
B. ASSEMBLY/INSTALLATION OF UPPER WISHBONE |
348 |
|
C. INSTALLATION OF FRONT SHOCK ABSORBER |
348 |
|
D. INSTALLATION OF FRONT ANTIROLL BAR |
350 |
|
E. INSTALLATION OF FRONT WHEELS |
350 |
|
F. INSTALLATION OF TORSION BAR |
350 |
|
7.1.7. WHEEL ALIGNMENT |
352 |
|
A. CAMBER ANGLE ADJUSTMENT |
352 |
|
B. CASTOR ANGLE ADJUSTMENT |
352 |
|
C. TOE-IN ADJUSTMENT |
352 |
|
D. WHEEL LOCK ANGLE ADJUSTMENT |
353 |
|
7.2. REAR 5 LINK SUSPENSION |
354 |
|
7.2.1. CONSTRUCTIONAL DETAILS |
354 |
|
7.2.2. SPECIFICATIONS AND RECOMMENDATIONS |
354 |
|
7.2.3. SPECIAL TOOLS |
354 |
|
7.2.4. REMOVAL/DISMANTLING PROCEDURE |
356 |
|
A. REMOVAL OF REAR SHOCK ABSORBER |
356 |
|
B. REMOVAL OF REAR ANTIROLL BAR |
356 |
|
C. REMOVAL OF PAN HARD ROD |
356 |
|
D. REMOVAL OF TOP LINK |
358 |
|
E. REMOVAL OF COIL SPRING |
358 |
|
F. REMOVAL OF BOTTOM LINK |
358 |
|
7.2.5. INSPECTION OF COMPONENTS |
360 |
|
7.2.6. ASSEMBLY/INSTALLATION PROCEDURE |
360 |
|
A. ASSEMBLY/INSTALLATION OF BOTTOM LINK |
360 |
|
B. INSTALLATION OF COIL SPRING |
360 |
|
C. INSTALLATION OF TOP LINK |
362 |
|
D. ASSEMBLY/INSTALLATION OF PANHARD ROD |
362 |
|
E. INSTALLATION OF REAR ANTIROLL BAR |
362 |
|
F. INSTALLATION OF REAR SHOCK ABSORBER |
362 |
|
7.3. WHEELS AND TYRES |
363 |
|
8. FRONT LIVE AXLE (4X2) |
367 |
|
8.1. TECHNICAL SPECIFICATIONS |
370 |
|
8.2. SPECIAL TOOLS |
371 |
|
8.3. DISMANTLING OF FRONT AXLE |
373 |
|
A. REMOVAL OF FRONT WHEELS |
373 |
|
B. REMOVAL OF FRONT HUB ASSEMBLY |
373 |
|
C. DISMANTLING OF FRONT HUB ASSEMBLY |
373 |
|
D. FRONT HUB ASSEMBLY WITH ABS TONER RING |
374 |
|
E. REMOVAL OF STUB AXLE ASSEMBLY |
375 |
|
F. DISMANTLING OF STUB AXLE ASSEMBLY |
375 |
|
8.4. INSPECTION OF PARTS |
375 |
|
8.5. ASSEMBLY INSTALLATION OF PARTS |
376 |
|
A. ASSEMBLY OF STUB AXLE |
376 |
|
B. INSTALLATION OF STUB AXLE |
376 |
|
C. ASSEMBLY / INSTALLATION OF FRONT HUB COMPLETE |
377 |
|
D. INSTALLATION OF FRONT WHEELS |
379 |
|
E. PRELOADING OF TORSION BAR |
379 |
|
F. WHEEL ALIGNMENT |
379 |
|
9. FRONT LIVE AXLE (4X4) |
380 |
|
9.1. CONSTRUCTION |
383 |
|
9.2. SPECIFICATION & SERVICE DATA |
386 |
|
9.3. SPECIAL TOOLS LIST |
387 |
|
9.4. 2 - WAY LOCK FREE RUNNING HUB |
388 |
|
A. REMOVAL AND INSTALLATION OF FREE RUNNING HUB ON VEHICLE |
389 |
|
9.5. REMOVAL OF WHEEL END WITH CV SHAFT FROM VEHICLE |
391 |
|
A. WHEEL END ASSEMBLY |
391 |
|
B. CARRIER CENTRE SECTION |
397 |
|
C. C. V. JOINT SHAFTS |
411 |
|
9.6. TROUBLE SHOOTING |
417 |
|
9.7. AUTOMATIC LOCKING HUB |
418 |
|
9.7.1. SPECIFICATIONS |
419 |
|
9.7.2. INTRODUCTION |
420 |
|
9.7.3. DIAGNOSIS |
422 |
|
9.7.4. DIS-ASSEMBLY INSPECTION & LUBRICATION |
423 |
|
9.7.5. ASSEMBLY |
425 |
|
9.7.6. LIST OF SERVICEABLE PARTS |
427 |
|
9.7.7. SOLUTION TO NOISE PROBLEM |
428 |
|
10. REAR AXLE |
429 |
|
10.1. CONSTRUCTION |
432 |
|
10.2. SPECIFICATION & SERVICE DATA |
434 |
|
10.3. SPECIAL TOOLS LIST |
435 |
|
10.4. REMOVAL FROM VEHICLE |
436 |
|
10.5. DISASSEMBLY |
437 |
|
A. UNITISED BEARING |
438 |
|
B. CARRIER CENTRE SECTION |
439 |
|
C. DRIVE PINION |
443 |
|
10.6. CLEANING AND INSPECTION |
444 |
|
10.7. ASSEMBLY |
446 |
|
A) UNITISED BEARING |
446 |
|
B) PINION BEARING CUP |
451 |
|
C) CARRIER CENTRE SECTION |
453 |
|
D) DIFFERENTIAL |
456 |
|
10.8. INTERPRETATION OF TOOTH CONTACT PATTERN |
459 |
|
10.9. TROUBLE SHOOTING |
462 |
|
11. PROPELLER SHAFT |
463 |
|
11.1. CONSTRUCTION |
466 |
|
11.2. LIST OF SPECIAL TOOLS & SERVICE DATA |
468 |
|
11.3. REMOVAL FROM VEHICLE |
469 |
|
11.4. DISASSEMBLY |
469 |
|
11.5. INSPECTION |
472 |
|
11.6. LUBRICATION |
474 |
|
11.7. ASSEMBLY |
475 |
|
11.8. INSTALLATION ON VEHICLE |
477 |
|
11.9. TROUBLE SHOOTING |
478 |
|
12. BRAKES |
479 |
|
12.1. TECHNICAL SPECIFICATIONS |
482 |
|
12.2. TIGHTENING TORQUES |
483 |
|
12.3. SCHEMATIC CIRCUIT OF BRAKE LINES |
484 |
|
12.4. FRONT DISC BRAKES |
488 |
|
A. DISC BRAKES CONSTRUCTION & WORKING |
488 |
|
B. CALIPER OPERATION |
489 |
|
C. BRAKE MAINTENANCE |
490 |
|
D. REMOVAL INSTALLATION OF PADS |
490 |
|
E. DISMANTLING AND ASSEMBLY OF CALIPER |
492 |
|
F. HOSE REPLACEMENT |
494 |
|
12.5. REAR DRUM BRAKES |
496 |
|
A. DRUM BRAKE CONSTRUCTION AND WORKING |
496 |
|
B. BRAKE MAINTENANCE |
497 |
|
C. DRUM INSPECTION |
498 |
|
D. REMOVAL AND FITTING OF SHOES |
498 |
|
E. WHEEL CYLINDER SERVICING |
502 |
|
12.6. TANDEM MASTER CYLINDER |
504 |
|
12.7. BLEEDING THE HYDRAULIC SYSTEM |
509 |
|
12.8. ZERO DEAD STROKE DOUBLE DIAPHRAGM VACUUM BOOSTER |
511 |
|
A. FUNCTION, CONSTRUCTION AND OPERATION |
513 |
|
B. SERVICE CHECK |
520 |
|
C. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF VACUUM BOOSTER |
522 |
|
12.9. PARKING BRAKE |
524 |
|
12.10. LOAD CONSCIOUS PRESSURE REDUCING VALVE (LCRV) |
527 |
|
12.11. TROUBLE SHOOTING HINTS FOR THE BRAKE SYSTEM |
528 |
|
13. ANTI-LOCK BRAKING SYSTEM |
532 |
|
13.1. TECHNICAL SPECIFICATIONS |
535 |
|
13.2. HYDRAULIC LINES FOR ABS |
536 |
|
13.3. ABS CIRCUIT DIAGRAM |
538 |
|
13.4. ANTILOCK BRAKE SYSTEM - THEORY |
539 |
|
13.5. COMPONENTS OF BOSCH ABS 5.3 SYSTEM |
546 |
|
13.6. ELECTRONIC BRAKES DISTRIBUTION (EBD) |
549 |
|
13.7. ABS SYSTEM FAILURE WARNING LIGHT |
551 |
|
13.8. REMOVAL / INSTALLATION OF ABS COMPONENTS |
552 |
|
13.9. ABS DIAGNOSTICS |
561 |
|
A. ABS DIAGNOSTIC TESTER |
563 |
|
B. ABS FAULT CODES |
570 |
|
C. REPAIR GUIDELINES |
587 |
|
D. ABS 5.3 SYSTEM TEST |
608 |
|
14. STEERING |
623 |
|
14.1. EXPLODED VIEWS |
626 |
|
14.2. DESIGN AND FUNCTION |
630 |
|
14.3. OIL FILLING AND AIR BLEEDING |
634 |
|
14.4. DISMANTLING AND ASSEMBLY TOOLS |
636 |
|
14.5. REMOVING THE STEERING UNIT FROM THE VEHICLE |
637 |
|
14.6. DISMANTLING THE STEERING UNIT |
638 |
|
14.7. CHECKING THE STEERING PARTS |
639 |
|
14.8. TECHNICAL DATA AND SET VALUES |
640 |
|
14.9. ASSEMBLY OF THE STEERING UNIT AND FUNCTION TESTING. |
640 |
|
14.10. FITTING THE STEERING UNIT ON THE VEHICLE |
643 |
|
14.11. TROUBLES AND REMEDIES |
645 |
|
14.12. MAINTENANCE AND FUNCTIONAL DESCRIPTION OF VANE PUMP |
648 |
|
14.13. STEERING COLUMN |
650 |
|
15. ELECTRICAL |
653 |
|
15.1. TECHNICAL SPECIFICATIONS |
657 |
|
15.2. CIRCUIT DIAGRAM SYMBOLS |
658 |
|
15.3. WIRE COLOUR CODING |
660 |
|
15.4. LIST OF BULBS USED IN SAFARI |
660 |
|
15.5. FUSES & RELAYS |
661 |
|
15.6. ALTERNATOR |
664 |
|
15.7. STARTER MOTOR |
666 |
|
15.8. INSTRUMENT CLUSTER |
667 |
|
15.9. FUEL GAUGE TANK UNIT |
670 |
|
15.10. HEAD LAMP / TAIL LAMP ASSY |
671 |
|
15.11. HORN |
677 |
|
15.12. COMBI SWITCH |
678 |
|
15.13. DIGITAL CLOCK |
679 |
|
15.14. MUSIC SYSTEM |
680 |
|
15.15. SWITCHES, INTERIOR LAMPS AND OTHER COMPONENTS |
681 |
|
A. GLOVE BOX SWITCH |
681 |
|
B. FRONT INTERIOR LAMP |
681 |
|
C. FUEL FLAP SOLENOID |
682 |
|
D RADIO ANTENNA |
682 |
|
E. WINDOW WINDING SWITCHES |
683 |
|
F. TRANSFER CASE SELECTION SWITCH |
684 |
|
G. DOOR MIRROR SWITCH |
685 |
|
H. RHEOSTAT |
686 |
|
I. ROOF LAMP |
686 |
|
J. FACIA SWITCHES |
687 |
|
K. STEERING LOCK CUM IGNITION SWITCH |
688 |
|
15.16 ANTITHEFT DEVICE |
689 |
|
15.17. CONTROLS UNITS |
691 |
|
A. HEATED REAR WINDOW CONTROLLER |
691 |
|
B. BUZZER UNIT |
692 |
|
C. CHIME UNIT |
693 |
|
D. FRONT WIPER CONTROLLER |
694 |
|
E. INTERIOR LIGHT DELAY UNIT |
695 |
|
F. FLASHER UNIT |
696 |
|
G. GLOW PLUG TIMER |
697 |
|
H. EGR CONTROLLER |
699 |
|
15.18. CENTRAL LOCKING SYSTEM |
700 |
|
15.19. WIPER SYSTEM |
702 |
|
15.20. TROUBLESHOOTING GUIDELINES |
708 |
|
15.21. WIRING DIAGRAMS |
710 |
|
15.21.1. GENERAL INFORMATION |
711 |
|
15.21.2. EARTHING LOCATIONS FOR RHO VEHICLES |
712 |
|
15.21.3. CONNECTORS & LOCATION ZONE CHARTS |
713 |
|
15.21.4. CONNECTOR LOCATION DETAILS FOR RHO VEHICLE |
715 |
|
15.21.5. CIRCUIT SCHEMATIC - SUPPLY CONFIGURATION |
717 |
|
15.21.6. CIRCUIT SCHEMATIC - STARTING I CHARGING 4DL - EURO-II |
718 |
|
15.21.7. CIRCUIT SCHEMATIC - STARTING I CHARGING 4DL - EURO-III |
719 |
|
15.21.8. CIRCUIT SCHEMATIC - IMMOBILISER (TRANSPONDER TYPE) |
720 |
|
15.21.9. CIRCUIT SCHEMATIC - IMMOBILISER WITH KEYLESS ENTRY CLU |
721 |
|
15.21.10. CIRCUIT SCHEMATIC - CENTRAL LOCKING SYSTEM |
722 |
|
15.21.11. CIRCUIT SCHEMATIC - HEAD LAMP & PARKING LAMPS |
723 |
|
15.21.12. CIRCUIT SCHEMATIC - HEAD LAMP LEVELING |
724 |
|
15.21.13. CIRCUIT SCHEMATIC - DIRECTION INDICATORS & HAZARD WARNING |
725 |
|
15.21.14. CIRCUIT SCHEMATIC - FRONT / REAR FOG LAMPS, STOP & REVERSE LAMPS |
726 |
|
15.21.15. CIRCUIT SCHEMATIC - INTERIOR LIGHTS |
727 |
|
15.21.16. CIRCUIT SCHEMATIC - INSTRUMENT CLUSTER |
728 |
|
15.21.17. CIRCUIT SCHEMATIC - FRONT WIPER & WASHER |
729 |
|
15.21.18. CIRCUIT SCHEMATIC - REAR WIPER & WASHER |
730 |
|
15.21.19. CIRCUIT SCHEMATIC - POWER WINDOWS |
731 |
|
15.21.20. CIRCUIT SCHEMATIC - AIR BAG SYSTEM (SRS) |
732 |
|
15.21.21. CIRCUIT SCHEMATIC - ANTI LOCK BRAKING SYSTEM (ABS) |
733 |
|
15.21.22. CIRCUIT SCHEMATIC - AIR CONDITIONING [4DL WITH ROOF A/C] |
734 |
|
15.21.23. CIRCUIT SCHEMATIC - AIR CONDITIONING [4PL WITH ROOF A/C] |
735 |
|
15.21.24. CIRCUIT SCHEMATIC - TRANSFER CASE |
736 |
|
15.21.25. CIRCUIT SCHEMATIC - CIGAR LIGHTER, CLOCK & MUSIC SYSTEM |
737 |
|
15.21.26. CIRCUIT SCHEMATIC - AUDIBLE WARNING DEVICES |
738 |
|
15.21.27. ENGINE COOLING FAN (4DL), FUEL FLAP SOLENOID, PARKING BRAKE & BRAKE FLUID |
739 |
|
15.21.28. CIRCUIT SCHEMATIC - ENGINE COOLING FAN (4PL) |
740 |
|
15.21.29. CIRCUIT SCHEMATIC - REAR VIEW MIRROR (OUTER) & HEATED REAR WINDOW (HRW) |
741 |
|
15.22. WIRING HARNESSES |
742 |
|
16. BODY |
747 |
|
16.1. TECHNICAL SPECIFICATIONS |
750 |
|
16.2. EXPLODED VIEWS |
751 |
|
16.3. REMOVAL / INSTALLATION OF FRONT / REAR DOOR INNER TRIM |
762 |
|
16.4. REMOVAL / INSTALLATION OF TAIL GATE INNER TRIMS |
763 |
|
16.5. REMOVAL / INSTALLATION OF FRONT / REAR DOOR |
764 |
|
16.6. REMOVAL / INSTALLATION OF TAIL GATE |
765 |
|
16.7. REMOVAL / INSTALLATION OF DOOR OUTER HANDLE |
766 |
|
16.8. REMOVAL / INSTALLATION OF DOOR INNER HANDLE |
767 |
|
16.9. REMOVAL / INSTALLATION OF DOOR LATCH |
768 |
|
16.10. REMOVAL / INSTALLATION OF WINDOW GLASS |
769 |
|
16.11. REMOVAL / INSTALLATION OF WINDOW WINDING REGULATOR |
770 |
|
16.12. REMOVAL / INSTALLATION OF DOOR MIRROR |
771 |
|
16.13. REMOVAL / INSTALLATION OF BONNET |
772 |
|
16.14. REMOVAL / INSTALLATION OF FENDER |
773 |
|
16.15. REMOVAL / INSTALLATION OF FRONT BUMPER |
774 |
|
16.16. REMOVAL / INSTALLATION OF REAR BUMPER |
775 |
|
16.17. REMOVAL / INSTALLATION OF FRONT SEAT |
776 |
|
16.18. REMOVAL / INSTALLATION OF REAR SEAT |
777 |
|
16.19. PROCEDURE FOR REMOVAL / ASSEMBLY OF SEAT BELT |
778 |
|
16.20. PROCEDURE FOR REMOVAL / ASSEMBLY OF DASHBOARD |
780 |
|
16.21. PROCEDURE FOR REMOVAL / ASSEMBLY OF ROOF LINING |
782 |
|
16.22. REMOVAL / INSTALLATION OF JUMP SEAT |
783 |
|
16.23. BODY MOUNTING LOCATIONS |
784 |
|
16.24. PROCEDURE FOR FIXING OF WIND SCREEN GLASS, SIDE FIXED GLASSES & TAIL GATE GLASS |
785 |
|
16.25. PROCEDURE FOR FIXING SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS |
786 |
|
16.26. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS |
786 |
|
16.27. PROCEDURE FOR FIXING DOOR GLASS WEATHER STRIP AT ENDS (BOTTOM OF STYLING STRIP) |
787 |
|
16.28. PROCEDURE FOR FIXING HAND BRAKE CONSOLE GARNISH |
787 |
|
16.29. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD (MODIFIED) TRIMS |
788 |
|
16.30. IMPORTANT BODY DIMENSIONS |
789 |
|
17. AIR BAGS |
792 |
|
17.1. SCHEMATIC CIRCUIT DIAGRAM - SRS (SUPPLEMENTARY RESTRAINT SYSTEM) |
795 |
|
17.2. WIRING HARNESS ROUTING - SRS (SUPPLEMENTARY RESTRAINT SYSTEM) |
796 |
|
17.3. SAFARI OCCUPANT RESTRAINT SYSTEM |
797 |
|
17.4. WORKING OF RPLL BELTS |
798 |
|
17.5. SAFETY PRECAUTIONS |
799 |
|
17.6. PROCEDURE FOR REMOVAL OF STEERING WHEEL, DRIVER AND CO-DRIVER AIR BAG MODULE |
800 |
|
17.7. CO-DRIVER AIR BAG |
801 |
|
17.8. PROCEDURE FOR INSTALLATION OF STEERING WHEEL, DRIVER & CO-DRIVER AIR BAG MODULE AND SEAT BELTS. |
802 |
|
17.9. PROCEDURE FOR INSTALLATION AND REMOVAL OF COMBI-SWITCH, ADAPTOR PLATE & CLOCK SPRING. |
803 |
|
17.10. SRS WARNING LAMP FAULT CODES |
805 |
|
17.11. DIAGNOSTICS FOR AIR BAG (ORS) SYSTEM |
807 |
|
17.12. SAFARI ERROR CODES LIST FOR AC4 (AIRBAG ECU) |
812 |
|
18. AIR CONDITIONING |
816 |
|
18.1. SPECIFICATIONS |
819 |
|
18.2. A/C SCHEMATIC DRAWINGS |
820 |
|
18.3. BASIC COMPONENTS |
826 |
|
18.4. AIR-CONDITIONING CONTROLS |
828 |
|
18.5. MAGNETIC CLUTCH |
830 |
|
18.6. VACUUM SOLENOID VALVE |
831 |
|
18.7. DUAL PRESSURE SWITCH |
832 |
|
18.8. ANTIFREEZING DEVICE |
832 |
|
18.9. REMOVAL AND FITMENT OF A/C COMPONENTS |
833 |
|
18.10. ROOF A/C UNIT |
839 |
|
18.11. REFRIGERANT (R.134A) |
842 |
|
18.12. COMPRESSOR OIL |
843 |
|
18.13. SERVICE AND REPAIRS |
844 |
|
18.14. CHARGING THE SYSTEM |
847 |
|
18.15. TROUBLE SHOOTING |
849 |
|
18.16. DO'S AND DON'TS |
854 |
|
18.17. A/C CHECK UP POINTS |
855 |
|
TATA SAFARI 2.2L VTT DICOR |
858 |
|
1. GENERAL |
862 |
|
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS |
864 |
|
1.2. LIFTING AND JACKING POINTS |
868 |
|
1.3. TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
869 |
|
1.4. AGGREGATE / CHASSIS NUMBERING SYSTEM |
870 |
|
1.5. TECHNICAL SPECIFICATIONS |
878 |
|
1.6. FILLING CAPACITIES |
880 |
|
1.7. FUEL, LUBRICANTS & COOLANTS |
880 |
|
A. FUEL |
880 |
|
B. LUBRICANTS & OILS |
880 |
|
C. COOLANTS |
881 |
|
1.8. SERVICE SCHEDULE |
882 |
|
2. ENGINE 2.2L DICOR BS3 |
885 |
|
2.1. TECHNICAL SPECIFICATION |
888 |
|
2.2. LIST OF SPECIAL TOOLS |
889 |
|
2.3. TIGHTENING TORQUE TABLE |
890 |
|
2.4. PRELIMINARY INSPECTION OF ENGINE |
893 |
|
2.5. ENGINE REMOVAL AND FITMENT ON VEHICLE |
895 |
|
2.6. ENGINE OVERHAUL PROCEDURE(ON STAND PROCEDURES) |
896 |
|
A. REMOVAL AND FITMENT OF ALTERNATOR,AC COMPRESSOR AND PS PUMP& AUXILIARY BELT ADJUSTMENT PROCEDURE |
896 |
|
B. REMOVAL OF CYLINDER HEAD FROM CYLINDER BLOCK |
899 |
|
C. DISMANTLING OF CYLINDER HEAD SUB-ASSEMBLIES |
915 |
|
D. INSPECTION OF CYLINDER HEAD SUB-ASSEMBLIES |
918 |
|
E. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES |
921 |
|
F. DISMANTLING OF CYLINDER BLOCK SUB-ASSEMBLIES |
924 |
|
G. INSPECTION OF CYLINDER BLOCK SUB-ASSEMBLIES |
932 |
|
H. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
940 |
|
I. ASSEMBLY OF CYLINDER HEAD ON CYLINDER BLOCK |
949 |
|
J. ENGINE TIMING BELT FITMENT AND SETTING PROCEDURE |
957 |
|
2.7. ENGINE SERVICE DATA |
966 |
|
A. VALVE, VALVE SEAT |
966 |
|
B. VALVE GUIDE, VALVE SEAT INSERT |
967 |
|
C. CAMSHAFT |
968 |
|
D. PISTON AND PISTON RINGS |
969 |
|
E. CONNECTING ROD |
970 |
|
F. CRANK SHAFT |
971 |
|
G. CYLINDER BLOCK AND ASSEMBLY CLEARANCES |
972 |
|
2.8. ENGINE SYSTEM SCHEMATIC LAYOUTS |
973 |
|
A. COOLING SYSTEM |
973 |
|
B. LUBRICATION SYSTEM |
977 |
|
C. BLOW-BY SYSTEM/CRANK CASE VENTILATION |
980 |
|
D. AIR INTAKE SYSTEM |
982 |
|
E. VACUUM MANAGEMENT SYSTEM |
985 |
|
F. VNT (VARIABLE NOZZLE TURBINE) TURBOCHARGER |
987 |
|
G. EGR (EXHAUST GAS RECIRCULATION) SYSTEM |
996 |
|
2.9. ENGINE TESTING |
998 |
|
2.10. ENGINE TROUBLE SHOOTING |
999 |
|
2.11. ENGINE EXPLODED VIEWS |
1002 |
|
2.12. DIAGNOSTICS |
1025 |
|
A. ECU AND EMS SENSORS |
1025 |
|
B. DIAGNOSTIC SYSTEM INSTALLATION AND OPERATING PROCEDURE |
1036 |
|
C. DTC (DIAGNOSTIC TROUBLE CODES) LIST |
1050 |
|
3. CLUTCH |
235 |
|
3.1. CONSTRUCTIONAL DETAILS |
239 |
|
3.2. FACTORS AFFECTING CLUTCH WEAR |
239 |
|
3.3. PRELIMINARY INSPECTION |
239 |
|
3.4. SPECIFICATIONS AND RECOMMENDATIONS |
241 |
|
3.5. REMOVAL OF CLUTCH FROM VEHICLE |
241 |
|
3.6. INSPECTION OF COMPONENTS |
242 |
|
3.7. INSTALLATION OF CLUTCH ON VEHICLE |
242 |
|
3.8. CLUTCH ACTUATION MECHANISM REMOVAL |
243 |
|
3.9. CLUTCH MASTER CYLINDER |
245 |
|
3.9A. DISMANTLING OF MASTER CYLINDER |
245 |
|
3.9B. INSPECTION AND ASSEMBLY OF MASTER CYLINDER |
245 |
|
3.10. CLUTCH SLAVE CYLINDER |
246 |
|
A. DISMANTLING OF CLUTCH SLAVE CYLINDER |
246 |
|
B. INSPECTION AND ASSEMBLY CLUTCH SLAVE CYLINDER |
246 |
|
3.11. INSTALLATION OF CLUTCH ACTUATION MECHANISM |
246 |
|
3.12. BLEEDING THE CLUTCH SYSTEM |
247 |
|
3.13. CLUTCH PEDAL LINKAGE ADJUSTMENT |
247 |
|
4. GEAR BOX G-76 |
1068 |
|
4.1. CONSTRUCTION |
1072 |
|
A.SECTIONAL VIEW |
1072 |
|
4.2. TECHNICAL SPECIFICATIONS |
1073 |
|
4.3. TIGHTENING TORQUE |
1074 |
|
4.4. SPECIAL TOOLS LIST |
1075 |
|
4.5. REMOVAL OF G-76 GEAR BOX FROM VEHICLE |
1077 |
|
4.6. EXPLODED ILLUSTRATED VIEW - GEAR BOX |
1081 |
|
4.7. DISMANTLING OF GEAR BOX |
1082 |
|
4.8. EXPLODED ILLUSTRATED VIEW - MAIN SHAFT |
1091 |
|
4.9. DISASSEMBLY OF MAIN SHAFT |
1092 |
|
4.10. DISASSEMBLY OF DRIVE SHAFT |
1097 |
|
4.11. EXPLODED ILLUSTRATED VIEW - COUNTER SHAFT & REVERSE IDLER SHAFT |
1098 |
|
4.12. DISASSEMBLY OF COUNTER SHAFT |
1099 |
|
4.13. DISASSEMBLY OF REMOVAL IDLER GEAR SHAFT |
1099 |
|
4.14. DISASSEMBLY OF GEAR BOX HOUSING REAR HALF |
1100 |
|
4.15. REPLACEMENT OF SELECTOR SHAFT |
1100 |
|
4.16. DISASSEMBLY OF GEAR CASE FRONT & REAR |
1101 |
|
4.17. INSPECTION |
1101 |
|
4.18. IDENTIFICATION OF PARAMETERS |
1102 |
|
A. ENGAGING GEARS |
1102 |
|
B. SYNCHRO CONES |
1102 |
|
C. SHIFTER SLEEVES |
1103 |
|
D. SHIFTER FORKS |
1104 |
|
E. SHIFTER SHAFTS |
1104 |
|
4.19. ASSEMBLY OF SUB-ASSEMBLIES |
1105 |
|
A. SUB ASSY. OF ENGAGING GEAR |
1105 |
|
B. SUB ASSY. OF MAIN SHAFT |
1106 |
|
C. SUB ASSY. OF COUNTER SHAFT |
1111 |
|
D. SUB ASSY. OF DRIVE SHAFT |
1111 |
|
E. SUB ASSY. OF REMOVAL IDLER GEAR SHAFT |
1112 |
|
4.20. MEASUREMENT OF CONTROL DIMENSIONS |
1113 |
|
4.21. SUBASSEMBLY OF GEAR BOX HOUSING COVER FRONT |
1119 |
|
4.22. SUB ASSEMBLY OF GEAR CASE COVER REAR |
1119 |
|
4.23. ASSEMBLY OF SHIFTER AND SELECTOR SHAFTS |
1120 |
|
4.24. SUB ASSY. OF GEAR BOX HOUSING - REAR HALF |
1121 |
|
4.25. ASSEMBLY OF GEAR BOX |
1122 |
|
4.26. ASSEMBLY OF GEAR SHIFT LINKAGE |
1127 |
|
4.27. INSTALLATION OF GEAR BOX ASSY. ON VEHICLE |
1128 |
|
4.28. TROUBLE SHOOTING |
1130 |
|
4.29. IMPROVEMENTS-SUPPLEMENT |
1131 |
|
5. TRANSFER CASE |
306 |
|
5.1. TECHNICAL SPECIFICATION |
309 |
|
5.2. SPECIAL TOOLS AND TORQUE TABLE |
310 |
|
5.3. CONSTRUCTION AND PARTS IDENTIFICATION |
311 |
|
5.4. TRANSFER CASE WORKING |
314 |
|
5.5. ELECTRONIC CONTROL UNIT & SELF DIAGNOSIS |
316 |
|
5.6. REMOVAL AND INSTALLATION |
319 |
|
5.7. DISASSEMBLY |
320 |
|
5.8. CLEANING & INSPECTION |
325 |
|
5.9. ASSEMBLY |
326 |
|
5.10. LUBRICATION |
334 |
|
5.11. TROUBLESHOOTING |
335 |
|
6. SUSPENSION (WHEELS AND TYRES) |
336 |
|
6.1. FRONT INDEPENDENT SUSPENSION |
340 |
|
6.1.1. CONSTRUCTIONAL DETAILS |
340 |
|
6.1.2. SPECIFICATIONS AND RECOMMENDATIONS |
340 |
|
6.1.3. SPECIAL TOOLS |
342 |
|
6.1.4. REMOVAL/DISMANTLING PROCEDURE |
342 |
|
A. REMOVAL OF FRONT WHEELS |
342 |
|
B. REMOVAL OF FRONT ANTIROLL BAR |
342 |
|
C. REMOVAL OF FRONT SHOCK ABSORBER |
342 |
|
D. REMOVAL OF TORSION BAR |
344 |
|
E. REMOVAL/DISMANTLING OF UPPER WISHBONE |
344 |
|
F. REMOVAL/DISMANTLING OF LOWER WISHBONE |
346 |
|
6.1.5. INSPECTION OF PARTS |
858 |
|
6.1.6. ASSEMBLY/INSTALLATION PROCEDURE |
858 |
|
A. ASSEMBLY/INSTALLATION OF LOWER WISHBONE |
858 |
|
B. ASSEMBLY/INSTALLATION OF UPPER WISHBONE |
858 |
|
C. INSTALLATION OF FRONT SHOCK ABSORBER |
858 |
|
D. INSTALLATION OF FRONT ANTIROLL BAR |
858 |
|
E. INSTALLATION OF FRONT WHEELS |
858 |
|
F. INSTALLATION OF TORSION BAR |
858 |
|
6.1.7. WHEEL ALIGNMENT |
858 |
|
A. CAMBER ANGLE ADJUSTMENT |
858 |
|
B. CASTOR ANGLE ADJUSTMENT |
858 |
|
C. TOE-IN ADJUSTMENT |
858 |
|
D. WHEEL LOCK ANGLE ADJUSTMENT |
858 |
|
6.2. REAR 5 LINK SUSPENSION |
354 |
|
6.2.1. CONSTRUCTIONAL DETAILS |
354 |
|
6.2.2. SPECIFICATIONS AND RECOMMENDATIONS |
354 |
|
6.2.3. SPECIAL TOOLS |
354 |
|
6.2.4. REMOVAL/DISMANTLING PROCEDURE |
356 |
|
A. REMOVAL OF REAR SHOCK ABSORBER |
356 |
|
B. REMOVAL OF REAR ANTIROLL BAR |
356 |
|
C. REMOVAL OF PAN HARD ROD |
356 |
|
D. REMOVAL OF TOP LINK |
358 |
|
E. REMOVAL OF COIL SPRING |
358 |
|
F. REMOVAL OF BOTTOM LINK |
358 |
|
6.2.5. INSPECTION OF COMPONENTS |
360 |
|
6.2.6. ASSEMBLY/INSTALLATION PROCEDURE |
360 |
|
A. ASSEMBLY/INSTALLATION OF BOTTOM LINK |
360 |
|
B. INSTALLATION OF COIL SPRING |
360 |
|
C. INSTALLATION OF TOP LINK |
362 |
|
D. ASSEMBLY/INSTALLATION OF PANHARD ROD |
362 |
|
E. INSTALLATION OF REAR ANTIROLL BAR |
362 |
|
F. INSTALLATION OF REAR SHOCK ABSORBER |
362 |
|
6.3. WHEELS AND TYRES |
363 |
|
7. FRONT LIVE AXLE (4X2) |
367 |
|
7.1. TECHNICAL SPECIFICATIONS |
370 |
|
7.2. SPECIAL TOOLS |
371 |
|
7.3. DISMANTLING OF FRONT AXLE |
373 |
|
A. REMOVAL OF FRONT WHEELS |
373 |
|
B. REMOVAL OF FRONT HUB ASSEMBLY |
373 |
|
C. DISMANTLING OF FRONT HUB ASSEMBLY |
373 |
|
D. FRONT HUB ASSEMBLY WITH ABS TONER RING |
374 |
|
E. REMOVAL OF STUB AXLE ASSEMBLY |
375 |
|
F. DISMANTLING OF STUB AXLE ASSEMBLY |
375 |
|
7.4. INSPECTION OF PARTS |
375 |
|
7.5. ASSEMBLY INSTALLATION OF PARTS |
376 |
|
A. ASSEMBLY OF STUB AXLE |
376 |
|
B. INSTALLATION OF STUB AXLE |
376 |
|
C. ASSEMBLY / INSTALLATION OF FRONT HUB COMPLETE |
377 |
|
D. INSTALLATION OF FRONT WHEELS |
379 |
|
E. PRELOADING OF TORSION BAR |
379 |
|
F. WHEEL ALIGNMENT |
379 |
|
8. FRONT LIVE AXLE (4X4) |
380 |
|
8.1. CONSTRUCTION |
383 |
|
8.2. SPECIFICATION & SERVICE DATA |
386 |
|
8.3. SPECIAL TOOLS LIST |
387 |
|
8.4. 2 - WAY LOCK FREE RUNNING HUB |
388 |
|
A. REMOVAL AND INSTALLATION OF FREE RUNNING HUB ON VEHICLE |
388 |
|
8.5. REMOVAL OF WHEEL END WITH CV SHAFT FROM VEHICLE |
389 |
|
A. WHEEL END ASSEMBLY |
391 |
|
B. CARRIER CENTRE SECTION |
397 |
|
C. C. V. JOINT SHAFTS |
411 |
|
8.6. TROUBLE SHOOTING |
417 |
|
8.7. AUTOMATIC LOCKING HUB |
418 |
|
8.7.1. SPECIFICATIONS |
419 |
|
8.7.2. INTRODUCTION |
420 |
|
8.7.3. DIAGNOSIS |
422 |
|
8.7.4. DIS-ASSEMBLY INSPECTION & LUBRICATION |
423 |
|
8.7.5. ASSEMBLY |
425 |
|
8.7.6. LIST OF SERVICEABLE PARTS |
427 |
|
8.7.7. SOLUTION TO NOISE PROBLEM |
428 |
|
9. REAR AXLE |
429 |
|
9.1. CONSTRUCTION |
432 |
|
9.2. SPECIFICATION & SERVICE DATA |
434 |
|
9.3. SPECIAL TOOLS LIST |
435 |
|
9.4. REMOVAL FROM VEHICLE |
436 |
|
9.5. DISASSEMBLY |
437 |
|
A. UNITISED BEARING |
438 |
|
B. CARRIER CENTRE SECTION |
439 |
|
C. DRIVE PINION |
443 |
|
9.6. CLEANING AND INSPECTION |
444 |
|
9.7. ASSEMBLY |
446 |
|
A) UNITISED BEARING |
446 |
|
B) PINION BEARING CUP |
451 |
|
C) CARRIER CENTRE SECTION |
453 |
|
D) DIFFERENTIAL |
456 |
|
9.8. INTERPRETATION OF TOOTH CONTACT PATTERN |
459 |
|
9.9. TROUBLE SHOOTING |
462 |
|
10. PROPELLER SHAFT |
463 |
|
10.1. CONSTRUCTION |
466 |
|
10.2. LIST OF SPECIAL TOOLS & SERVICE DATA |
468 |
|
10.3. REMOVAL FROM VEHICLE |
469 |
|
10.4. DISASSEMBLY |
469 |
|
10.5. INSPECTION |
472 |
|
10.6. LUBRICATION |
474 |
|
10.7. ASSEMBLY |
475 |
|
10.8. INSTALLATION ON VEHICLE |
477 |
|
10.9. TROUBLE SHOOTING |
478 |
|
11. BRAKES |
1133 |
|
11.1. TECHNICAL SPECIFICATION |
1136 |
|
11.2. TIGHTENING TORQUE |
1137 |
|
11.3. BRAKE SYSTEM CIRCUIT SCHEMATIC (ABS) |
1138 |
|
11.4. BRAKE SYSTEM CIRCUIT SCHEMATIC (NON-ABS) |
1140 |
|
11.5. VACCUM CIRCUIT SCHEMATIC LAYOUT |
1142 |
|
11.6. VACCUM TANK |
1143 |
|
12. ANTI-LOCK BRAKING SYSTEM |
532 |
|
12.1. TECHNICAL SPECIFICATIONS |
535 |
|
12.2. HYDRAULIC LINES FOR ABS |
536 |
|
12.3. ABS CIRCUIT DIAGRAM |
536 |
|
12.4. ANTILOCK BRAKE SYSTEM - THEORY |
539 |
|
12.5. COMPONENTS OF BOSCH ABS 5.3 SYSTEM |
546 |
|
12.6. ELECTRONIC BRAKES DISTRIBUTION (EBD) |
549 |
|
12.7. ABS SYSTEM FAILURE WARNING LIGHT |
551 |
|
12.8. REMOVAL / INSTALLATION OF ABS COMPONENTS |
552 |
|
12.9. ABS DIAGNOSTICS |
561 |
|
A. ABS DIAGNOSTIC TESTER |
563 |
|
B. ABS FAULT CODES |
570 |
|
C. REPAIR GUIDELINES |
587 |
|
D. ABS 5.3 SYSTEM TEST |
608 |
|
13. STEERING |
623 |
|
13.1. EXPLODED VIEWS |
626 |
|
13.2. DESIGN AND FUNCTION |
630 |
|
13.3. OIL FILLING AND AIR BLEEDING |
634 |
|
13.4. DISMANTLING AND ASSEMBLY TOOLS |
636 |
|
13.5. REMOVING THE STEERING UNIT FROM THE VEHICLE |
637 |
|
13.6. DISMANTLING THE STEERING UNIT |
638 |
|
13.7. CHECKING THE STEERING PARTS |
639 |
|
13.8. TECHNICAL DATA AND SET VALUES |
640 |
|
13.9. ASSEMBLY OF THE STEERING UNIT AND FUNCTION TESTING |
640 |
|
13.10. FITTING THE STEERING UNIT ON THE VEHICLE |
643 |
|
13.11. TROUBLES AND REMEDIES |
645 |
|
13.12. MAINTENANCE AND FUNCTIONAL DESCRIPTION OF VANE PUMP |
648 |
|
13.13. STEERING COLUMN |
650 |
|
14. FUEL SYSTEM |
1144 |
|
14.1. INTRODUCTION TO DICOR SYSTEM |
1147 |
|
14.2. DICOR SYSTEM SCHEMATIC LAYOUT |
1149 |
|
14.3. DICOR SYSTEM CLEANLINESS INSTRUCTIONS |
1150 |
|
14.4. FUEL SYSTEM EXPLODED VIEW |
1152 |
|
14.5. FUEL SYSTEM COMPONENTS |
1154 |
|
A. COMMON RAIL |
1154 |
|
B. INJECTOR |
1154 |
|
C. HP PUMP |
1156 |
|
D. SEDIMENTER |
1156 |
|
E. FUEL FILTER |
1158 |
|
F. PEAR PUMP / PRIMING PUMP |
1159 |
|
G. FUEL TANK |
1160 |
|
H. FUEL TANK STRAINER |
1162 |
|
I. FUEL GAUGE (TANK UNIT) |
1162 |
|
J. FUEL LEVEL GAUGE (DASH BOARD) |
1163 |
|
K. FUEL FILLER CAP |
1164 |
|
L. FUEL HOSES AND FUEL LINES |
1164 |
|
15. EXHAUST SYSTEM |
1165 |
|
15.1. EXPLODED VIEW OF EXHAUST SYSTEM |
1168 |
|
15.2. TIGHTENING TORQUES |
1169 |
|
15.3. CLOSE COUPLED CATALYTICE CONVERTER (CCC) |
1170 |
|
A. REMOVAL |
1170 |
|
B. FITMENT |
1170 |
|
C. CARE AND MAINTENANCE |
1170 |
|
15.4. EXHAUST PIPE |
1171 |
|
A. REMOVAL |
1171 |
|
B. FITMENT |
1171 |
|
C. GENERAL MAINTENANCE |
1171 |
|
16. ELECTRICAL |
653 |
|
16.1. TECHNICAL SPECIFICATIONS |
657 |
|
16.2. CIRCUIT DIAGRAM SYMBOLS |
658 |
|
16.3. WIRE COLOUR CODING |
660 |
|
16.4. LIST OF BULBS USED IN SAFARI |
660 |
|
16.5. FUSES & RELAYS |
661 |
|
16.6. ALTERNATOR |
664 |
|
16.7. STARTER MOTOR |
666 |
|
16.8. INSTRUMENT CLUSTER |
667 |
|
16.9. FUEL GAUGE TANK UNIT |
670 |
|
16.10. HEAD LAMP / TAIL LAMP ASSY |
671 |
|
16.11. HORN |
677 |
|
16.12. COMBI SWITCH |
678 |
|
16.13. DIGITAL CLOCK |
679 |
|
16.14. MUSIC SYSTEM |
680 |
|
16.15. SWITCHES, INTERIOR LAMPS AND OTHER COMPONENTS |
681 |
|
A. GLOVE BOX SWITCH |
681 |
|
B. FRONT INTERIOR LAMP |
681 |
|
C. FUEL FLAP SOLENOID |
682 |
|
D RADIO ANTENNA |
682 |
|
E. WINDOW WINDING SWITCHES |
683 |
|
F. TRANSFER CASE SELECTION SWITCH |
684 |
|
G. DOOR MIRROR SWITCH |
685 |
|
H. RHEOSTAT |
686 |
|
I. ROOF LAMP |
686 |
|
J. FACIA SWITCHES |
687 |
|
K. STEERING LOCK CUM IGNITION SWITCH |
688 |
|
16.16 ANTITHEFT DEVICE |
689 |
|
16.17. CONTROLS UNITS |
691 |
|
A. HEATED REAR WINDOW CONTROLLER |
691 |
|
B. BUZZER UNIT |
692 |
|
C. CHIME UNIT |
693 |
|
D. FRONT WIPER CONTROLLER |
694 |
|
E. INTERIOR LIGHT DELAY UNIT |
695 |
|
F. FLASHER UNIT |
696 |
|
G. GLOW PLUG TIMER |
697 |
|
H. EGR CONTROLLER |
699 |
|
16.18. CENTRAL LOCKING SYSTEM |
700 |
|
16.19. WIPER SYSTEM |
702 |
|
16.20. TROUBLESHOOTING GUIDELINES |
708 |
|
16.21. WIRING DIAGRAMS |
710 |
|
16.21.1. GENERAL INFORMATION |
711 |
|
16.21.2. EARTHING LOCATIONS FOR RHO VEHICLES |
712 |
|
16.21.3. CONNECTORS & LOCATION ZONE CHARTS |
713 |
|
16.21.4. CONNECTOR LOCATION DETAILS FOR RHO VEHICLE |
715 |
|
16.21.5. CIRCUIT SCHEMATIC - SUPPLY CONFIGURATION |
717 |
|
16.21.6. CIRCUIT SCHEMATIC - STARTING I CHARGING 4DL - EURO-II |
718 |
|
16.21.7. CIRCUIT SCHEMATIC - STARTING I CHARGING 4DL - EURO-III |
719 |
|
16.21.8. CIRCUIT SCHEMATIC - IMMOBILISER (TRANSPONDER TYPE) |
720 |
|
16.21.9. CIRCUIT SCHEMATIC - IMMOBILISER WITH KEYLESS ENTRY CLU |
721 |
|
16.21.10. CIRCUIT SCHEMATIC - CENTRAL LOCKING SYSTEM |
722 |
|
16.21.11. CIRCUIT SCHEMATIC - HEAD LAMP & PARKING LAMPS |
723 |
|
16.21.12. CIRCUIT SCHEMATIC - HEAD LAMP LEVELING |
724 |
|
16.21.13. CIRCUIT SCHEMATIC - DIRECTION INDICATORS & HAZARD WARNING |
725 |
|
16.21.14. CIRCUIT SCHEMATIC - FRONT / REAR FOG LAMPS, STOP & REVERSE LAMPS |
726 |
|
16.21.15. CIRCUIT SCHEMATIC - INTERIOR LIGHTS |
727 |
|
16.21.16. CIRCUIT SCHEMATIC - INSTRUMENT CLUSTER |
728 |
|
16.21.17. CIRCUIT SCHEMATIC - FRONT WIPER & WASHER |
729 |
|
16.21.18. CIRCUIT SCHEMATIC - REAR WIPER & WASHER |
730 |
|
16.21.19. CIRCUIT SCHEMATIC - POWER WINDOWS |
731 |
|
16.21.20. CIRCUIT SCHEMATIC - AIR BAG SYSTEM (SRS) |
732 |
|
16.21.21. CIRCUIT SCHEMATIC - ANTI LOCK BRAKING SYSTEM (ABS) |
733 |
|
16.21.22. CIRCUIT SCHEMATIC - AIR CONDITIONING [4DL WITH ROOF A/C] |
734 |
|
16.21.23. CIRCUIT SCHEMATIC - AIR CONDITIONING [4PL WITH ROOF A/C] |
735 |
|
16.21.24. CIRCUIT SCHEMATIC - TRANSFER CASE |
736 |
|
16.21.25. CIRCUIT SCHEMATIC - CIGAR LIGHTER, CLOCK & MUSIC SYSTEM |
737 |
|
16.21.26. CIRCUIT SCHEMATIC - AUDIBLE WARNING DEVICES |
738 |
|
16.21.27. ENGINE COOLING FAN (4DL), FUEL FLAP SOLENOID, PARKING BRAKE & BRAKE FLUID |
739 |
|
16.21.28. CIRCUIT SCHEMATIC - ENGINE COOLING FAN (4PL) |
740 |
|
16.21.29. CIRCUIT SCHEMATIC - REAR VIEW MIRROR (OUTER) & HEATED REAR WINDOW (HRW) |
741 |
|
16.22. WIRING HARNESSES |
742 |
|
17. BODY |
747 |
|
17.1. TECHNICAL SPECIFICATIONS |
750 |
|
17.2. EXPLODED VIEWS |
751 |
|
17.3. REMOVAL / INSTALLATION OF FRONT / REAR DOOR INNER TRIM |
762 |
|
17.4. REMOVAL / INSTALLATION OF TAIL GATE INNER TRIMS |
763 |
|
17.5. REMOVAL / INSTALLATION OF FRONT / REAR DOOR |
764 |
|
17.6. REMOVAL / INSTALLATION OF TAIL GATE |
765 |
|
17.7. REMOVAL / INSTALLATION OF DOOR OUTER HANDLE |
766 |
|
17.8. REMOVAL / INSTALLATION OF DOOR INNER HANDLE |
767 |
|
17.9. REMOVAL / INSTALLATION OF DOOR LATCH |
768 |
|
17.10. REMOVAL / INSTALLATION OF WINDOW GLASS |
769 |
|
17.11. REMOVAL / INSTALLATION OF WINDOW WINDING REGULATOR |
770 |
|
17.12. REMOVAL / INSTALLATION OF DOOR MIRROR |
771 |
|
17.13. REMOVAL / INSTALLATION OF BONNET |
772 |
|
17.14. REMOVAL / INSTALLATION OF FENDER |
773 |
|
17.15. REMOVAL / INSTALLATION OF FRONT BUMPER |
774 |
|
17.16. REMOVAL / INSTALLATION OF REAR BUMPER |
775 |
|
17.17. REMOVAL / INSTALLATION OF FRONT SEAT |
776 |
|
17.18. REMOVAL / INSTALLATION OF REAR SEAT |
777 |
|
17.19. PROCEDURE FOR REMOVAL / ASSEMBLY OF SEAT BELT |
778 |
|
17.20. PROCEDURE FOR REMOVAL / ASSEMBLY OF DASHBOARD |
780 |
|
17.21. PROCEDURE FOR REMOVAL / ASSEMBLY OF ROOF LINING |
782 |
|
17.22. REMOVAL / INSTALLATION OF JUMP SEAT |
783 |
|
17.23. BODY MOUNTING LOCATIONS |
783 |
|
17.24. PROCEDURE FOR FIXING OF WIND SCREEN GLASS, SIDE FIXED GLASSES & TAIL GATE GLASS |
785 |
|
17.25. PROCEDURE FOR FIXING SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS |
786 |
|
17.26. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS |
786 |
|
17.27. PROCEDURE FOR FIXING DOOR GLASS WEATHER STRIP AT ENDS (BOTTOM OF STYLING STRIP) |
787 |
|
17.28. PROCEDURE FOR FIXING HAND BRAKE CONSOLE GARNISH |
787 |
|
17.29. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD (MODIFIED) TRIMS |
788 |
|
17.30. IMPORTANT BODY DIMENSIONS |
789 |
|
18. AIR BAGS |
792 |
|
18.1. SCHEMATIC CIRCUIT DIAGRAM - SRS (SUPPLEMENTARY RESTRAINT SYSTEM) |
795 |
|
18.2. WIRING HARNESS ROUTING - SRS (SUPPLEMENTARY RESTRAINT SYSTEM) |
796 |
|
18.3. SAFARI OCCUPANT RESTRAINT SYSTEM |
797 |
|
18.4. WORKING OF RPLL BELTS |
798 |
|
18.5. SAFETY PRECAUTIONS |
799 |
|
18.6. PROCEDURE FOR REMOVAL OF STEERING WHEEL, DRIVER AND CO-DRIVER AIR BAG MODULE |
800 |
|
18.7. CO-DRIVER AIR BAG |
801 |
|
18.8. PROCEDURE FOR INSTALLATION OF STEERING WHEEL, DRIVER & CO-DRIVER AIR BAG MODULE AND SEAT BELTS |
802 |
|
18.9. PROCEDURE FOR INSTALLATION AND REMOVAL OF COMBI-SWITCH, ADAPTOR PLATE & CLOCK SPRING |
803 |
|
18.10. SRS WARNING LAMP FAULT CODES |
805 |
|
18.11. DIAGNOSTICS FOR AIR BAG (ORS) SYSTEM |
807 |
|
18.12. SAFARI ERROR CODES LIST FOR AC4 (AIRBAG ECU) |
812 |
|
19. AIR CONDITIONING |
816 |
|
19.1. SPECIFICATIONS |
819 |
|
19.2. A/C SCHEMATIC DRAWINGS |
820 |
|
19.3. BASIC COMPONENTS |
826 |
|
19.4. AIR-CONDITIONING CONTROLS |
828 |
|
19.5. MAGNETIC CLUTCH |
830 |
|
19.6. VACUUM SOLENOID VALVE |
831 |
|
19.7. DUAL PRESSURE SWITCH |
832 |
|
19.8. ANTIFREEZING DEVICE |
832 |
|
19.9. REMOVAL AND FITMENT OF A/C COMPONENTS |
833 |
|
19.10. ROOF A/C UNIT |
839 |
|
19.11. REFRIGERANT (R.134A) |
842 |
|
19.12. COMPRESSOR OIL |
843 |
|
19.13. SERVICE AND REPAIRS |
844 |
|
19.14. CHARGING THE SYSTEM |
847 |
|
19.15. TROUBLE SHOOTING |
849 |
|
19.16. DO'S AND DON'TS |
854 |
|
19.17. A/C CHECK UP POINTS |
855 |
|
TATA SAFARI DICOR 3L |
1172 |
|
1. GENERAL |
1176 |
|
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS |
1178 |
|
1.2. LIFTING AND JACKING POINTS |
1182 |
|
1.3. TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS |
1183 |
|
1.4. CHASSIS NUMBERING SYSTEM |
1184 |
|
1.5. AGGREGATE NUMBERING SYSTEM |
1185 |
|
A. FRAME |
1185 |
|
B. ENGINE |
1185 |
|
C. GEAR BOX |
1186 |
|
D. CAB |
1187 |
|
1.6. TECHNICAL SPECIFICATIONS |
1188 |
|
1.7. FILLING CAPACITIES |
1191 |
|
1.8. FUEL, LUBRICANTS & COOLANTS |
1191 |
|
A. FUEL |
1191 |
|
B. LUBRICANTS & OILS |
1191 |
|
C. COOLANTS |
1192 |
|
1.9. SERVICE SCHEDULE |
1193 |
|
2. ENGINE 3 L DICOR |
1197 |
|
2.1. INTRODUCTION OF DICOR TECHNOLOGY |
1200 |
|
2.2. ECU AND SENSORS |
1202 |
|
2.3. UNIQUE CR STRATEGIES |
1208 |
|
2.4. INDIVIDUAL INJECTORS CHARATERISATION (I2C) |
1208 |
|
2.5. ACCELEROMETER PILOT CONTROL STRATEGY (APC) |
1208 |
|
2.6. SENSOR CHECK VALUES |
1209 |
|
2.7. TECHNICAL SPECIFICATIONS |
1210 |
|
2.8. SPECIAL TOOLS |
1211 |
|
2.9. TIGHTENING TORQUES |
1213 |
|
2.10. FUELS, LUBRICANTS AND COOLANTS |
1215 |
|
2.11. PRELIMINARY INESPECTION OF ENGINE |
1217 |
|
2.12. ENGINE REPAIR DATA |
1219 |
|
2.13. REMOVAL OF ENGINE FROM VEHICLE |
1239 |
|
2.14. ASSEMBLY OF ENGINE ON VEHICLE |
1245 |
|
2.15. ENGINE COVER |
1246 |
|
2.16. REPLACEMENT OF OIL SEAL IN TIMING HOUSING COVER |
1247 |
|
2.17. TIMING HOUSING COVER |
1249 |
|
2.18. FUEL INJECTION SYSTEM |
1250 |
|
A. CR SYSTEMS |
1250 |
|
B. HP PUMP |
1252 |
|
C. RAIL |
1255 |
|
D. INJECTORS |
1257 |
|
E. HP PIPES |
1260 |
|
F. SEDIMENTER |
1263 |
|
G. FUEL FILTER |
1266 |
|
H. DO’S & DONT’S |
1269 |
|
2.19. REMOVAL & REFITTMENT OF |
1271 |
|
A. ENGINE HEAD |
1271 |
|
B. ADJUSTMENT OF VALVE CLEARANCE |
1274 |
|
C. ENGINE HEAD COVER |
1275 |
|
D. PRESSURE TESTING OF CYLINDER HEAD |
1278 |
|
E. ROCKER ARM AND PUSH ROD ASSEMBLY AASSEMBLY |
1279 |
|
F. VALVES,GUIDES,SPRINGS AND SEATS |
1282 |
|
G. PISTON AND CONNECTING ROD |
1287 |
|
H. CYLINDER BLOCK |
1292 |
|
I. FLY WHEEL / RING GEAR / CRANK SHAFT PULLEY |
1295 |
|
J. CRANK SHAFT |
1297 |
|
K. CAM SHAFT AND CAM GEAR |
1301 |
|
L. VACUUM PUMP |
1310 |
|
M. LUBRICATION SYSTEM |
1315 |
|
N. COOLING SYSTEM |
1322 |
|
O. ELECTRICAL EQUIPMENT OF ENGINE |
1329 |
|
P. AIR INTAKE SYSTEM |
1331 |
|
Q. EGR |
1332 |
|
R. BLOW-BY SYSTEM |
1336 |
|
2.20. EXPLODED VIEWS |
1338 |
|
2.21. ENGINE DIAGNOSITICS |
1357 |
|
A. GENERAL |
1357 |
|
B. CONNECTION DETAILS |
1357 |
|
C. SPECIFICATION |
1357 |
|
D. INSTALLATION AND OPERATING PROCEDURE |
1358 |
|
E. MAINTENANCE |
1365 |
|
3. CLUTCH |
1366 |
|
3.1. CONSTRUCTIONAL DETAILS |
1368 |
|
3.2. CLUTCH PARTS AND MOUNTING ARRANGEMENT |
1369 |
|
3.3. FACTORS AFFECTING CLUTCH WEAR |
1368 |
|
3.4. PRELIMINARY INSPECTION |
1368 |
|
3.5. REMOVAL OF CLUTCH FROM VEHICLE |
1371 |
|
3.6. SPECIFICATIONS AND RECOMMENDATIONS |
1372 |
|
3.7. INSPECTION OF COMPONENTS |
1372 |
|
3.8. INSTALLATION OF CLUTCH ON VEHICLE |
1372 |
|
3.9. CLUTCH ACTUATION MECHANISM REMOVAL |
1372 |
|
3.10. MASTER CYLINDER |
1375 |
|
A. DISMANTLING OF MASTER CYLINDER |
1375 |
|
B. INSPECTION AND ASSEMBLY OF MASTER CYLINDER |
1375 |
|
3.11. CLUTCH SLAVE CYLINDER |
1375 |
|
A. DISMANTLING OF CLUTCH SLAVE CYLINDER |
1375 |
|
B. INSPECTION AND ASSEMBLY CLUTCH SLAVE CYLINDER |
1375 |
|
3.12. INSTALLATION OF CLUTCH ACTUATION MECHANISM |
1376 |
|
3.13. BLEEDING THE CLUTCH SYSTEM |
1376 |
|
3.14. CLUTCH PEDAL LINKAGE ADJUSTMENT |
1376 |
|
3.15 EXPLODED VIEW |
1377 |
|
4. GEAR BOX |
248 |
|
4.1. CONSTRUCTION |
251 |
|
I. SECTIONAL VIEW |
251 |
|
II. EXPLODED ILLUSTRATED VIEW |
253 |
|
III. LIST OF PARTS |
254 |
|
4.2. TECHNICAL SPECIFICATIONS |
257 |
|
4.3. SPECIAL TOOLS LIST |
258 |
|
4.4. REMOVAL OF G-76 GEAR BOX FROM VEHICLE |
259 |
|
4.5. DISMANTLING OF GEAR BOX |
260 |
|
4.6. DISASSEMBLY |
267 |
|
I. DRIVE SHAFT |
267 |
|
II. MAIN SHAFT |
267 |
|
III COUNTER SHAFT |
270 |
|
IV. GEAR BOX HOUSING REAR HALF |
271 |
|
V. GEAR CASE COVER FRONT |
272 |
|
VI. GEAR CASE COVER REAR |
272 |
|
4.7. ASSEMBLY OF SUB-ASSEMBLIES |
273 |
|
I. GENERAL INSTRUCTIONS |
273 |
|
II. IDENTIFICATION PARAMETERS |
274 |
|
III. ENGAGING GEARS 1ST/2ND, 3RD/4TH, REV/5TH |
276 |
|
IV. MAIN SHAFT |
277 |
|
V. COUNTER SHAFT |
280 |
|
VI. DRIVE SHAFT |
280 |
|
4.8. MEASUREMENT OF CONTROL DIMENSIONS |
281 |
|
4.9. SUB- ASSEMBLY |
287 |
|
I. GEAR BOX HOUSING COVER FRONT |
287 |
|
II. GEAR BOX HOUSING COVER REAR |
287 |
|
III. SHIFTER AND SELECTOR SHAFTS |
288 |
|
IV. GEAR BOX HOUSING REAR HALF |
289 |
|
4.10. ASSEMBLY OF GEAR BOX |
290 |
|
4.11. ASSEMBLY OF GEAR SHIFT LINKAGE |
295 |
|
4.12. INSTALLATION OF GEAR BOX ON VEHICLE |
296 |
|
4.13. TROUBLESHOOTING |
297 |
|
4.14. G-76 GEAR BOX -SUPPLEMENT |
298 |
|
5. TRANSFER CASE |
306 |
|
5.1. TECHNICAL SPECIFICATION |
309 |
|
5.2. SPECIAL TOOLS AND TORQUE TABLE |
310 |
|
5.3. CONSTRUCTION AND PARTS IDENTIFICATION |
311 |
|
5.4. TRANSFER CASE WORKING |
314 |
|
5.5. ELECTRONIC CONTROL UNIT & SELF DIAGNOSIS |
316 |
|
5.6. REMOVAL AND INSTALLATION |
319 |
|
5.7. DISASSEMBLY |
320 |
|
5.8. CLEANING & INSPECTION |
325 |
|
5.9. ASSEMBLY |
326 |
|
5.10. LUBRICATION |
334 |
|
5.11. TROUBLESHOOTING |
335 |
|
6. SUSPENSION (WHEELS AND TYRES) |
336 |
|
6.1. FRONT INDEPENDENT SUSPENSION |
340 |
|
6.1.1. CONSTRUCTIONAL DETAILS |
340 |
|
6.1.2. SPECIFICATIONS AND RECOMMENDATIONS |
340 |
|
6.1.3. SPECIAL TOOLS |
342 |
|
6.1.4. REMOVAL/DISMANTLING PROCEDURE |
342 |
|
A. REMOVAL OF FRONT WHEELS |
342 |
|
B. REMOVAL OF FRONT ANTIROLL BAR |
342 |
|
C. REMOVAL OF FRONT SHOCK ABSORBER |
342 |
|
D. REMOVAL OF TORSION BAR |
344 |
|
E. REMOVAL/DISMANTLING OF UPPER WISHBONE |
344 |
|
F. REMOVAL/DISMANTLING OF LOWER WISHBONE |
346 |
|
6.1.5. INSPECTION OF PARTS |
346 |
|
6.1.6. ASSEMBLY/INSTALLATION PROCEDURE |
346 |
|
A. ASSEMBLY/INSTALLATION OF LOWER WISHBONE |
346 |
|
B. ASSEMBLY/INSTALLATION OF UPPER WISHBONE |
348 |
|
C. INSTALLATION OF FRONT SHOCK ABSORBER |
348 |
|
D. INSTALLATION OF FRONT ANTIROLL BAR |
350 |
|
E. INSTALLATION OF FRONT WHEELS |
350 |
|
F. INSTALLATION OF TORSION BAR |
350 |
|
6.1.7. WHEEL ALIGNMENT |
352 |
|
A. CAMBER ANGLE ADJUSTMENT |
352 |
|
B. CASTOR ANGLE ADJUSTMENT |
352 |
|
C. TOE-IN ADJUSTMENT |
352 |
|
D. WHEEL LOCK ANGLE ADJUSTMENT |
353 |
|
6.2. REAR 5 LINK SUSPENSION |
354 |
|
6.2.1. CONSTRUCTIONAL DETAILS |
354 |
|
6.2.2. SPECIFICATIONS AND RECOMMENDATIONS |
354 |
|
6.2.3. SPECIAL TOOLS |
354 |
|
6.2.4. REMOVAL/DISMANTLING PROCEDURE |
356 |
|
A. REMOVAL OF REAR SHOCK ABSORBER |
356 |
|
B. REMOVAL OF REAR ANTIROLL BAR |
356 |
|
C. REMOVAL OF PAN HARD ROD |
356 |
|
D. REMOVAL OF TOP LINK |
358 |
|
E. REMOVAL OF COIL SPRING |
358 |
|
F. REMOVAL OF BOTTOM LINK |
358 |
|
6.2.5. INSPECTION OF COMPONENTS |
360 |
|
6.2.6. ASSEMBLY/INSTALLATION PROCEDURE |
360 |
|
A. ASSEMBLY/INSTALLATION OF BOTTOM LINK |
360 |
|
B. INSTALLATION OF COIL SPRING |
360 |
|
C. INSTALLATION OF TOP LINK |
362 |
|
D. ASSEMBLY/INSTALLATION OF PANHARD ROD |
362 |
|
E. INSTALLATION OF REAR ANTIROLL BAR |
362 |
|
F. INSTALLATION OF REAR SHOCK ABSORBER |
362 |
|
6.3. WHEELS AND TYRES |
363 |
|
7. FRONT LIVE AXLE (4X2) |
367 |
|
7.1. TECHNICAL SPECIFICATIONS |
370 |
|
7.2. SPECIAL TOOLS |
371 |
|
7.3. DISMANTLING OF FRONT AXLE |
373 |
|
A. REMOVAL OF FRONT WHEELS |
373 |
|
B. REMOVAL OF FRONT HUB ASSEMBLY |
373 |
|
C. DISMANTLING OF FRONT HUB ASSEMBLY |
373 |
|
D. FRONT HUB ASSEMBLY WITH ABS TONER RING |
374 |
|
E. REMOVAL OF STUB AXLE ASSEMBLY |
375 |
|
F. DISMANTLING OF STUB AXLE ASSEMBLY |
375 |
|
7.4. INSPECTION OF PARTS |
375 |
|
7.5. ASSEMBLY INSTALLATION OF PARTS |
376 |
|
A. ASSEMBLY OF STUB AXLE |
376 |
|
B. INSTALLATION OF STUB AXLE |
376 |
|
C. ASSEMBLY / INSTALLATION OF FRONT HUB COMPLETE |
377 |
|
D. INSTALLATION OF FRONT WHEELS |
379 |
|
E. PRELOADING OF TORSION BAR |
379 |
|
F. WHEEL ALIGNMENT |
379 |
|
8. FRONT LIVE AXLE (4X4) |
380 |
|
8.1. CONSTRUCTION |
383 |
|
8.2. SPECIFICATION & SERVICE DATA |
386 |
|
8.3. SPECIAL TOOLS LIST |
387 |
|
8.4. 2 - WAY LOCK FREE RUNNING HUB |
388 |
|
A. REMOVAL AND INSTALLATION OF FREE RUNNING HUB ON VEHICLE |
389 |
|
8.5. REMOVAL OF WHEEL END WITH CV SHAFT FROM VEHICLE |
391 |
|
A. WHEEL END ASSEMBLY |
391 |
|
B. CARRIER CENTRE SECTION |
397 |
|
C. C. V. JOINT SHAFTS |
411 |
|
8.6. TROUBLE SHOOTING |
417 |
|
8.7. AUTOMATIC LOCKING HUB |
418 |
|
8.7.1. SPECIFICATIONS |
419 |
|
8.7.2. INTRODUCTION |
420 |
|
8.7.3. DIAGNOSIS |
422 |
|
8.7.4. DIS-ASSEMBLY INSPECTION & LUBRICATION |
423 |
|
8.7.5. ASSEMBLY |
425 |
|
8.7.6. LIST OF SERVICEABLE PARTS |
427 |
|
8.7.7. SOLUTION TO NOISE PROBLEM |
428 |
|
9.. REAR AXLE |
429 |
|
9.1. CONSTRUCTION |
432 |
|
9.2. SPECIFICATION & SERVICE DATA |
434 |
|
9.3. SPECIAL TOOLS LIST |
435 |
|
9.4. REMOVAL FROM VEHICLE |
436 |
|
9.5. DISASSEMBLY |
437 |
|
A. UNITISED BEARING |
438 |
|
B. CARRIER CENTRE SECTION |
439 |
|
C. DRIVE PINION |
443 |
|
9.6. CLEANING AND INSPECTION |
444 |
|
9.7. ASSEMBLY |
446 |
|
A) UNITISED BEARING |
446 |
|
B) PINION BEARING CUP |
451 |
|
C) CARRIER CENTRE SECTION |
453 |
|
D) DIFFERENTIAL |
456 |
|
9.8. INTERPRETATION OF TOOTH CONTACT PATTERN |
459 |
|
9.9. TROUBLE SHOOTING |
462 |
|
10. PROPELLER SHAFT |
1383 |
|
10.1. CONSTRUCTION |
1385 |
|
10.2. LIST OF SPECIAL TOOLS & SERVICE DATA |
1388 |
|
10.3. REMOVAL FROM VEHICLE |
1389 |
|
10.4. DISASSEMBLY |
1389 |
|
10.5. INSPECTION |
1392 |
|
10.6. LUBRICATION |
1394 |
|
10.6. ASSEMBLY |
1395 |
|
10.7. INSTALLATION ON VEHICLE |
1397 |
|
10.8. TROUBLE SHOOTING |
1398 |
|
11. BRAKES |
1399 |
|
11.1. TECHNICAL SPECIFICATIONS |
1402 |
|
11.2. TIGHTENING TORQUES |
1403 |
|
11.3. SCHEMATIC- HYDRAULIC BRAKE FOR NON ABS WITH BYPASS VALVE |
1404 |
|
11.4. SCHEMATIC - HYDAULIC LINES FOR ABS RHD (DICOR) |
1405 |
|
11.5. BYPASS VALVE |
1406 |
|
11.6. BLEEDING OF BRAKE ACTUATION SYSTEM WITH BYPASS(ABS & NON ABS) |
1406 |
|
11.7. BLEEDING OF BRAKE WITH ABS |
1406 |
|
12. ANTI-LOCK BRAKING SYSTEM |
532 |
|
12.1. TECHNICAL SPECIFICATIONS |
535 |
|
12.2. HYDRAULIC LINES FOR ABS |
536 |
|
12.3. ABS CIRCUIT DIAGRAM |
538 |
|
12.4. ANTILOCK BRAKE SYSTEM - THEORY |
539 |
|
12.5. COMPONENTS OF BOSCH ABS 5.3 SYSTEM |
546 |
|
12.6. ELECTRONIC BRAKES DISTRIBUTION (EBD) |
549 |
|
12.7. ABS SYSTEM FAILURE WARNING LIGHT |
551 |
|
12.8. REMOVAL / INSTALLATION OF ABS COMPONENTS |
552 |
|
12.9. ABS - ECU DIAGNOSTICS |
1407 |
|
12.9.1. GENERAL |
1409 |
|
12.9.2. DETAILED DESCRIPTION |
1409 |
|
12.9.3. SPECIFICATION |
1409 |
|
12.9.4. INSTALLATION AND OPERATING PROCEDURE |
1410 |
|
12.9.5. MAINTENANCE |
1412 |
|
13. STEERING |
623 |
|
13.1. EXPLODED VIEWS |
626 |
|
13.2. DESIGN AND FUNCTION |
630 |
|
13.3. OIL FILLING AND AIR BLEEDING |
634 |
|
13.4. DISMANTLING AND ASSEMBLY TOOLS |
636 |
|
13.5. REMOVING THE STEERING UNIT FROM THE VEHICLE |
637 |
|
13.6. DISMANTLING THE STEERING UNIT |
638 |
|
13.7. CHECKING THE STEERING PARTS |
639 |
|
13.8. TECHNICAL DATA AND SET VALUES |
640 |
|
13.9. ASSEMBLY OF THE STEERING UNIT AND FUNCTION TESTING. |
640 |
|
13.10. FITTING THE STEERING UNIT ON THE VEHICLE |
643 |
|
13.11. TROUBLES AND REMEDIES |
645 |
|
13.12. MAINTENANCE AND FUNCTIONAL DESCRIPTION OF VANE PUMP |
648 |
|
13.13. STEERING COLUMN |
650 |
|
14. FUEL SYSTEM |
1413 |
|
14.1. FUEL SYSTEM 4PL ENGINE |
1413 |
|
14.1.1. TECHNICAL SPECIFICATION |
1416 |
|
14.1.2. EXPLODED VIEWS |
1417 |
|
A) ASSEMBLY FUEL TANK WITH FILLER PIPE |
1417 |
|
B) SCHEMATIC CIRCUIT FOR MPFI FUEL LINES EURO III - RHD |
1418 |
|
14.1.3. GENERAL OPERATION OF EVAPORATIVE EMISSION SYSTEM |
1419 |
|
14.1.4. FUEL TANK |
1420 |
|
14.1.5. FUEL TANK PURGING PROCEDURE |
1422 |
|
14.1.6. ELECTRIC INTANK FUEL PUMP WITH IN BUILT PRESSURE REGULATOR |
1424 |
|
14.1.7. FUEL LEVEL GAUGE (DASHBOARD) |
1425 |
|
14.1.8. FUEL FILTER |
1426 |
|
14.1.9. FUEL FILLER CAP |
1427 |
|
14.1.10. FUEL HOSES AND LINES |
1428 |
|
14.1.11. FUEL LEVEL WARNING LIGHT |
1429 |
|
14.1.12. EVAPORATIVE EMISSION CONTROL SYSTEM |
1430 |
|
A) RESTRICTOR |
1430 |
|
B) VAPOUR SEPARATOR |
1430 |
|
C) TANK PRESSURE VALVE |
1431 |
|
D) CARBON CANISTER |
1432 |
|
E) CANISTER PURGE VALVE |
1433 |
|
14.2. FUEL SYSTEM DICOR ENGINE |
1435 |
|
14.2.1. EXPLODED VIEWS |
1437 |
|
A) ASSEMBLY FUEL TANK, FILLER PIPE, FUEL LINES & CLAMPS |
1437 |
|
14.2.2. FUEL SYSTEM |
1439 |
|
14.2.3. FUEL TANK |
1439 |
|
14.2.4. PURGING OF FUEL TANK |
1440 |
|
14.2.5. FUEL TANK STRAINER |
1441 |
|
14.2.6. FUEL GUAGE TANK UNIT |
1442 |
|
14.2.7. FUEL FILLER CAP |
1443 |
|
14.2.8. FUEL FILLER & SEDIMENTER |
1443 |
|
14.2.9. FUEL HOSES AND LINES |
1444 |
|
15. EXHAUST SYSTEM |
1445 |
|
15.1. TIGHTENING TORQUE |
1447 |
|
15.2. EXPLODED VIEW |
1448 |
|
A. EXHAUST SYSTEM ENGINE DICOR |
1448 |
|
15.3. EXHAUST SYTEM FOR DICOR |
1449 |
|
15.4. SAFETY PRECAUTIONS FOR CATALYTIC CONVERTOR |
1450 |
|
16. ELECTRICALS |
1451 |
|
16.1. TECHNICAL SPECIFICATIONS |
1454 |
|
16.2. CIRCUIT DIAGRAM SYMBOLS |
1455 |
|
16.3. WIRE COLOUR CODING |
1457 |
|
16.4. LIST OF BULBS USED IN SAFARI |
1457 |
|
16.5. FUSES & RELAYS |
1458 |
|
16.6. ALTERNATOR |
1461 |
|
16.7. STARTER MOTOR |
1463 |
|
16.8. INSTRUMENT CLUSTER |
1464 |
|
16.9. FUEL GAUGE |
1467 |
|
16.10. HEAD LAMP / TAIL LAMP ASSY |
1468 |
|
16.11. HORN |
1475 |
|
16.12. COMBI SWITCH |
1476 |
|
16.13. ANALOG CLOCK |
1477 |
|
16.14. MUSIC SYSTEM |
1478 |
|
16.15. SWITCHES, INTERIOR LAMPS AND OTHER COMPONENTS |
1479 |
|
A. GLOVE BOX SWITCH |
1479 |
|
B. FRONT INTERIOR LAMP |
1479 |
|
C. FUEL FLAP SOLENOID |
1480 |
|
D RADIO ANTENA |
1480 |
|
E. WINDOW WINDING SWITCHES |
1481 |
|
F. TRANSFER CASE SELECTION SWITCH |
1482 |
|
G. DOOR MIRROR SWITCH |
1483 |
|
I. ROOF LAMP |
1484 |
|
J. FACIA SWITCHES |
1485 |
|
K. STEERING LOCK CUM IGNITION SWITCH |
1486 |
|
16.16. ANTITHEFT DEVICE |
1486 |
|
16.17. CONTROLS UNITS |
1487 |
|
A. HEATED REAR WINDOW CONTROLLER |
1487 |
|
B. BUZZER UNIT |
1488 |
|
C. CHIME UNIT |
1489 |
|
D. FRONT WIPER CONTROLLER |
1490 |
|
E. INTERIOR LIGHT DELAY UNIT |
1491 |
|
F. FLASHER UNIT |
1492 |
|
G. GLOW PLUG TIMER |
1493 |
|
H. EGR CONTROLLER |
1495 |
|
16.18. CENTRAL LOCKING SYSTEM |
1496 |
|
16.19. WIPER SYSTEM |
1498 |
|
16.20. TROUBLESHOOTING GUIDELINES |
1504 |
|
16.21. WIRING DIAGRAMS |
1506 |
|
16.21.1. GENERAL INFORMATON |
1507 |
|
16.21.2. EARTHING LOCATIONS FOR RHD/LHD VEHICLES |
1508 |
|
16.21.3. CONNECTOR & LOCATION DETAILS FOR RHD/LHD VEHICLES |
1509 |
|
16.21.4. SUPPLY CONFIGURATION |
1513 |
|
16.21.5. STARTING / CHARGING (DICOR-BSIII & EURO-III) |
1514 |
|
16.21.6. REVERSE GUIDE SYSTEM |
1515 |
|
16.21.7. IMMOBILISER (RF TYPE) WITH KEYLESS ENTRY |
1516 |
|
16.21.8. CENTRAL LOCKING SYSTEM (LX) |
1517 |
|
16.21.9. HEAD LAMP & PARKING LAMP |
1518 |
|
16.21.10. HEAD LAMP LEVELLING |
1519 |
|
16.21.11. DIRECTION INDICATORS & HAZARD WARNING |
1520 |
|
16.21.12. FRONT / REAR FOG LAMPS, STOP & REVERSE LAMPS |
1521 |
|
16.21.13. INTERIOR LAMPS |
1522 |
|
16.21.14. ELECTRIC INSTRUMENT CLUSTER |
1523 |
|
16.21.15. FRONT WIPER & WASHER |
1524 |
|
16.21.16. REAR WIPER & WASHER |
1525 |
|
16.21.17. POWER WINDOWS |
1526 |
|
16.21.18. AIR BAG SYSTEM (SRS) |
1527 |
|
16.21.19. ANTI-LOCK BRAKING SYSTEM (ABS) |
1528 |
|
16.21.20. AIR CONDITIONING (DICOR WITH ROOF A/C) |
1529 |
|
16.21.21. TRANSFER CASE (4X4) |
1530 |
|
16.21.22. CIGAR LIGHTER,POWER POINT, CLOCK & MUSIC SYSTEM |
1531 |
|
16.21.23. AUDIBLE WARNING DEVICES |
1532 |
|
16.21.24. FUEL FLAP SOLENOID, PARKING BRAKE & BRAKE FLUID |
1533 |
|
16.21.25. ENGINE COOLING FAN (4 DLTCIC & DICOR) |
1534 |
|
16.21.25. REAR VIEW MIRROR (OUTER) & HEATED REAR WINDOW (HRW) |
1535 |
|
16.21.26. EMS - DICOR |
1536 |
|
16.22. WIRING HARNESSES |
1537 |
|
16.23. REVERSE GUIDE SYSTEM |
1542 |
|
17. BODY |
1550 |
|
17.1. TECHNICAL SPECIFICATIONS |
1552 |
|
17.2. EXPLODED VIEWS |
1553 |
|
17.3. REMOVAL / INSTALLATION OF FRONT / REAR DOOR INNER TRIM |
1559 |
|
17.4. REMOVAL / INSTALLATION OF TAIL GATE INNER TRIMS |
1560 |
|
17.5. REMOVAL / INSTALLATION OF FRONT / REAR DOOR |
1561 |
|
17.6. REMOVAL / INSTALLATION OF TAIL GATE |
1562 |
|
17.7. REMOVAL / INSTALLATION OF DOOR OUTER HANDLE |
1563 |
|
17.8. REMOVAL / INSTALLATION OF DOOR INNER HANDLE |
1564 |
|
17.9. REMOVAL / INSTALLATION OF DOOR LATCH |
1565 |
|
17.10. REMOVAL / INSTALLATION OF WINDOW GLASS |
1566 |
|
17.11. REMOVAL / INSTALLATION OF WINDOW WINDING REGULATOR |
1567 |
|
17.12. REMOVAL / INSTALLATION OF DOOR MIRROR |
1568 |
|
17.13. REMOVAL / INSTALLATION OF BONNET |
1569 |
|
17.14. REMOVAL / INSTALLATION OF FENDER |
1570 |
|
17.15. REMOVAL / INSTALLATION OF FRONT BUMPER |
1571 |
|
17.16. REMOVAL / INSTALLATION OF REAR BUMPER |
1572 |
|
17.17. REMOVAL / INSTALLATION OF FRONT SEAT |
1573 |
|
17.18. REMOVAL / INSTALLATION OF REAR SEAT |
1574 |
|
17.19. PROCEDURE FOR REMOVAL / ASSEMBLY OF SEAT BELT |
1575 |
|
17.20. EXPLODED VIEW OF DASH BOARD |
1576 |
|
17.20A. REMOVAL / INSTALLATION OF DASHBOARD |
1577 |
|
17.21. EXPLODED VIEW OF INTERNAL TRIMS |
1578 |
|
17.21A. REMOVAL / INSTALLATION OF ROOF LINING |
1579 |
|
17.22. REMOVAL / INSTALLATION OF JUMP SEAT |
1580 |
|
17.23. BODY MOUNTING LOCATIONS |
1581 |
|
17.24. PROCEDURE FOR FIXING OF WIND SCREEN GLASS, SIDE FIXED GLASSES & TAIL GATE GLASS |
1582 |
|
17.25. PROCEDURE FOR FIXING SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS |
1583 |
|
17.26. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS |
1583 |
|
17.27. PROCEDURE FOR FIXING DOOR GLASS WEATHER STRIP AT ENDS (BOTTOM OF STYLING STRIP) |
1584 |
|
17.28. PROCEDURE FOR FIXING HAND BRAKE CONSOLE GARNISH |
1584 |
|
17.29. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD (MODIFIED) TRIMS |
1585 |
|
17.30. IMPORTANT BODY DIMENSIONS |
1586 |
|
18. AIR BAGS |
792 |
|
18.1. SCHEMATIC CIRCUIT DIAGRAM - SRS (SUPPLEMENTARY RESTRAINT SYSTEM) |
795 |
|
18.2. WIRING HARNESS ROUTING - SRS (SUPPLEMENTARY RESTRAINT SYSTEM) |
796 |
|
18.3. SAFARI OCCUPANT RESTRAINT SYSTEM |
797 |
|
18.4. WORKING OF RPLL BELTS |
798 |
|
18.5. SAFETY PRECAUTIONS |
799 |
|
18.6. PROCEDURE FOR REMOVAL OF STEERING WHEEL, DRIVER AND CO-DRIVER AIR BAG MODULE |
800 |
|
18.7. CO-DRIVER AIR BAG |
801 |
|
18.8. PROCEDURE FOR INSTALLATION OF STEERING WHEEL, DRIVER & CO-DRIVER AIR BAG MODULE AND SEAT BELTS. |
802 |
|
18.9. PROCEDURE FOR INSTALLATION AND REMOVAL OF COMBI-SWITCH, ADAPTOR PLATE & CLOCK SPRING. |
803 |
|
18.10. SRS WARNING LAMP FAULT CODES |
805 |
|
18.11. DIAGNOSTICS FOR AIR BAG (ORS) SYSTEM |
807 |
|
18.12. SAFARI ERROR CODES LIST FOR AC4 (AIRBAG ECU) |
812 |
|
19. AIR CONDITIONING |
816 |
|
19.1. SPECIFICATIONS |
819 |
|
19.2. A/C SCHEMATIC DRAWINGS |
820 |
|
19.3. BASIC COMPONENTS |
826 |
|
19.4. AIR-CONDITIONING CONTROLS |
828 |
|
19.5. MAGNETIC CLUTCH |
830 |
|
19.6. VACUUM SOLENOID VALVE |
831 |
|
19.7. DUAL PRESSURE SWITCH |
832 |
|
19.8. ANTIFREEZING DEVICE |
832 |
|
19.9. REMOVAL AND FITMENT OF A/C COMPONENTS |
833 |
|
19.10. ROOF A/C UNIT |
839 |
|
19.11. REFRIGERANT (R.134A) |
842 |
|
19.12. COMPRESSOR OIL |
843 |
|
19.13. SERVICE AND REPAIRS |
844 |
|
19.14. CHARGING THE SYSTEM |
847 |
|
19.15. TROUBLE SHOOTING |
849 |
|
19.16. DO'S AND DON'TS |
854 |
|
19.17. A/C CHECK UP POINTS |
855 |