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 HARNESSES	710
16. BODY	715
16.1. TECHNICAL SPECIFICATIONS	718
16.2. EXPLODED VIEWS	719
16.3. REMOVAL / INSTALLATION OF FRONT / REAR DOOR INNER TRIM	730
16.4. REMOVAL / INSTALLATION OF TAIL GATE INNER TRIMS	731
16.5. REMOVAL / INSTALLATION OF FRONT / REAR DOOR	732
16.6. REMOVAL / INSTALLATION OF TAIL GATE	733
16.7. REMOVAL / INSTALLATION OF DOOR OUTER HANDLE	734
16.8. REMOVAL / INSTALLATION OF DOOR INNER HANDLE	735
16.9. REMOVAL / INSTALLATION OF DOOR LATCH	736
16.10. REMOVAL / INSTALLATION OF WINDOW GLASS	737
16.11. REMOVAL / INSTALLATION OF WINDOW WINDING REGULATOR	738
16.12. REMOVAL / INSTALLATION OF DOOR MIRROR	739
16.13. REMOVAL / INSTALLATION OF BONNET	740
16.14. REMOVAL / INSTALLATION OF FENDER	741
16.15. REMOVAL / INSTALLATION OF FRONT BUMPER	742
16.16. REMOVAL / INSTALLATION OF REAR BUMPER	743
16.17. REMOVAL / INSTALLATION OF FRONT SEAT	744
16.18. REMOVAL / INSTALLATION OF REAR SEAT	745
16.19. PROCEDURE FOR REMOVAL / ASSEMBLY OF SEAT BELT	746
16.20. PROCEDURE FOR REMOVAL / ASSEMBLY OF DASHBOARD	748
16.21. PROCEDURE FOR REMOVAL / ASSEMBLY OF ROOF LINING	750
16.22. REMOVAL / INSTALLATION OF JUMP SEAT	751
16.23. BODY MOUNTING LOCATIONS	752
16.24. PROCEDURE FOR FIXING OF WIND SCREEN GLASS, SIDE FIXED GLASSES & TAIL GATE GLASS	753
16.25. PROCEDURE FOR FIXING SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS	754
16.26. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS	754
16.27. PROCEDURE FOR FIXING DOOR GLASS WEATHER STRIP AT ENDS (BOTTOM OF STYLING STRIP)	755
16.28. PROCEDURE FOR FIXING HAND BRAKE CONSOLE GARNISH	755
16.29. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD (MODIFIED) TRIMS	756
16.30. IMPORTANT BODY DIMENSIONS	757
17. AIR BAGS	760
17.1. SCHEMATIC CIRCUIT DIAGRAM - SRS (SUPPLEMENTARY RESTRAINT SYSTEM)	763
17.2. WIRING HARNESS ROUTING - SRS (SUPPLEMENTARY RESTRAINT SYSTEM)	764
17.3. SAFARI OCCUPANT RESTRAINT SYSTEM	765
17.4. WORKING OF RPLL BELTS	766
17.5. SAFETY PRECAUTIONS	767
17.6. PROCEDURE FOR REMOVAL OF STEERING WHEEL, DRIVER AND CO-DRIVER AIR BAG MODULE	768
17.7. CO-DRIVER AIR BAG	769
17.8. PROCEDURE FOR INSTALLATION OF STEERING WHEEL, DRIVER & CO-DRIVER AIR BAG MODULE AND SEAT BELTS.	770
17.9. PROCEDURE FOR INSTALLATION AND REMOVAL OF COMBI-SWITCH, ADAPTOR PLATE & CLOCK SPRING.	771
17.10. SRS WARNING LAMP FAULT CODES	773
17.11. DIAGNOSTICS FOR AIR BAG (ORS) SYSTEM	775
17.12. SAFARI ERROR CODES LIST FOR AC4 (AIRBAG ECU)	780
17.13. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT	784
18. AIR CONDITIONING	785
18.1. SPECIFICATIONS	788
18.2. A/C SCHEMATIC DRAWINGS	789
18.3. BASIC COMPONENTS	795
18.4. AIR-CONDITIONING CONTROLS	797
18.5. MAGNETIC CLUTCH	799
18.6. VACUUM SOLENOID VALVE	800
18.7. DUAL PRESSURE SWITCH	801
18.8. ANTIFREEZING DEVICE	801
18.9. REMOVAL AND FITMENT OF A/C COMPONENTS	802
18.10. ROOF A/C UNIT	808
18.11. REFRIGERANT (R.134A)	811
18.12. COMPRESSOR OIL	812
18.13. SERVICE AND REPAIRS	813
18.14. CHARGING THE SYSTEM	816
18.15. TROUBLE SHOOTING	818
18.16. DO'S AND DON'TS	823
18.17. A/C CHECK UP POINTS	824
TATA SAFARI 2.2L VTT DICOR	827
1. GENERAL	831
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS	833
1.2. LIFTING AND JACKING POINTS	837
1.3. TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS	838
1.4. AGGREGATE / CHASSIS NUMBERING SYSTEM	839
1.5. TECHNICAL SPECIFICATIONS	847
1.6. FILLING CAPACITIES	849
1.7. FUEL, LUBRICANTS & COOLANTS	849
A. FUEL	849
B. LUBRICANTS & OILS	849
C. COOLANTS	850
1.8. SERVICE SCHEDULE	851
2. ENGINE 2.2L DICOR BS3	854
2.1. TECHNICAL SPECIFICATION	857
2.2. LIST OF SPECIAL TOOLS	858
2.3. TIGHTENING TORQUE TABLE	859
2.4. PRELIMINARY INSPECTION OF ENGINE	862
2.5. ENGINE REMOVAL AND FITMENT ON VEHICLE	864
2.6. ENGINE OVERHAUL PROCEDURE(ON STAND PROCEDURES)	865
A. REMOVAL AND FITMENT OF ALTERNATOR,AC COMPRESSOR AND PS PUMP& AUXILIARY BELT ADJUSTMENT PROCEDURE	865
B. REMOVAL OF CYLINDER HEAD FROM CYLINDER BLOCK	868
C. DISMANTLING OF CYLINDER HEAD SUB-ASSEMBLIES	884
D. INSPECTION OF CYLINDER HEAD SUB-ASSEMBLIES	887
E. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES	890
F. DISMANTLING OF CYLINDER BLOCK SUB-ASSEMBLIES	893
G. INSPECTION OF CYLINDER BLOCK SUB-ASSEMBLIES	901
H. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES	909
I. ASSEMBLY OF CYLINDER HEAD ON CYLINDER BLOCK	918
J. ENGINE TIMING BELT FITMENT AND SETTING PROCEDURE	926
2.7. ENGINE SERVICE DATA	935
A. VALVE, VALVE SEAT	935
B. VALVE GUIDE, VALVE SEAT INSERT	936
C. CAMSHAFT	937
D. PISTON AND PISTON RINGS	938
E. CONNECTING ROD	939
F. CRANK SHAFT	940
G. CYLINDER BLOCK AND ASSEMBLY CLEARANCES	941
2.8. ENGINE SYSTEM SCHEMATIC LAYOUTS	942
A. COOLING SYSTEM	942
B. LUBRICATION SYSTEM	946
C. BLOW-BY SYSTEM/CRANK CASE VENTILATION	949
D. AIR INTAKE SYSTEM	951
E. VACUUM MANAGEMENT SYSTEM	954
F. VNT (VARIABLE NOZZLE TURBINE) TURBOCHARGER	956
G. EGR (EXHAUST GAS RECIRCULATION) SYSTEM	965
2.9. ENGINE TESTING	967
2.10. ENGINE TROUBLE SHOOTING	968
2.11. ENGINE EXPLODED VIEWS	971
2.12. DIAGNOSTICS	994
A. ECU AND EMS SENSORS	994
B. DIAGNOSTIC SYSTEM INSTALLATION AND OPERATING PROCEDURE	1005
C. DTC (DIAGNOSTIC TROUBLE CODES) LIST	1019
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	1037
4.1. CONSTRUCTION	1041
A.SECTIONAL VIEW	1041
4.2. TECHNICAL SPECIFICATIONS	1042
4.3. TIGHTENING TORQUE	1043
4.4. SPECIAL TOOLS LIST	1044
4.5. REMOVAL OF G-76 GEAR BOX FROM VEHICLE	1046
4.6. EXPLODED ILLUSTRATED VIEW - GEAR BOX	1050
4.7. DISMANTLING OF GEAR BOX	1051
4.8. EXPLODED ILLUSTRATED VIEW - MAIN SHAFT	1060
4.9. DISASSEMBLY OF MAIN SHAFT	1061
4.10. DISASSEMBLY OF DRIVE SHAFT	1066
4.11. EXPLODED ILLUSTRATED VIEW - COUNTER SHAFT & REVERSE IDLER SHAFT	1067
4.12. DISASSEMBLY OF COUNTER SHAFT	1068
4.13. DISASSEMBLY OF REMOVAL IDLER GEAR SHAFT	1068
4.14. DISASSEMBLY OF GEAR BOX HOUSING REAR HALF	1069
4.15. REPLACEMENT OF SELECTOR SHAFT	1069
4.16. DISASSEMBLY OF GEAR CASE FRONT & REAR	1070
4.17. INSPECTION	1070
4.18. IDENTIFICATION OF PARAMETERS	1071
A. ENGAGING GEARS	1071
B. SYNCHRO CONES	1071
C. SHIFTER SLEEVES	1072
D. SHIFTER FORKS	1073
E. SHIFTER SHAFTS	1073
4.19. ASSEMBLY OF SUB-ASSEMBLIES	1074
A. SUB ASSY. OF ENGAGING GEAR	1074
B. SUB ASSY. OF MAIN SHAFT	1075
C. SUB ASSY. OF COUNTER SHAFT	1080
D. SUB ASSY. OF DRIVE SHAFT	1080
E. SUB ASSY. OF REMOVAL IDLER GEAR SHAFT	1081
4.20. MEASUREMENT OF CONTROL DIMENSIONS	1082
4.21. SUBASSEMBLY OF GEAR BOX HOUSING COVER FRONT	1088
4.22. SUB ASSEMBLY OF GEAR CASE COVER REAR	1088
4.23. ASSEMBLY OF SHIFTER AND SELECTOR SHAFTS	1089
4.24. SUB ASSY. OF GEAR BOX HOUSING - REAR HALF	1090
4.25. ASSEMBLY OF GEAR BOX	1091
4.26. ASSEMBLY OF GEAR SHIFT LINKAGE	1096
4.27. INSTALLATION OF GEAR BOX ASSY. ON VEHICLE	1097
4.28. TROUBLE SHOOTING	1099
4.29. IMPROVEMENTS-SUPPLEMENT	1100
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	827
6.1.6. ASSEMBLY/INSTALLATION PROCEDURE	827
A. ASSEMBLY/INSTALLATION OF LOWER WISHBONE	827
B. ASSEMBLY/INSTALLATION OF UPPER WISHBONE	827
C. INSTALLATION OF FRONT SHOCK ABSORBER	827
D. INSTALLATION OF FRONT ANTIROLL BAR	827
E. INSTALLATION OF FRONT WHEELS	827
F. INSTALLATION OF TORSION BAR	827
6.1.7. WHEEL ALIGNMENT	827
A. CAMBER ANGLE ADJUSTMENT	827
B. CASTOR ANGLE ADJUSTMENT	827
C. TOE-IN ADJUSTMENT	827
D. WHEEL LOCK ANGLE ADJUSTMENT	827
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	1102
11.1. TECHNICAL SPECIFICATION	1105
11.2. TIGHTENING TORQUE	1106
11.3. BRAKE SYSTEM CIRCUIT SCHEMATIC (ABS)	1107
11.4. BRAKE SYSTEM CIRCUIT SCHEMATIC (NON-ABS)	1109
11.5. VACCUM CIRCUIT SCHEMATIC LAYOUT	1111
11.6. VACCUM TANK	1112
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	1113
14.1. INTRODUCTION TO DICOR SYSTEM	1116
14.2. DICOR SYSTEM SCHEMATIC LAYOUT	1118
14.3. DICOR SYSTEM CLEANLINESS INSTRUCTIONS	1119
14.4. FUEL SYSTEM EXPLODED VIEW	1121
14.5. FUEL SYSTEM COMPONENTS	1123
A. COMMON RAIL	1123
B. INJECTOR	1123
C. HP PUMP	1125
D. SEDIMENTER	1125
E. FUEL FILTER	1127
F. PEAR PUMP / PRIMING PUMP	1128
G. FUEL TANK	1129
H. FUEL TANK STRAINER	1131
I. FUEL GAUGE (TANK UNIT)	1131
J. FUEL LEVEL GAUGE (DASH BOARD)	1132
K. FUEL FILLER CAP	1133
L. FUEL HOSES AND FUEL LINES	1133
15. EXHAUST SYSTEM	1134
15.1. EXPLODED VIEW OF EXHAUST SYSTEM	1137
15.2. TIGHTENING TORQUES	1138
15.3. CLOSE COUPLED CATALYTICE CONVERTER (CCC)	1139
A. REMOVAL	1139
B. FITMENT	1139
C. CARE AND MAINTENANCE	1139
15.4. EXHAUST PIPE	1140
A. REMOVAL	1140
B. FITMENT	1140
C. GENERAL MAINTENANCE	1140
16. BODY	715
16.1. TECHNICAL SPECIFICATIONS	718
16.2. EXPLODED VIEWS	719
16.3. REMOVAL / INSTALLATION OF FRONT / REAR DOOR INNER TRIM	730
16.4. REMOVAL / INSTALLATION OF TAIL GATE INNER TRIMS	731
16.5. REMOVAL / INSTALLATION OF FRONT / REAR DOOR	732
16.6. REMOVAL / INSTALLATION OF TAIL GATE	733
16.7. REMOVAL / INSTALLATION OF DOOR OUTER HANDLE	734
16.8. REMOVAL / INSTALLATION OF DOOR INNER HANDLE	735
16.9. REMOVAL / INSTALLATION OF DOOR LATCH	736
16.10. REMOVAL / INSTALLATION OF WINDOW GLASS	737
16.11. REMOVAL / INSTALLATION OF WINDOW WINDING REGULATOR	738
16.12. REMOVAL / INSTALLATION OF DOOR MIRROR	739
16.13. REMOVAL / INSTALLATION OF BONNET	740
16.14. REMOVAL / INSTALLATION OF FENDER	741
16.15. REMOVAL / INSTALLATION OF FRONT BUMPER	742
16.16. REMOVAL / INSTALLATION OF REAR BUMPER	743
16.17. REMOVAL / INSTALLATION OF FRONT SEAT	744
16.18. REMOVAL / INSTALLATION OF REAR SEAT	745
16.19. PROCEDURE FOR REMOVAL / ASSEMBLY OF SEAT BELT	746
16.20. PROCEDURE FOR REMOVAL / ASSEMBLY OF DASHBOARD	748
16.21. PROCEDURE FOR REMOVAL / ASSEMBLY OF ROOF LINING	750
16.22. REMOVAL / INSTALLATION OF JUMP SEAT	751
16.23. BODY MOUNTING LOCATIONS	751
16.24. PROCEDURE FOR FIXING OF WIND SCREEN GLASS, SIDE FIXED GLASSES & TAIL GATE GLASS	753
16.25. PROCEDURE FOR FIXING SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS	754
16.26. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS	754
16.27. PROCEDURE FOR FIXING DOOR GLASS WEATHER STRIP AT ENDS (BOTTOM OF STYLING STRIP)	755
16.28. PROCEDURE FOR FIXING HAND BRAKE CONSOLE GARNISH	755
16.29. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD (MODIFIED) TRIMS	756
16.30. IMPORTANT BODY DIMENSIONS	757
17. AIR BAGS	760
17.1. SCHEMATIC CIRCUIT DIAGRAM - SRS (SUPPLEMENTARY RESTRAINT SYSTEM)	763
17.2. WIRING HARNESS ROUTING - SRS (SUPPLEMENTARY RESTRAINT SYSTEM)	764
17.3. SAFARI OCCUPANT RESTRAINT SYSTEM	765
17.4. WORKING OF RPLL BELTS	766
17.5. SAFETY PRECAUTIONS	767
17.6. PROCEDURE FOR REMOVAL OF STEERING WHEEL, DRIVER AND CO-DRIVER AIR BAG MODULE	768
17.7. CO-DRIVER AIR BAG	769
17.8. PROCEDURE FOR INSTALLATION OF STEERING WHEEL, DRIVER & CO-DRIVER AIR BAG MODULE AND SEAT BELTS	770
17.9. PROCEDURE FOR INSTALLATION AND REMOVAL OF COMBI-SWITCH, ADAPTOR PLATE & CLOCK SPRING	771
17.10. SRS WARNING LAMP FAULT CODES	773
17.11. DIAGNOSTICS FOR AIR BAG (ORS) SYSTEM	775
17.12. SAFARI ERROR CODES LIST FOR AC4 (AIRBAG ECU)	780
17.13. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT	784
18. AIR CONDITIONING	785
18.1. SPECIFICATIONS	788
18.2. A/C SCHEMATIC DRAWINGS	789
18.3. BASIC COMPONENTS	795
18.4. AIR-CONDITIONING CONTROLS	797
18.5. MAGNETIC CLUTCH	799
18.6. VACUUM SOLENOID VALVE	800
18.7. DUAL PRESSURE SWITCH	801
18.8. ANTIFREEZING DEVICE	801
18.9. REMOVAL AND FITMENT OF A/C COMPONENTS	802
18.10. ROOF A/C UNIT	808
18.11. REFRIGERANT (R.134A)	811
18.12. COMPRESSOR OIL	812
18.13. SERVICE AND REPAIRS	813
18.14. CHARGING THE SYSTEM	816
18.15. TROUBLE SHOOTING	818
18.16. DO'S AND DON'TS	823
18.17. A/C CHECK UP POINTS	824
TATA SAFARI DICOR 3L	1141
1. GENERAL	1145
1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS	1147
1.2. LIFTING AND JACKING POINTS	1151
1.3. TIGHTENING TORQUES OF STANDARD BOLTS AND NUTS	1152
1.4. CHASSIS NUMBERING SYSTEM	1153
1.5. AGGREGATE NUMBERING SYSTEM	1154
A. FRAME	1154
B. ENGINE	1154
C. GEAR BOX	1155
D. CAB	1156
1.6. TECHNICAL SPECIFICATIONS	1157
1.7. FILLING CAPACITIES	1160
1.8. FUEL, LUBRICANTS & COOLANTS	1160
A. FUEL	1160
B. LUBRICANTS & OILS	1160
C. COOLANTS	1161
1.9. SERVICE SCHEDULE	1162
2. ENGINE 3 L DICOR	1166
2.1. INTRODUCTION OF DICOR TECHNOLOGY	1169
2.2. ECU AND SENSORS	1171
2.3. UNIQUE CR STRATEGIES	1177
2.4. INDIVIDUAL INJECTORS CHARATERISATION (I2C)	1177
2.5. ACCELEROMETER PILOT CONTROL STRATEGY (APC)	1177
2.6. SENSOR CHECK VALUES	1178
2.7. TECHNICAL SPECIFICATIONS	1179
2.8. SPECIAL TOOLS	1180
2.9. TIGHTENING TORQUES	1182
2.10. FUELS, LUBRICANTS AND COOLANTS	1184
2.11. PRELIMINARY INESPECTION OF ENGINE	1186
2.12. ENGINE REPAIR DATA	1188
2.13. REMOVAL OF ENGINE FROM VEHICLE	1208
2.14. ASSEMBLY OF ENGINE ON VEHICLE	1214
2.15. ENGINE COVER	1215
2.16. REPLACEMENT OF OIL SEAL IN TIMING HOUSING COVER	1216
2.17. TIMING HOUSING COVER	1218
2.18. FUEL INJECTION SYSTEM	1219
A. CR SYSTEMS	1219
B. HP PUMP	1221
C. RAIL	1224
D. INJECTORS	1226
E. HP PIPES	1229
F. SEDIMENTER	1232
G. FUEL FILTER	1235
H. DO’S & DONT’S	1238
2.19. REMOVAL & REFITTMENT OF	1240
A. ENGINE HEAD	1240
B. ADJUSTMENT OF VALVE CLEARANCE	1243
C. ENGINE HEAD COVER	1244
D. PRESSURE TESTING OF CYLINDER HEAD	1247
E. ROCKER ARM AND PUSH ROD ASSEMBLY AASSEMBLY	1248
F. VALVES,GUIDES,SPRINGS AND SEATS	1251
G. PISTON AND CONNECTING ROD	1256
H. CYLINDER BLOCK	1261
I. FLY WHEEL / RING GEAR / CRANK SHAFT PULLEY	1264
J. CRANK SHAFT	1266
K. CAM SHAFT AND CAM GEAR	1270
L. VACUUM PUMP	1279
M. LUBRICATION SYSTEM	1284
N. COOLING SYSTEM	1291
O. ELECTRICAL EQUIPMENT OF ENGINE	1298
P. AIR INTAKE SYSTEM	1300
Q. EGR	1301
R. BLOW-BY SYSTEM	1305
2.20. EXPLODED VIEWS	1307
2.21. ENGINE DIAGNOSITICS	1326
A. GENERAL	1326
B. CONNECTION DETAILS	1326
C. SPECIFICATION	1326
D. INSTALLATION AND OPERATING PROCEDURE	1327
E. MAINTENANCE	1334
3. CLUTCH	1335
3.1. CONSTRUCTIONAL DETAILS	1337
3.2. CLUTCH PARTS AND MOUNTING ARRANGEMENT	1338
3.3. FACTORS AFFECTING CLUTCH WEAR	1337
3.4. PRELIMINARY INSPECTION	1337
3.5. REMOVAL OF CLUTCH FROM VEHICLE	1340
3.6. SPECIFICATIONS AND RECOMMENDATIONS	1341
3.7. INSPECTION OF COMPONENTS	1341
3.8. INSTALLATION OF CLUTCH ON VEHICLE	1341
3.9. CLUTCH ACTUATION MECHANISM REMOVAL	1341
3.10. MASTER CYLINDER	1344
A. DISMANTLING OF MASTER CYLINDER	1344
B. INSPECTION AND ASSEMBLY OF MASTER CYLINDER	1344
3.11. CLUTCH SLAVE CYLINDER	1344
A. DISMANTLING OF CLUTCH SLAVE CYLINDER	1344
B. INSPECTION AND ASSEMBLY CLUTCH SLAVE CYLINDER	1344
3.12. INSTALLATION OF CLUTCH ACTUATION MECHANISM	1345
3.13. BLEEDING THE CLUTCH SYSTEM	1345
3.14. CLUTCH PEDAL LINKAGE ADJUSTMENT	1345
3.15 EXPLODED VIEW	1346
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	1352
10.1. CONSTRUCTION	1354
10.2. LIST OF SPECIAL TOOLS & SERVICE DATA	1357
10.3. REMOVAL FROM VEHICLE	1358
10.4. DISASSEMBLY	1358
10.5. INSPECTION	1361
10.6. LUBRICATION	1363
10.6. ASSEMBLY	1364
10.7. INSTALLATION ON VEHICLE	1366
10.8. TROUBLE SHOOTING	1367
11. BRAKES	1368
11.1. TECHNICAL SPECIFICATIONS	1371
11.2. TIGHTENING TORQUES	1372
11.3. SCHEMATIC- HYDRAULIC BRAKE FOR NON ABS WITH BYPASS VALVE	1373
11.4. SCHEMATIC - HYDAULIC LINES FOR ABS RHD (DICOR)	1374
11.5. BYPASS VALVE	1375
11.6. BLEEDING OF BRAKE ACTUATION SYSTEM WITH BYPASS(ABS & NON ABS)	1375
11.7. BLEEDING OF BRAKE WITH ABS	1375
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	1376
12.9.1. GENERAL	1378
12.9.2. DETAILED DESCRIPTION	1378
12.9.3. SPECIFICATION	1378
12.9.4. INSTALLATION AND OPERATING PROCEDURE	1379
12.9.5. MAINTENANCE	1381
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	1382
14.1. FUEL SYSTEM 4PL ENGINE	1382
14.1.1. TECHNICAL SPECIFICATION	1385
14.1.2. EXPLODED VIEWS	1386
A) ASSEMBLY FUEL TANK WITH FILLER PIPE	1386
B) SCHEMATIC CIRCUIT FOR MPFI FUEL LINES EURO III - RHD	1387
14.1.3. GENERAL OPERATION OF EVAPORATIVE EMISSION SYSTEM	1388
14.1.4. FUEL TANK	1389
14.1.5. FUEL TANK PURGING PROCEDURE	1391
14.1.6. ELECTRIC INTANK FUEL PUMP WITH IN BUILT PRESSURE REGULATOR	1393
14.1.7. FUEL LEVEL GAUGE (DASHBOARD)	1394
14.1.8. FUEL FILTER	1395
14.1.9. FUEL FILLER CAP	1396
14.1.10. FUEL HOSES AND LINES	1397
14.1.11. FUEL LEVEL WARNING LIGHT	1398
14.1.12. EVAPORATIVE EMISSION CONTROL SYSTEM	1399
A) RESTRICTOR	1399
B) VAPOUR SEPARATOR	1399
C) TANK PRESSURE VALVE	1400
D) CARBON CANISTER	1401
E) CANISTER PURGE VALVE	1402
14.2. FUEL SYSTEM DICOR ENGINE	1404
14.2.1. EXPLODED VIEWS	1406
A) ASSEMBLY FUEL TANK, FILLER PIPE, FUEL LINES & CLAMPS	1406
14.2.2. FUEL SYSTEM	1408
14.2.3. FUEL TANK	1408
14.2.4. PURGING OF FUEL TANK	1409
14.2.5. FUEL TANK STRAINER	1410
14.2.6. FUEL GUAGE TANK UNIT	1411
14.2.7. FUEL FILLER CAP	1412
14.2.8. FUEL FILLER & SEDIMENTER	1412
14.2.9. FUEL HOSES AND LINES	1413
15. EXHAUST SYSTEM	1414
15.1. TIGHTENING TORQUE	1416
15.2. EXPLODED VIEW	1417
A. EXHAUST SYSTEM ENGINE DICOR	1417
15.3. EXHAUST SYTEM FOR DICOR	1418
15.4. SAFETY PRECAUTIONS FOR CATALYTIC CONVERTOR	1419
16. ELECTRICALS	1420
16.1. TECHNICAL SPECIFICATIONS	1423
16.2. CIRCUIT DIAGRAM SYMBOLS	1424
16.3. WIRE COLOUR CODING	1426
16.4. LIST OF BULBS USED IN SAFARI	1426
16.5. FUSES & RELAYS	1427
16.6. ALTERNATOR	1430
16.7. STARTER MOTOR	1432
16.8. INSTRUMENT CLUSTER	1433
16.9. FUEL GAUGE	1436
16.10. HEAD LAMP / TAIL LAMP ASSY	1437
16.11. HORN	1444
16.12. COMBI SWITCH	1445
16.13. ANALOG CLOCK	1446
16.14. MUSIC SYSTEM	1447
16.15. SWITCHES, INTERIOR LAMPS AND OTHER COMPONENTS	1448
A. GLOVE BOX SWITCH	1448
B. FRONT INTERIOR LAMP	1448
C. FUEL FLAP SOLENOID	1449
D RADIO ANTENA	1449
E. WINDOW WINDING SWITCHES	1450
F. TRANSFER CASE SELECTION SWITCH	1451
G. DOOR MIRROR SWITCH	1452
I. ROOF LAMP	1453
J. FACIA SWITCHES	1454
K. STEERING LOCK CUM IGNITION SWITCH	1455
16.16. ANTITHEFT DEVICE	1455
16.17. CONTROLS UNITS	1456
A. HEATED REAR WINDOW CONTROLLER	1456
B. BUZZER UNIT	1457
C. CHIME UNIT	1458
D. FRONT WIPER CONTROLLER	1459
E. INTERIOR LIGHT DELAY UNIT	1460
F. FLASHER UNIT	1461
G. GLOW PLUG TIMER	1462
H. EGR CONTROLLER	1464
16.18. CENTRAL LOCKING SYSTEM	1465
16.19. WIPER SYSTEM	1467
16.20. TROUBLESHOOTING GUIDELINES	1473
16.21. WIRING HARNESSES	1475
16.22. REVERSE GUIDE SYSTEM	1480
17. BODY	1488
17.1. TECHNICAL SPECIFICATIONS	1490
17.2. EXPLODED VIEWS	1491
17.3. REMOVAL / INSTALLATION OF FRONT / REAR DOOR INNER TRIM	1497
17.4. REMOVAL / INSTALLATION OF TAIL GATE INNER TRIMS	1498
17.5. REMOVAL / INSTALLATION OF FRONT / REAR DOOR	1499
17.6. REMOVAL / INSTALLATION OF TAIL GATE	1500
17.7. REMOVAL / INSTALLATION OF DOOR OUTER HANDLE	1501
17.8. REMOVAL / INSTALLATION OF DOOR INNER HANDLE	1502
17.9. REMOVAL / INSTALLATION OF DOOR LATCH	1503
17.10. REMOVAL / INSTALLATION OF WINDOW GLASS	1504
17.11. REMOVAL / INSTALLATION OF WINDOW WINDING REGULATOR	1505
17.12. REMOVAL / INSTALLATION OF DOOR MIRROR	1506
17.13. REMOVAL / INSTALLATION OF BONNET	1507
17.14. REMOVAL / INSTALLATION OF FENDER	1508
17.15. REMOVAL / INSTALLATION OF FRONT BUMPER	1509
17.16. REMOVAL / INSTALLATION OF REAR BUMPER	1510
17.17. REMOVAL / INSTALLATION OF FRONT SEAT	1511
17.18. REMOVAL / INSTALLATION OF REAR SEAT	1512
17.19. PROCEDURE FOR REMOVAL / ASSEMBLY OF SEAT BELT	1513
17.20. EXPLODED VIEW OF DASH BOARD	1514
17.20A. REMOVAL / INSTALLATION OF DASHBOARD	1515
17.21. EXPLODED VIEW OF INTERNAL TRIMS	1516
17.21A. REMOVAL / INSTALLATION OF ROOF LINING	1517
17.22. REMOVAL / INSTALLATION OF JUMP SEAT	1518
17.23. BODY MOUNTING LOCATIONS	1519
17.24. PROCEDURE FOR FIXING OF WIND SCREEN GLASS, SIDE FIXED GLASSES & TAIL GATE GLASS	1520
17.25. PROCEDURE FOR FIXING SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS	1521
17.26. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD TRIMS ON DOORS, BONNET SIDE PANELS AND REAR SIDE PANELS	1521
17.27. PROCEDURE FOR FIXING DOOR GLASS WEATHER STRIP AT ENDS (BOTTOM OF STYLING STRIP)	1522
17.28. PROCEDURE FOR FIXING HAND BRAKE CONSOLE GARNISH	1522
17.29. PROCEDURE FOR REFITMENT / REPLACEMENT OF SIDE PLASTIC MOULD (MODIFIED) TRIMS	1523
17.30. IMPORTANT BODY DIMENSIONS	1524
18. AIR BAGS	760
18.1. SCHEMATIC CIRCUIT DIAGRAM - SRS (SUPPLEMENTARY RESTRAINT SYSTEM)	763
18.2. WIRING HARNESS ROUTING - SRS (SUPPLEMENTARY RESTRAINT SYSTEM)	764
18.3. SAFARI OCCUPANT RESTRAINT SYSTEM	765
18.4. WORKING OF RPLL BELTS	766
18.5. SAFETY PRECAUTIONS	767
18.6. PROCEDURE FOR REMOVAL OF STEERING WHEEL, DRIVER AND CO-DRIVER AIR BAG MODULE	768
18.7. CO-DRIVER AIR BAG	769
18.8. PROCEDURE FOR INSTALLATION OF STEERING WHEEL, DRIVER & CO-DRIVER AIR BAG MODULE AND SEAT BELTS.	770
18.9. PROCEDURE FOR INSTALLATION AND REMOVAL OF COMBI-SWITCH, ADAPTOR PLATE & CLOCK SPRING.	771
18.10. SRS WARNING LAMP FAULT CODES	773
18.11. DIAGNOSTICS FOR AIR BAG (ORS) SYSTEM	775
18.12. SAFARI ERROR CODES LIST FOR AC4 (AIRBAG ECU)	780
18.13. INSPECTION, REPAIR AND REPLACEMENT REQUIRED IN SRS SYSTEM AFTER ACCIDENT	784
19. AIR CONDITIONING	785
19.1. SPECIFICATIONS	788
19.2. A/C SCHEMATIC DRAWINGS	789
19.3. BASIC COMPONENTS	795
19.4. AIR-CONDITIONING CONTROLS	797
19.5. MAGNETIC CLUTCH	799
19.6. VACUUM SOLENOID VALVE	800
19.7. DUAL PRESSURE SWITCH	801
19.8. ANTIFREEZING DEVICE	801
19.9. REMOVAL AND FITMENT OF A/C COMPONENTS	802
19.10. ROOF A/C UNIT	808
19.11. REFRIGERANT (R.134A)	811
19.12. COMPRESSOR OIL	812
19.13. SERVICE AND REPAIRS	813
19.14. CHARGING THE SYSTEM	816
19.15. TROUBLE SHOOTING	818
19.16. DO'S AND DON'TS	823
19.17. A/C CHECK UP POINTS	824

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