SERVICE MANUAL
GENERAL GENERAL
GENERAL
GENERAL INTRODUCTION This Section provides workshop practices and repair procedures for the TATA HEXA. The Procedures outlined in this manual provide focus on the specialized aspects of the vehicles, assuming the technician proficient in common workshop practices and repairs. Using this manual as a guide will assist in achieving a reputation for trusted workmanship. The section provides repair procedures / instructions for a components manufactured by a TATA MOTORS LTD and Some proprietary components. This section also provides important information such as a lubricant / fluid brands and types, vehicle specifications and the service and maintenance schedule.
GENERAL
GENERAL
GENERAL 1 2.1 VEHICLE SPECIFICATION Engine Model TATA 2.2L VARICOR Type Direct injection, Common rail, Turbocharged, Intercooled Diesel Engine No. Of Cylinders 4 inline Capacity 2179 cc Maximum Engine Output 1) 115 kW (156 Ps) @ 4000 +/- 100 rpm as per CMVR / 115 - (9) 1996 2) 110 kW (150 Ps ) @ 4000 rpm as per CMVR / 115 - (9) 1996 Maximum Torque 1) 400 Nm @ 1750 - 2500 rpm as per CMVR 115 - (9) 1996 2) 320 Nm @ 1500 – 3000 rpm as per CMVR 115 –(9) 1996 Transmission Model 1) G85, 6 Speed with overdrives 2) Auto Transmission 6 speed (6L50) 3) GBS-76 -5 speed/ 4.1, MK-II with overdrives Rear Axle Type ABS with LSD / ESP without LSD Steering Type Rack and Pinion steering with power assistance (Hydraulic). Brakes Service Brake Vacuum assisted independent hydraulic brakes on front & rear through tandem master cylinder. Vacuum pump camshaft driven Front Brakes Ventilated disc brakes with twin pot caliper Rear Brake Disc brake - single pot caliper with DIH Anti-lock Braking System (ABS) 4 channel , 4 sensors (For ABS) Electronic Stability Program (ESP) 4 Channel, 4 Sensors & Other Sensors Parking Brake Lever type, Console mounted, Cable operated mechanical linkage acting on Rear wheels through DIH.
GENERAL 2 Frame Type Ladder type cranked frame with Box section members and welded cross members Suspension Front Double wishbone type with coil springs over Shock Absorber Rear Coil spring type 5 link rigid axle suspension Shock Absorber Hydraulic double acting telescopic at Front & Rear Anti-roll Bar At both front & rear Wheels & Tyres Tyres Passenger Radial, Tubeless. 1) 235/55 R19 (105 T) 2) 235/70 R16 (105 S) Wheel Rims 1) 7.5J X 19 Alloy 2) 6.5J X 16 Stylized Steel No. of Wheels Front : 2 Rear : 2 Spare : 1 Fuel Tank Capacity 60 Litres Electrical System System Voltage 12 Volts (-ve earth) Alternator Capacity 155 amps Battery 12V, 75Ah/80Ah 20 Hrs Performance Max. Speed at rated GVW 1) 170 kmph 2) 180 kmph Grade Restartability (at rated GVW) 43% Max. gradeability (at rated GVW) 61%
GENERAL 3 Passenger Capacity Passenger Capacity Front Seat: Driver + 1, Middle Seat: 3 (Bench Seat, 60:40) or 2 (Captain Seats) Rear Seat: 2 (Front Facing) Luggage Space Net inside loading space ~ 1000 mm wide x ~ 800 mm long (with 4 passengers + Driver) Weights (Kg) Variants Gross Vehicle Weight (GVW) Kerb Weight XM 4x2 (7 seater) 2738 2113 XM 4x2 (6 seater) 2719 2094 XT 4x2 (7 seater) 2806 2181 XT 4x2 (6 seater) 2787 2162 XT 4x4 (7 seater) 2905 2280 XT 4x4 (6 seater) 2886 2261 XMA 4x2 (7 Seater) 2755 2130 XMA 4x2 (6 Seater) 2736 2111 XMA 4x4 (7 Seater) 2855 2230 XMA 4x4 (6 Seater) 2836 2211 XTA 4x2 (7 Seater) 2800 2175 XTA 4x2 (6 Seater) 2781 2156 XE 4x2 (7 Seater) 2738 2113 XE 4x2 (6 Seater) 2719 2094 Main Chassis Dimension as per ISO:612 In mm Wheel Base 2850 Track Front 1) 1590 (with 19” tyres) 2) 1580 (with 16” tyres) Track Rear 1) 1560 (with 19” tyres) 2) 1550 (with 16” tyres) Overall Length 4788 over rear bumper Overall Height 1785 Max. Width 1900 Ground Clearance 1) 209 mm (unladen - with 19” tyres) 2) 200 mm (unladen - with 16” tyres)
GENERAL 4 2.2 VEHICLE DIMENSIONS
GENERAL 5 2.3 RECOMMENDATIONS Lamp Condensation/Fogging Condition- Condensation is a natural phenomenon in Lamps. This occurs mainly because of atmospheric condition/weather change. During normal condensation, thin film of mist is visible on the inside surface of the exterior plastic lens. Generally, this condition is considered normal & can be eliminated by turning on the Headlamp with engine running or during normal driving conditions. Note: Headlamp fogging/condensation is a natural occurrence & Headlamp assembly replacement will not be necessary to resolve the issue. High pressure washer jet direct on vent systems of lamp are not recommended, there might be possibility to water ingress causing heavy fogging. 2.3.1 REPAIRS AND REPLACEMENT The following precaution and practices should be followed in order to reduce risk and conduct efficient and correct repair. 1. Go through the precaution and general information section given for that particular system or repair in this Workshop Manual. 2. Only TATAGENUINE SPARE PARTS should be used. Similar parts of other models should not be used, unless they have the same part number. 3. Do not use standard tools where special tools are recommended. 4. Whenever any hose is disconnected attach a tag to identify it. 5. Plug the ports, plugs and other openings of aggregates like FIP, TMC, etc. when remove from the vehicle. 6. When an assembly is dismantled, all reusable parts should be arranged in the sequence of its assembly in a clean enameled tray, in order to facilitate the assembly. 7. Do not use jack to lift the vehicle for any jobs to be carried out beneath the vehicle, always use lifts. 8. Disconnect the battery before conducting any repairs. OIL SEALS NOTE Ensure that the seal is free from pits, scores, corrosion and general damage prior to fitting replacement seal. 1. Always replace oil seals when rebuilding an assembly. 2. Carefully examine seal before fitting to ensure that it is clean and undamaged. 3. Coat the sealing lips with clean grease; pack dust excluder seals with grease. 4. Ensure that seal spring, if provided, is correctly fitted. 5. Place lip of seal towards fluid to be sealed and slide into position on shaft, using a fitting sleeve (5) when possible to protect sealing lip from damage by sharp corners, threads or splines. If the fitting sleeve is not available, use plastic tube or tape to prevent damage to sealing lip. 6. Grease outside diameter of seal, place on the housing and press into position, using great care and if possible a ’bell piece’ (6) to ensure that seal is not tilted. In some cases, it may be preferable to fit seal to housing before fitting to shaft. Never let weight of unsupported shaft rest in seal.
GENERAL 6 7. If correct service tool is not available, use a suitable drift approximately 0.4 mm (0.015 in) smaller than outside diameter of seal. Use a hammer VERY GENTLY on drift if a press is not suitable. 8. Press or drift seal in to depth of housing if housing is shouldered or flush with face of housing where no shoulder is provided. Ensure that the seal does not enter the housing in a tilted position. NOTE Most cases of failure or leakage of oil seals are due to careless fitting, and resulting damage to both seals and sealing surfaces. Care in fitting is essential if good results are to be obtained. Never use a seal which has been improperly stored or handled, such as hung on a hook or nail. BEARINGS BALL AND ROLLER BEARINGS ! CAUTION Never refit a ball or roller bearing without first ensuring that it is in good condition. 1. Remove all traces of lubricant from bearing under inspection by washing in a suitable degreaser; maintain absolute cleanliness throughout operations. 2. Inspect visually for markings of any form on rolling elements, raceways, outer surface of outer rings or inner surface of inner rings. Reject any bearings found to be marked, since any marking in these areas indicates onset of wear. 3. Holding inner race between finger and thumb of one hand, spin outer race and check that it revolves absolutely smoothly. Repeat, holding outer race and spinning inner race. 4. Rotate outer ring gently with a reciprocating motion, while holding inner ring; feel for any check or obstruction to rotation, and reject bearing if action is not perfectly smooth. 5. Lubricate bearing generously with lubricant appropriate to installation. 6. Inspect shaft and bearing housing for discoloration or other marking suggesting that movement has taken place between bearing and seating. (This is particularly to be expected if related markings were found in point 2). 7. Ensure that shaft and housing are clean and free from burrs before fitting bearing. 8. If one bearing assembly of a pair shows an imperfection it is generally advisable to replace both with new bearings; an exception could be made if the faulty bearing had covered a low mileage, and it could be established that damage was confined to it only. 9. When fitting bearing to shaft, apply force only to inner ring of bearing, and only to outer ring when fitting into housing, as shown above. 10.In the case of grease lubricated bearings (e.g. hub bearings) fill space between bearing and outer seal with recommended grade of grease before fitting seal. 11. Always mark components of separable bearings (e.g. taper roller bearings) in dismantling, to ensure correct reassembly. Never fit new rollers in a used outer ring, always fit a complete new bearing assembly.
GENERAL 7 2.4 GENERAL INFORMATION 2.4.1 ABBREVIATIONS USED IN THIS MANUAL The following abbreviations can be seen in this manual: ABBREVIATIONS DESCRIPTION ABS Antilock Braking System CMC Clutch Master Cylinder CSC Clutch Slave Cylinder DAB Driver Air Bag EDC Engine Drag Control ESP Electronic Stability Program FAD Front Axle Disconnect HBA Hydraulic Brake Assist HLA Hydraulic Lash Adjuster PAB Passenger Air Bag RAP Rack and Pinion SRS Supplementary Restraint System TCS Traction Control System TMC Tandem Master Cylinder TOD Torque On Demand VIN Vehicle Identification Number 2.4.2 VEHICLE IDENTIFICATION NUMBER (VIN) The vehicle identification number can be spotted at two locations. The locations are given below: The VIN number plate is located on the wiper motor mounting panel. Same number is punched on Chassis long member. VIN PLATE LOCATION The VIN plate is mounted on the wiper motor mounting bracket. The plate is riveted with the panel at the RHS side. VIN PUNCHED LOCATION The same VIN number is also punched on the RHS long member of the chassis between the third and fourth body mounting bracket from the front end.
GENERAL 8 2.5 VEHICLE JACKING AND LIFTING POINTS !! WARNING Using Jacking brackets for lifting vehicle on 2 post is not advisable as width of bracket is less. It is recommended to use long member bottom area adjacent to jack brackets indicated below for lifting vehicle using 2 posts. FOR 4X2 VEHICLE The 4X2 vehicle is fitted with four jacking brackets on the long member as marked in the below figure as 1 and vehicle lifting points on the long member are marked as 2. FOR 4X4 VEHICLE The 4X4 vehicle is having two jacking brackets at the rear and can be directly jacked up in the front end at the long members marked as 1. Similarly, the vehicle lifting points on the long members are marked as 2. NOTE In case of 4X4 vehicle the front jacking and vehicle lifting points are at the same point on the long member.
GENERAL 9 2.6 SPARE WHEEL REPLACEMENT 1. Open the tail gate and open the load cover and t take out the tools tray. 2. Take out the spare wheel arrestor by pulling it upwards. 3. Pull out the rear tow hook cover and remove the same. 4. Insert the spare wheel handle with extension through the window. Rotate the handle anticlockwise to lower the spare wheel till it rests on the ground. 5. Remove the holding bracket from the spare wheel and separate the same from the vehicle. 2.7 EMERGENCY TOWING INFORMATION For towing, the best way is to use a wrecker (A vehicle used to tow away broken-down vehicles); alternatively, a rigid tow bar can be used. Avoid using a flexible cable or rope as your vehicle may crash into the towing vehicle when it stops suddenly. In addition, do the following: 1. Release parking Brakes. 2. Shift the gear to neutral. 3. Switch ‘ON’ the hazard warning signals of both the vehicles to warn other road users. 4. Wherever possible, keep engine running so that power steering assistance and brake vacuum are available. 5. Limit the speed to 20-30 Kmph. 6. In case of brake failure, use the parking brake to control the vehicle. NOTE Towing procedure for Automatic Transmission vehicle with Drained or Disconnected Battery “is mentioned in Automatic Transmission section. If the vehicle needs to be towed, call professional towing service If it is not possible to shift the gear to neutral, then disconnect the propeller shaft and remove it before towing. If it is not possible to shift the transmission or start the engine or if the wheels are jammed, the vehicle must be transported on flat bed truck, where the vehicle is loaded into the back of a truck. ! CAUTION Trying to lift or tow the vehicle by bumpers will cause serious damage. The bumpers are not designed to support the vehicle’s weight.
GENERAL 10 2.8 JUMP STARTING A jump start or boost is a term for a method of starting a vehicle which has a ‘dead’ (discharged) battery. A second battery (often in another vehicle) is temporarily connected to the dead battery, to provide the initial charge required to start the engine. Once the engine is running, it will recharge the dead battery, so the second battery can be detached. However, if the engine stops running too soon, the battery may not have built up enough charge to restart the engine, so a further jump start may be required. Most vehicles use a 12-volt battery which provides power to a starting motor for the engine. When the engine is running, electrical power from its alternator restores the charge to the battery in preparation for the next start. When a battery is discharged, such as by accidentally leaving the headlights switched on when parked, the vehicle’s engine will not "start/crank" when the ignition key is turned. !! WARNING Do not allow battery electrolyte to come in contact with eyes, skin, fabrics or painted surfaces. The fluid contains sulphuric acid which can cause injury and severe damage. Wear rubber gloves, to avoid risk of contacts. INSTRUCTIONS 1. Make sure that battery providing jump start has the same voltage as the battery in the vehicle (12V). The voltage and capacity are given in the battery. 2. Pull a vehicle with a charged battery next to the vehicle with the dead battery, situating the two batteries as close together as possible without allowing the two vehicles to touch. 3. Keep the engine with good battery off and all connection turned off. Similarly switch off all electrical accessories of the vehicle with dead battery. 4. The connection of –ve lead point should be kept as far as possible away from the discharged battery and close to the starter motor. 5. Attach a positive jumper cable clamp to the positive terminal (the one with the plus sign) of the charged battery. 6. Connect the other red-handled clamp to the positive terminal of the dead battery. 7. Attach the black/negative cable to the vehicle with the dead battery; clamp it somewhere where the current can ground out, such as a bolt or bracket on the engine. You can also attach it to any metal, unpainted part of the vehicle's frame. 8. Ground the other black/negative cable on the charging vehicle, as described in the previous step. NOTE Care should be taken as there is possibility of spark to be produced. 9. Attempt to start the vehicle that has the dead battery should be made at the intervals of one minute and should not last more than 15 sec. 10.After starting, allow both engines to idle for approximately 3 minutes with the leads still connected. 11.Once the dead vehicle is running, remove the clamps one at a time in reverse order. 12.Allow the jump-started vehicle to run for half an hour in order to charge the battery. It will charge whether driving or idling. !! WARNING Avoid connecting of negative terminal battery of the dead battery directly to the negative terminal of the good battery as there are chances of battery explosion. The voltage from a vehicle battery is dangerous whether the engine is running or not. Do not touch the metal ends of the jumper cables with your hands, nor touch them to each other. Never grasp both battery terminals at the same time. NOTE Always check your owner’s manual before jumpstarting a vehicle. Some new vehicles have special 'jump-start lugs' where jumper cables are attached rather than to the battery cables. These allow the potentially damaging surge of current to bypass the electrical system (and all those fancy, new onboard computers). If the dead vehicle won't respond, there might be a problem in another part of the ignition system. Consult a mechanic. ! CAUTION Sometimes starting or running the charged vehicle while jump-starting the dead one can release a power surge into the charging vehicle and blow a fuse, damage the alternator, or harm other areas of the electrical system.
GENERAL 11 2.9 SERVICE AND MAINTENANCE SCHEDULE Sr. No. Operation Frequency (Kms) PDI 5,000-5,500 10,000-10,500 20,000-20,500 30,000-30,500 40,000-40,500 50,000-50,500 60,000-60,500 70,000-70,500 80,000-80,500 90,000-90,500 1,00,000-1,00,500 Months - 3 6 12 18 24 30 36 42 48 54 60 General 1 Wash the vehicle & clean the condenser with compressed air. Every Service ● ● ● ● ● ● ● ● ● ● ● ● 2 Check & Top up Fluids if required: Engine oil, Coolant, Brake/ Clutch Fluid, Battery Electrolyte, Power Steering Oil, Gear Box Oil, Transfer case (if applicable) & Front Axle 4X4 (if applicable) / Rear Axle Oil Every 10,000 or 6 Months ● ● ● ● ● ● ● ● ● ● 3 Drain water accumulated in Fuel Pre filter cum sedimenter and fuel filter (OR whenever the Warning lamp glows) Every Service ● ● ● ● ● ● ● ● ● ● ● ● 4 Check engine compartment for loose fasteners and for any leakages in fuel lines, coolant hoses, air hoses, vacuum hoses and hydraulic line connections. Attend if necessary. Every Service ● ● ● ● ● ● ● ● ● ● ● ● 5 Check Underbody for loose fasteners and for any damage or leakage in fuel pipes, hydraulic line connections, rack & pinion & exhaust system including rubber hangers. Attend if necessary. Every Service ● ● ● ● ● ● ● ● ● ● ● ●
GENERAL 12 Sr. No. Operation Frequency (Kms) PDI 5,000-5,500 10,000-10,500 20,000-20,500 30,000-30,500 40,000-40,500 50,000-50,500 60,000-60,500 70,000-70,500 80,000-80,500 90,000-90,500 1,00,000-1,00,500 Months - 3 6 12 18 24 30 36 42 48 54 60 6 Apply grease on door latches, locks, check straps, strikers, bonnet opening lever, bonnet hinges & lock plate, tailgate hinges & door lock inner ratchet. Every 10,000 or 6 Months ● ● ● ● ● ● ● ● ● ● 7 Check for proper tightening of Door latch & Striker screws, Tail gate latch and striker screws Every 10,000 or 6 Months ● ● ● ● ● ● ● ● ● ● 8 Check & ensure normal working of the vehicle using diagnostic equipment. Every Service ● ● ● ● ● ● ● ● ● ● ● ● 9 Reset the Service interval in Instrument Cluster Every 10,000 or 6 Months ● ● ● ● ● ● ● ● ● ● 2.2L Varicor Engine 1 Replace Engine Oil and Oil filter (Every 20,000 Km OR 1 year whichever is earlier) Every 20K or 12 months ● ● ● ● ● 2 Replace element / cartridge of Prefilter cum Sedimenter (Every 20,000 Km OR 1 year whichever is earlier) Every 20K or 12 months ● ● ● ● ● 3 Change Main Fuel filter (Every 60,000 Km OR 3 years whichever is earlier) Every 60K or 36 months ●
GENERAL 13 Sr. No. Operation Frequency (Kms) PDI 5,000-5,500 10,000-10,500 20,000-20,500 30,000-30,500 40,000-40,500 50,000-50,500 60,000-60,500 70,000-70,500 80,000-80,500 90,000-90,500 1,00,000-1,00,500 Months - 3 6 12 18 24 30 36 42 48 54 60 4 Change Air filter element (Every 40,000 Km OR 2 years whichever is earlier) Every 40K or 24 months ● ● 5 Check accessory Drive belts ( Alternator & Compressor ) adjust tension if required, change if damaged (Every 10,000 Km OR 1 years whichever is earlier) Every 10K or 12 months ● ● ● ● ● ● ● ● ● ● 6 Replace Timing Belt & Timing Belt tensioner Every 1,50,000 kms OR 5 years/60 months whichever is earlier 7 Change Engine Coolant (Every 60,000 km OR 3 year / 36 months whichever is earlier) Every 60K or 36 months ● 8 Check Accessory drive for Power Steering Pump. Change if damaged (Every 10,000 km OR 1 year, whichever is earlier) Every 10K or 12 months ● ● ● ● ● ● ● ● ● ● Gear Box 1 Replace Gear Box Oil and Clean Breather (Manual Transmission -- if applicable) (First at 40,000 km OR 2 years and thereafter every 90,000 km OR 5 years whichever is earlier ) Every 90K or 5 Years ●
GENERAL 14 Sr. No. Operation Frequency (Kms) PDI 5,000-5,500 10,000-10,500 20,000-20,500 30,000-30,500 40,000-40,500 50,000-50,500 60,000-60,500 70,000-70,500 80,000-80,500 90,000-90,500 1,00,000-1,00,500 Months - 3 6 12 18 24 30 36 42 48 54 60 2 Clean Breather of 6L550 - Automatic Transmission Every 10000 or 6 months ● ● ● ● ● ● ● ● ● ● 3 Change Gearbox Oil (6L550 - Automatic Transmission) (If applicable) Filled for life time 4 Change oil in TOD (For 4X4 Only - if applicable) Filled for life time Propeller Shaft 1 Grease propeller shaft with grease gun (at slip joint - splines end) & check Centre bracket mounting bolts for looseness. Tighten if necessary. Every 10,000 or 6 months ● ● ● ● ● ● ● ● ● ● 2 Check for rubber cracks on Torsional Vibration Damper (TVD), replace if necessary Every 10,000 or 6 months ● ● ● ● ● ● ● ● ● ● 3 Change TVD (Every 60,000 km) or 3 Years whichever is earlier Every 60,000 or 3 Years ● Front Axle (For 4x4) / Rear Axle 1 Replace Axle Oil ( Front (For 4x4) (if applicable)/ Rear) (Every 80,000 km OR 4 years / 48 months whichever is earlier) Every 80,000 or 4 Years ● 2 Clean Breather in front (for 4x4) (if applicable) and Rear axle Every 10,000 or 6 months ● ● ● ● ● ● ● ● ● ●
GENERAL 15 Sr. No. Operation Frequency (Kms) PDI 5,000-5,500 10,000-10,500 20,000-20,500 30,000-30,500 40,000-40,500 50,000-50,500 60,000-60,500 70,000-70,500 80,000-80,500 90,000-90,500 1,00,000-1,00,500 Months - 3 6 12 18 24 30 36 42 48 54 60 Suspension & Steering 1 Check wheel alignment/ Steering wheel spoke alignment/ wheel balancing & adjust if necessary Every 20,000 or 12 months ● ● ● ● ● 2 Check shock absorber and rubber bushes. Replace if necessary (First at 30,000 km and thereafter at every service) Every Service ● ● ● ● ● ● ● ● 3 Check condition of rubber bushes in Top & Lower wishbones, coil spring rubber seat, Anti roll bars, Rear links, Pan-hard rod, rubber boots/dust cover/ bellow in Rack & pinion, steering ball joints & column, Suspension Ball Joints Replace if necessary. Every 30,000 or 18 months ● ● ● 4 Replace Power steering Oil & filter element (Every 1,00,000 OR 3 years, whichever is earlier) Every 1,00,000 or 3 Years ● Brakes 1 Check parking brakes, adjust if necessary Every Service ● ● ● ● ● ● ● ● ● ● ● 2 Check front brake & rear brake pads, regrease DIH liner resting points. Replace if necessary. Every 10,000 or 6 months ● ● ● ● ● ● ● ● ● ●
GENERAL 16 Sr. No. Operation Frequency (Kms) PDI 5,000-5,500 10,000-10,500 20,000-20,500 30,000-30,500 40,000-40,500 50,000-50,500 60,000-60,500 70,000-70,500 80,000-80,500 90,000-90,500 1,00,000-1,00,500 Months - 3 6 12 18 24 30 36 42 48 54 60 3 Replace Brake Fluid (Every 40,000 km or 2 years/24 months whichever is earlier) Every 40,000 or 24 months ● ● Electricals 1 Check headlamp focusing & functioning of all electrical equipment’s Every 20,000 or 12 months ● ● ● ● ● 2 Check for looseness of + Ve Terminals on Alternator and Starter motor Every 30,000 or 18 months ● ● ● AC System 1 Check HVAC System for satisfactory performance, attend if required. Every Service ● ● ● ● ● ● ● ● ● ● ● ● 2 Check and Clean A.C Filter Every 20,000 or 12 months ● ● ● ● ● Wheel & Tyres 1 Tyre Rotation Every 10,000 or 6 months ● ● ● ● ● ● ● ● ● ●
GENERAL 17 Additional Maintenance Schedule under Severe Driving Conditions Sr. No. Operation Frequency Condition A B C D 1 Engine oil and oil filter Change every 10,000 kms OR 6 months ● ● ● ● 2 Air filter element Change at every 20,000 km or 18 months whichever is earlier ● ● 3 Front (For 4X4) & rear axle oil change Change at first 20,000 kms (18 months) & thereafter at 50,000 kms (36 months) ● ● ● A - Driving in conditions such as Patrolling, Taxi, Pickup Van, Vehicle Towing, with Trailer Towing B - Driving on Dusty / Sandy roads C - Frequently operating in mountainous area D - More than 50% (in terms of kms) driving in heavy city traffic NOTE: In case of emergency, a large amount of water without engine coolant may be added in order to reach a vehicle service location.
GENERAL 18 3.0 LUBRICANTS, FLUIDS AND CAPACITIES 3.1.1 LUBRICANTS ENGINE OIL Recommended grade of engine oil confirming to API CI4 Plus, (SAE 15W-40) or higher grade engine oil to be used. Specification and range of ambient temperature at which these can be used are given in the table below: Ambient temp. in ºC Engine oil grade -5 and above SAE 15W40 -10 to 0 SAE 5W30 -20 to -10 SAE 0W30 COOLANTS Presence of dirt in coolant chokes up passages in radiator, cylinder head and crankcase, thereby causing overheating of engine. To prevent rust formation and freezing of coolant inside the passages of radiator, crankcase and cylinder head use premixed coolant as recommended. It is recommended that the entire cooling system should be drained and filled with fresh premixed coolant. 3.1.2 RECOMMENDED LUBRICANTS AND FLUID CAPACITIES Item Specification Company and Brand Qty. ENGINE OIL API CI4 Plus, (SAE 15W-40) EXXON MOBIL Super Diesel 15W40 CI-4 Plus 7.5 Litres PETRONAS TATA MOTORS Genuine Oil - Engine Oil CI4+ 15W40 HPCL HP Milcy CI4+ Tata Motors Genuine oil IOCL Servo Tata Motors Genuine oil CI4 Plus COOLANT 40:60 ratio Premixed Sunstar Tata Motors Genuine Coolant 2200 Approx. 9 Litres IOCL Servo Tata Motors Genuine Coolant 4060 GEAR BOX G-85 G-76 Synthetic gear oil 75W90 GL4 HPCL HP GO XP 75W90 Tata Motors Genuine Oil G85- 3.25 Litres G76- 2.2 Litres Castrol SYNTRO 75W90 GL4 IOCL Servo Tata Motors Genuine Gear Oil - 75W 90 EXXON MOBIL MOBILUBE 1 SHC 75 W 90 Automatic Transmission (6L50) ATF DEXRON-VI EXXON MOBIL IMP 6544 MOBIL DEXRON-VI Approx. 11.4 Litres TOD -- SHELL Spirex S3 ATF MD3 1.2 - 1.4 Litres
GENERAL 19 Item Specification Company and Brand Qty. POWER STEERING OIL ATF-DEXRON IID Castrol ATF DEX III 1.6 Litres HPCL HP ATF DEX III Tata Motors GENUINE OIL IOCL Servo Tata Motors Transdex III EXXON MOBIL ATF 220 REAR AXLE (Limited Slip Differential) 85W140 API-GL5 Anglomol 6043 HPCL HP Gear Oil XP 85W140 Tata Motors Genuine Oil 1.8 Litres and 0.09 Litres (For friction modifier) CASTROL Extra Long Life Rear Axle Oil 85W140 PETRONAS TATA MOTORS Genuine Oil - Axle Oil 85W140 IOCL Servo Tata Motors Genuine Axle Oil - 85W 140 REAR AXLE (Standard Differential) 85W140 API-GL5 Anglomol 6043 HPCL HP Gear oil XP 85W140 Tata Motors Genuine Oil 1.8 Litres CASTROL Extra Long Life Rear Axle Oil 85W140 PETRONAS TATA MOTORS Genuine Oil - Axle Oil 85W140 IOCL Servo Tata Motors Genuine Axle Oil - 85W 140 LIVE FRONT AXLE 85W140 API-GL5 Anglomol 6043 HPCL HP Gear oil XP 85W140 Tata Motors Genuine Oil 1.50 Litres CASTROL Extra Long Life Rear Axle Oil 85W140 PETRONAS TATA MOTORS Genuine Oil - Axle Oil 85W140 IOCL Servo Tata Motors Genuine Axle Oil - 85W 140 BRAKE / CLUTCH FLUID SAE J 1703, DOT 4 S-CCI Golden Cruiser Tata Genuine Brake Fluid (DOT4) As required CASTROL Brake fluid DOT 4 Petronas TUTELA Brake Fluid TOP 4 TM
GENERAL 20 3.1.3 RECOMMENDED FUEL High Speed diesel conforming to IS1460 or EN 590 or equivalent is recommended to be used as fuel. At very low temperature, fluidity of diesel may become insufficient due to paraffin separation. It is therefore necessary to mix supplementary fuel with summer or winter grade diesel. The supplementary fuel to be used is kerosene or aviation turbine fuel. Ratio for mixing of supplementary fuel and diesel are shown in the table. Outside ambient Temp up to ºC Percentage (%) Summer Grade Diesel Supplementary Fuel Upto 0ºC 100 0 0 ºC to - 10 ºC 70 30 -10 ºC to -15 ºC 50 50 Care should be taken that the diesel and supplementary fuel are thoroughly mixed before filling. Outside ambient Temp up to ºC Percentage (%) Winter Grade Diesel Supplementary Fuel Upto -15ºC 100 0 -15 ºC to - 20 ºC 70 30 -20 ºC and above 50 50 !! WARNING Do not mix gasoline or alcohol with diesel. This mixture can cause explosion. 3.2 GENERAL FITTING REMINDERS 3.2.1 WORKSHOP SAFETY Refer the Section Precautions for Workshop Safety related advises and directions. 3.2.2 PREPARATION 1. Clean components and surrounding area prior to removal. 2. Plug off any openings exposed by component removal using greaseproof paper and masking tape. 3. Immediately block fuel, oil or hydraulic lines when separated, using plastic caps or plugs, to prevent loss of fluid and entry of dirt. 4. Close open ends of oil-ways, exposed by component removal, with tapered hardwood plugs or readily visible plastic plugs. 5. Once a component is removed, place it in a suitable container; use separate containers for each component and its associated parts. 6. Before dismantling a component, clean it thoroughly. 7. Clean bench and keep labels, markers ready before dismantling. 3.2.3 DISMANTLING 1. Observe cleanliness when dismantling components, particularly when brake, fuel or hydraulic system parts are being worked on. A particle of dirt or a cloth fragment could cause a dangerous malfunction if trapped in these systems. 2. Blow out all tapped holes, crevices, oil-ways and fluid passages with an air line. Ensure that any “O-rings” used for sealing are correctly replaced or renewed, if disturbed. 3. Use marking ink to identify mating parts, to ensure correct reassembly. If a centre punch or scriber is used, they may initiate cracks or distortion of components. 4. Wire together mating parts where necessary to prevent accidental interchange (e.g. roller bearing components). 5. Wire labels on to all parts which are to be renewed, and to parts requiring further inspection before being passed for reassembly; place these parts in separate containers from those containing parts for rebuild. 6. Do not discard a part due for renewal until it has been compared with the new part, to ensure that its correct replacement has been obtained.
GENERAL 21 3.2.4 GENERAL INSPECTION 1. Never inspect a component for wear or dimensional check unless it is absolutely clean; a slight smear of grease can conceal a failure. 2. When a component is to be checked dimensionally against figures quoted for it, use correct equipment (surface plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift checking equipment can be dangerous. 3. Reject a component if its dimensions are outside limits quoted, or if damage is apparent. A part may, however, be refitted if its critical dimension is exactly limit size, and is otherwise satisfactory. 4. Use ’Plastigauge’ for checking bearing surface clearances. Directions for its use and a scale giving bearing clearances in 0.0025 mm steps are provided with it. 3.2.5 JOINTS AND JOINT FACES 1. Always use correct gaskets where they are specified. 2. Use jointing compound only when recommended. Otherwise fit joints dry. 3. When jointing compound is used, apply in a thin uniform film to metal surfaces; take great care to prevent it from entering oil-ways, pipes or blind tapped holes. 4. Remove all traces of old jointing materials prior to reassembly. Do not use a tool which could damage joint faces. 5. Inspect joint faces for scratches or burrs and remove with a fine file or oil stone; do not allow removed material or dirt to enter tapped holes or enclosed parts. 6. Blow out any pipes, channels or crevices with compressed air, fit new ’O’ rings or seals displaced by air blast. 3.2.6 FLEXIBLE HYDRAULIC PIPES, HOSES 1. Before removing any brake or power steering hose, clean end fittings and area surrounding them as thoroughly as possible. 2. Obtain appropriate plugs or caps before detaching hose end fittings, so that ports can be immediately covered to exclude dirt. 3. Clean hose externally and blow through with airline. Examine carefully for cracks, separation of plies, security of end fittings and external damage. Reject any hose found faulty. 4. When refitting hose, ensure that no unnecessary bends are introduced, and that hose is not twisted before or during tightening of union nuts. 5. Containers for hydraulic fluid must be kept absolutely clean. 6. Do not store brake fluid in an unsealed container. It will absorb water, and fluid in this condition would be dangerous to use due to a lowering of its boiling point. 7. Do not allow brake fluid to be contaminated with mineral oil, or use a container which has previously contained mineral oil. 8. Do not re-use brake fluid bleed from system. 9. Always use clean brake fluid to clean hydraulic components. 10. Fit a cap to seal a hydraulic union and a plug to its socket after removal to prevent ingress of dirt. 11. Absolute cleanliness must be observed with hydraulic components at all times. 12. After any work on hydraulic systems, inspect carefully for leaks underneath the vehicle while a second operator applies maximum pressure to the brakes (engine running) and operates the steering.
ENGINE ENGINE 320Nm
ENGINE INTRODUCTION The 2.2 L VARICOR engine used on this vehicle is a state of art modern Direct Injection Common Rail diesel unit. This engine is using twin overhead camshafts and 16 valves which help in good breathing. Delphi common rail diesel injection system with 1600 bar injection pressure is used and controlled by a fast 32-bit electronic control unit. The engine performance is optimized for various engine speed, load and operating conditions depending upon the various sensors input. The turbocharger (VTT) used on this engine works on Variable Turbine Technology (VTT) has low inertia of turbine and compressor wheels which reduce the turbo lag at low engine speeds and improves the transient response of the vehicle. This turbocharger incorporates many movable vanes in the turbine housing to control the exhaust flow against the turbine blades which enables higher power, torque, lower fuel consumption and emissions of the engine. The actuation of the vane angle is done electrically by the EMS The fuel economy and emission has been optimized at source by means of low engine friction, faster engine warm up, centralized injectors, optimized combustion, closed coupled catalytic converter, closed loop operation of the turbocharger (VTT) etc. Hydraulic Lash Adjusters and Roller Finger Followers are used for maintenance free quiet operation and reduced friction. Toothed belt drive with automatic belt tensioner is used for quiet engine operation for longer period. The engine NVH is optimized by means of optimized engine mounts, multiple injection strategy etc. The engine weight has been optimized by using Aluminum cylinder head, gallery cooled piston, non-linered cylinder block with spherical skirt, superior alloy material for high strength. The CCC (Close Coupled Catalytic Converter) is fitted in this vehicle to further reduce the emissions. The CCC filters harmful carbon particles before they leave the exhaust.
ENGINE CONTENTS 1.1. GENERAL INFORMATION A ENGINE INTRODUCTION.................................................................................................................... 1 B TECHNICAL SPECIFICATION ............................................................................................................. 2 C RECOMMENDED LUBRICANTS AND FLUID CAPACITIES............................................................... 3 D SERVICE SCHEDULE.......................................................................................................................... 4 E ASSEMBLY CLEARANCES ................................................................................................................. 5 F SPECIAL TOOLS.................................................................................................................................. 6 1.2. GENERAL SYMPTOMS DIAGNOSIS................................................................................... 8 1.3. CONSTRUCTIONAL AND SERVICE DETAILS A ENGINE MOUNTING COMPONENTS............................................................................................... 11 B CYLINDER HEAD AND COVER ........................................................................................................ 13 C LUBRICATION SYSTEM COMPONENTS ......................................................................................... 15 D ENGINE .............................................................................................................................................. 17 E OIL SUMP ........................................................................................................................................... 19 F CYLINDER HEAD ............................................................................................................................... 21 G SPECIAL INSTALLATION .................................................................................................................. 23 H EXHAUST SYSTEM COMPONENTS ................................................................................................ 25 I INTAKE SYSTEM COMPONENTS .................................................................................................... 27 J ENGINE SUSPENSION...................................................................................................................... 29 K MOVING PARTS................................................................................................................................. 31 L ENGINE TIMING................................................................................................................................. 33 M FUEL INJECTION EQUIPMENT ........................................................................................................ 35 1.4. ENGINE TESTS AND MAINTENANCE A PRELIMINARY INSPECTION............................................................................................................. 37 B ENGINE TESTS.................................................................................................................................. 37 C REGULAR MAINTENANCE i ENGINE OIL REPLACEMENT....................................................................................................... 40 ii OIL FILTER REPLACEMENT ........................................................................................................ 40
ENGINE iii AIR FILTER ELEMENT CLEANING AND REPLACEMENT ......................................................... 41 iv MAIN FUEL FILTER REPLACEMENT .......................................................................................... 41 v DRAINING WATER FROM PRE-FILTER CUM SEDIMENTOR ................................................... 42 vi PRE-FILTER CUM SEDIMENTOR REPLACEMENT.................................................................... 43 vii PRE-FILTER CARTRIDGE REPLACEMENT................................................................................ 44 viii COOLANT REPLACEMENT.......................................................................................................... 48 1.5. REPAIR AND INSPECTION DETAILS A TIMING BELT...................................................................................................................................... 49 B FUEL TANK ........................................................................................................................................ 49 C CYLINDER HEAD ............................................................................................................................... 50 D VALVES .............................................................................................................................................. 51 E VALVE SEATS.................................................................................................................................... 52 F CRANKCASE...................................................................................................................................... 53 G VALVE SEAT INSERT ........................................................................................................................ 54 H HYDRAULIC LASH ADJUSTER......................................................................................................... 54 I CYLINDER HEAD COVER ................................................................................................................. 54 J VALVE GUIDES.................................................................................................................................. 55 K CAMSHAFT ........................................................................................................................................ 56 L PISTON AND PISTON RINGS ........................................................................................................... 57 M CONNECTING ROD ........................................................................................................................... 58 N CRANKSHAFT.................................................................................................................................... 60 1.6. ENGINE SYSTEM A AIR INTAKE SYSTEM ........................................................................................................................ 62 B BLOW BY SYSTEM............................................................................................................................ 64 C VACUUM MANAGEMENT SYSTEM.................................................................................................. 65 D COOLING SYSTEM............................................................................................................................ 67 E LUBRICATION SYSTEM .................................................................................................................... 70 F FUEL SYSTEM ................................................................................................................................... 74 G EXHAUST SYSTEM ........................................................................................................................... 83 H EXHAUST GAS RECIRCULATION SYSTEM .................................................................................... 86
ENGINE 1.7. ENGINE ON VEHICLE SERVICE PROCEDURE A ENGINE REMOVAL............................................................................................................................ 88 B AIR FILTER ASSEMBLY REMOVAL.................................................................................................. 90 C POWER STEERING PUMP BELT (STRETCH BELT) ....................................................................... 90 D ALTERNATOR AND AC BELT ........................................................................................................... 91 E INJECTOR REMOVAL........................................................................................................................ 92 F TIMING BELT REMOVAL ................................................................................................................... 93 G FITMENT OF TIMING BELT............................................................................................................... 95 H INTERCOOLER REMOVAL ............................................................................................................... 98 I RADIATOR REMOVAL ....................................................................................................................... 99 J COOLANT TANK REMOVAL ........................................................................................................... 101 K RADIATOR FAN SHROUD REMOVAL ............................................................................................ 102 L THERMOSTAT REMOVAL............................................................................................................... 102 M FUEL RAIL REMOVAL ..................................................................................................................... 103 N FUEL FILLER ASSEMBLY REMOVAL............................................................................................. 104 O FUEL TANK ...................................................................................................................................... 105 P TANK UNIT REMOVAL .................................................................................................................... 106 Q FUEL LEVEL SENSOR REMOVAL.................................................................................................. 108 R TANK PRESSURE VALVE REMOVAL ............................................................................................ 109 S FUEL TANK PURGING PROCEDURE ............................................................................................ 110 T POST SILENCER AND INTERMEDIATE PIPE ............................................................................... 111 U PRE-SILENCER AND MAIN SILENCER.......................................................................................... 111 V FRONT EXHAUST PIPE .................................................................................................................. 112 W CLOSE COUPLED CATALYTIC CONVERTER............................................................................... 112 X EGR COOLER MODULE.................................................................................................................. 113 Y TURBOCHARGER............................................................................................................................ 115
ENGINE 1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) A ENGINE DIS-ASSEMBLY i REMOVAL OF INTAKE MANIFOLD............................................................................................ 119 ii REMOVAL OF EXHAUST MANIFOLD........................................................................................ 124 iii REMOVAL OF OIL SUMP ........................................................................................................... 127 iv REMOVAL OF TIMING BELT ...................................................................................................... 128 v REMOVAL OF CYLINDER HEAD ............................................................................................... 130 vi REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES............................................................... 132 vii REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................ 135 viii PISTON CONNECTING ROD DIS-ASSEMBLY.......................................................................... 136 B ENGINE ASSEMBLY i FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES................................................................. 143 ii FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES...................................... 144 iii FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES .............................................................. 145 iv FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK .......................................................... 146 v FITMENT OFTIMING BELT ......................................................................................................... 147 vi FITMENT OF OIL SUMP ............................................................................................................. 149 vii FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS....................................................... 150 viii FITMENT OF INTAKE MANIFOLD AND PERIPHERALS........................................................... 153 ix ON ENGINE SUPPORT STAND ................................................................................................. 158 1.9. ENGINE MANAGEMENT SYSTEM (EMS) 160 SYSTEM OVERVIEW 161 BLOCK DIAGRAM 162 Connector Pin Assignment 163 ANTI-CRANKING FUNCTION 168 SENSORS AND ACTUATORS DETAILS 169 1. CRANK ANGLE SENSOR 169 2. CAM SENSOR 170 3. TEMPERATURE AND MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 172 4. CIMAF SENSOR (CONTINENTAL INTEGRATED MASS AIRFLOW SENSOR) 173 5. COOLANT TEMPERATURE SENSOR 175
ENGINE 6. FUEL TEMPERATURE SENSOR (FTS) 176 7. INLET METERING VALVE (IMV) 177 8. VENTURI 177 9. RAIL PRESSURE SENSOR 177 10. WATER IN FUEL SENSOR 178 11. ACCELERATOR PEDAL SENSOR 179 12. BRAKE SWITCH 180 13. CLUTCH SWITCH 182 14. GLOW PLUGS 183 15. VTT ACTUATOR 184 16. EGR VALVE ACTUATOR 186 17. EGR COOLER BYPASS VALVE (VACUUM SOLE-NOID VALVE) 188 18. INTAKE THROTTLE VALVE 189 19. GUIDELINES FOR PERFORMING IN SERVICE FUNCTIONAL RESET FOR SENSORS 190
ENGINE 1 1.1 GENERAL INFORMATION: A. ENGINE INTRODUCTION: The 2.2L VARICOR engine used on this vehicle is a state of art modern Direct Injection Common Rail diesel unit. This engine is using twin overhead camshafts and 16 valves which help in good breathing. Delphi common rail diesel injection system with 1600 bar injection pressure is used and controlled by a fast 32-bit electronic control unit. The engine performance is optimized for various engine speed, load and operating conditions depending upon the various sensors input. The turbocharger (VTT) used on this engine works on Variable Turbine Technology (VTT) has low inertia of turbine and compressor wheels which reduce the turbo lag at low engine speeds and improves the transient response of the vehicle. This turbocharger incorporates many movable vanes in the turbine housing to control the exhaust flow against the turbine blades which enables higher power, torque, lower fuel consumption and emissions of the engine. The actuation of the vane angle is done electrically by the EMS The fuel economy and emission has been optimized at source by means of low engine friction, faster engine warm up, centralized injectors, optimized combustion, closed coupled catalytic converter, closed loop operation of the turbocharger (VTT) etc. Hydraulic Lash Adjusters and Roller Finger Followers are used for maintenance free quiet operation and reduced friction. Toothed belt drive with automatic belt tensioner is used for quiet engine operation for longer period. The engine NVH is optimized by means of optimized engine mounts, multiple injection strategy etc. The engine weight has been optimized by using Aluminum cylinder head, gallery cooled piston, non-linered cylinder block with spherical skirt, superior alloy material for high strength. The CCC (Close Coupled Catalytic Converter) is fitted in this vehicle to further reduce the emissions. The CCC filters harmful carbon particles before they leave the exhaust.
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