ARIA

ARIA MY 14 Service Manual Supplement (This is to be referred in conjunction with Vol.1 of ARIA Workshop Manual)

The information provided in this manual is based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. C Copyright 2015 TATA MOTORS All rights reserved. The material in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS.

INTRODUCTION This supplement service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA ARIA. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. The contents which are not covered in this supplement workshop manual have to be read in conjunction with “TATA ARIA” workshop manual. Thismanual provides information about the following groups:  General  Engine.  Clutch  Electrical. In case of any further information / technical advice please refer to the Service Circulars / Bulletins issued periodically or please contact your nearest Customer support office or you can also write to us at: Tata Motors Limited Literature Development Cell PCBU – Customer Support, K-Block, Sector 15 & 15°, PCNTDA, Chikhali, Pune-410 501 Maharashtra.

INDEX SR. NO GROUP 1 GENERAL 2 ENGINE 3 CLUTCH 4 ELECTRICAL

GENERAL GENERAL

GENERAL INTRODUCTION This manual provides the information on good workshop practices and technical Specification. It also provides information on Service Schedule required for TATA ARIA. All maintenance work should be carried out as per the service Schedule chart

GENERAL Contents 1.1. TECHNICAL SPECIFICATION ....................................................................................1 1.2. RECOMMENDATION...................................................................................................7 1.3.1. ABBRIVATION USED..........................................................................................9 1.3.2. VEHICLE IDENTIFICATION NUMBER................................................................9 1.3.3. COMPONENT LOCATIONS ..............................................................................12 1.3.3.1. JACK, TOOL BAG AND WHEEL SPANNER LOCATION........................12 1.3.3.2. WARNING TRIANGLE ..............................................................................13 1.3.3.3. FRONT JACK HOOK ................................................................................12 1.3.3.4. REAR TOW HOOK....................................................................................12 1.4. VEHICLE JACKING AND LIFTING POINTS .............................................................13 1.5. SPARE WHEEL REPLACEMENT .............................................................................14 1.6. EMERGENCY TOWING INFORMATION...................................................................15 1.7. JUMP STARTING.......................................................................................................15 1.8. SERCIVICE SHEDULE ..............................................................................................17 1.9. LUBRICANTS, FLUIDS AND CAPACITIES ..............................................................21 1.9.1. LUBRICANTS ....................................................................................................21 1.9.2. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES............................21 1.9.3. RECOMMENDED FUEL ....................................................................................22 1.10. VEHICLE DIMENSIONS...........................................................................................23

GENERAL 1 1.1 TECHNICAL SPECIFICATIONS ENGINE Model TATA 2.2L VARICOR Type Direct Injection Common Rail Turbocharged Intercooled Diesel Engine. No. of cylinders 4 Inline Bore/ stroke 85mm X 96mm Capacity 2179 cc Max. Engine output 110 KW (150 PS) at 4000 rpm as per CMVR 115(9)1996. Max. Torque 320 Nm in the speed range of 1500-3000 rpm as per CMVR 115(9) 1996. Compression ratio 16 : 1 Firing order 1 – 3 – 4 – 2 Engine oil capacity Max. 7.5 Liters. Min. 5.5 Liters. CLUTCH Type Single plate dry friction diaphragm type Outside Diameter of Clutch Lining 258 mm Friction Area 560 cm2 (Approximate) GEAR BOX Model GBS– 76 – 5/4.1, MK-II with overdrive Type Synchromesh on all gears No. of gears 5 Forward and 1 Reverse. Gear Ratios 1st 4.1 2nd 2.22 3rd 1.37

GENERAL 2 4th 1.00 5th 0.73 Reverse 4.22 TRANSFER CASE Type Torque on demand. Single speed with 2H and Auto mode. REAR AXLE Type Single reduction, Banjo type rear axle with hypoid gears and semi floating axle shafts. For 4X4 version ESP without LSD ABS with LSD For 4X2 version ESP without LSD ABS with LSD RATIO 4X4 – 4.1 4X2 – 4.1 FRONT AXLE For 4X4 1. Independently suspended with Axle Disconnect 2. Axle ratio – 4.1 For 4X2 Independently suspended STEERING Type Rack and Pinion steering with power assistance (Hydraulic). Ratio 17.5 : 1 Steering Wheel 380 mm dia. with Low pivot Tilt mechanism for adjusting height and collapsible column. BRAKES Service Brakes Vacuum assisted independent hydraulic brakes on front and rear through tandem master cylinder. Vacuum pump camshaft driven. Front Brakes Ventilated disc brakes with twin pot caliper 4X4 4X2

GENERAL 3 Disc Dia. 302 298 Disc Thickness 26 26 C48X48 twin pot caliper with 8"+9" tandem booster with dia 26.99 TMC. Pedal ratio 4.0. Rear Brakes C48 Single pot caliper Disc brake (Drum in Hat) (Drum Dia. 206). Antilock Braking System 4 Channel , 4 sensor Electronic Stability Program 4 Channel, 4 Sensors and other Sensors Parking Brakes Lever type, Console mounted, Cable operated mechanical linkages acting on rear wheels through DIH. FRAME Type Ladder type cranked frame with box section members and welded cross members. Depth 152 mm (Max.) Width 80 mm (Max.) 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 type at front and rear. Antiroll Bar At both front and rear WHEELS AND TYRES Tyres PSR 235/70 R16 Passenger Radial Tubeless PSR 235/65 R17 Passenger Radial Tubeless Wheel Rims 6.5J X 16 Stylized Wheel Rims 7.5J X 17 Alloy Wheel Rims No. of wheels Front – 2 Rear – 2 Spare – 1 (Spare wheel fitted on chassis) FUEL TANK

GENERAL 4 Capacity 60 Liters ELECTRICAL SYSTEM System Voltage 12 Volts (-ve earth) Alternator Capacity 155 amps Battery 1) Pure Lx – 12V, 75Ah, 20 Hr Rate. 2) Pleasure & Pride – 12V, 80Ah, 20 Hr Rate. PERFORMANCE Max achievable speed at rated GVW (kmph) 4X4 4X2 170 170 Grade Restartability (at rated GVW) 4X4 4X2 24% at 1000 rpm 23% at 1000 rpm Max. gradeability at rated GVW 4X4 4X2 45% 44% WEIGHTS (Kg) Complete vehicle kerb weight as per ISO:1176 (With spare wheel and tools) BS III Pure Pleasure Prestige Pride 4X2 2050 2095 2095 – 4X4 – 2195 2195 2215 GROSS VEHCLE WEIGHT BS III (4X2) Pure Pleasure Prestige Pride 4X2 2675 2720 2720 – Front 1171 1200 1200 – Rear 1504 1520 1520 – BS IV (4X2) Pure Pleasure Prestige Pride 4X4 2685 2730 2730 –

GENERAL 5 Front 1176 1204 1204 – Rear 1509 1526 1526 – BS III (4X4) Pure Pleasure Prestige Pride 4X4 – 2820 2820 2840 Front – 1291 1291 1305 Rear – 1529 1529 1535 BS IV (4X4) Pure Pleasure Prestige Pride 4X4 – 2830 2830 2850 Front – 1295 1295 1309 Rear – 1535 1535 1541 Max. permissible FAW Pure Pleasure Prestige Pride 1350 1350 1350 1350 Max. permissible RAW Pure Pleasure Prestige Pride 1580 1580 1580 1580 KERB WEIGHT BS III (4X2) 4X2 2050 2095 2095 – Front 1094 1121 1121 – Rear 956 974 974 – BS IV (4X2) 4X2 2060 2105 2105 – Front 1099 1127 1127 – Rear 691 978 978 – BS III (4X4) Pure Pleasure Prestige Pride 4X4 – 2195 2195 2215 Front – 1213 1213 1229 Rear – 982 982 986

GENERAL 6 BS IV (4X4) Pure Pleasure Prestige Pride 4X4 – 2205 2205 2235 Front – 1218 1218 1234 Rear – 987 987 991 PASSENGER CAPACITY Front Seat Driver+1 Middle Seat 3 Rear Seat 2 (Front Facing) LUGGAGE SPACE Net inside loading space 1000 mm wide x 800 mm long (with 4 passengers + Driver) MAIN CHASSIS DIMENSION AS PER ISO:612 in mm Wheel Base 2850 Track Front 1580 Track Rear 1550 Front Overhang 905 Rear Overhang 1025 Over rear bumper Overall Length 4780 Over rear bumper Maximum Width 1895 - With Cladding 1860 - W/o Cladding Overall Height 1780 Min. Turning Circle dia 11.5 m Min. Turning Clearance Circle dia 12.5 m Ground Clearance 200 mm

GENERAL 7 1.2 RECOMMENDATIONS 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 TATA ARIA GENUINE 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. 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.

GENERAL 8 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 9 1.3 GENERAL INFORMATION 1.3.1 ABBREVIATIONS USED 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 1.3.2 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 10 CHASSIS NUMBERING SYSTEM (VIN) Chassis type number consists of 17 digits (6 barrels) 1 2 3 4 5 6 MAT XXXXXX X X X XXXXX BARREL 1: Indicates produced in Tata Motors, India BARREL 2: Chassis type, sales designation CHASSIS TYPE NO. DESCRIPTION ARIA PURE LX 4x2 VERSION 614 201 MUV, 28706628R, TATA ARIA, PURE-LX, 2.2L DICOR, BHARAT STAGE IV, DIESEL, HVAC, 4x2, 7, COLLAPSIBLE STEERING, NA ARIA PLEASURE 4X2 VERSION 614 013 MUV, 28706428R, TATA ARIA, PLEASURE, 2.2L DICOR, BHARAT STAGE IV, DIESEL, HVAC, 4x2, 7, DAB+PAB+ABS, NA ARIA PRIDE 4x4 VERSION 614 163 MUV,28706828R, TATA ARIA, PRIDE, 2.2L DICOR, BHARAT STAGE IV, DIESEL, HVAC, 4x4, 7, DAB+PAB+SAB+ESP, NA BARREL 3: Year of production CODE YEAR 9 01.04.2009 to 31.12.2009 A 01.01.2010 to 31.12.2010 B 01.01.2011 to 31.12.2011 BARREL 4: Plant Location CODE PLANT LOCATION 0 WC-1,Lucknow 1 Jamshedpur-I 2 Jamshedpur-II 3 Jamshedpur-III 4 WC-2,Lucknow 5 EC-1,Lucknow 6 Dharwad 7 D-Block, Pune 8 H-Block, Pune 9 J-Block, Pune, First Assembly Line A EC-2,Lucknow B IBF-1,Lucknow J Pantnagar-IV K Sanand L TML, Ranjangaon-II M Lucknow – MASOP N J-Block, Pune, Second Assembly Line P K-Block, Pune, First TCF Line R J14-Block, Pune S J13-Block, Pune T TML, Ranjangaon- U E9-Block, Pune V Pantnagar-l W K-Block, Pune, Second TCF Line X Singur Y Pantnagar-II Z Pantnagar-III

GENERAL 11 BARREL 5: Month of Manufacture CODE MONTH A January B February C March D April E May F June G July H August J September K October N November P December BARREL 6: Indicates cumulative serial number of chassis produced the year at each plant.

GENERAL 12 1.3.3 COMPONENT LOCATIONS 1.3.3.1 JACK, TOOL BAG AND WHEEL SPANNER LOCATION The jack is kept in the rear luggage space of your vehicle. Open the tail gate and lift the cover of the storage box to access the scissor jack. 1.3.3.2 WARNING TRIANGLE LOCATION Warning triangle is located below third row seat placed on vertical face & held with Velcro straps. 1.3.3.3 FRONT TOW HOOK LOCATION Front tow hook provision can be seen at the left side of front bumper after removal of cap. The cap can be removed by pulling it outwards. 1.3.3.4 REAR TOW HOOK LOCATION Rear tow hook provision can be seen at the centre on the rear bumper after removal of cover. This cover can be removed by pulling it outwards. Tow hook can be fitted on either of the holes provided at the rear.

GENERAL 13 1.4 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 14 1.5 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.

GENERAL 15 1.6 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 • 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. 1.7 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 ARIA (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

GENERAL 16 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 17 1.8 SERVICE AND MAINTENANCE SCHEDULE OPERATION Frequency (Km) PDI 1000-1500 5000-5500 15000-15500 30000-30500 45000-45500 60000-60500 75000-75500 90000-90500 105000-105500 GENERAL Wash the vehicle and clean the condenser with compressed air Every Service x x x x x x x x x x Check and Top up Fluids if required: Coolant, Brake / Clutch Fluid, Battery Electrolyte, Power Steering Oil. Every 15000 x x x x x x x Drain water accumulated in Fuel Pre filter cum sedimenter and fuel filter (OR whenever the Warning lamp glows)) Every Service x x x x x x x x x x Check engine compartment for loose fasteners, low pressure fuel lines, coolant hoses, air hoses, vacuum hoses and hydraulic line connections for leakages if any. Attend if necessary. Every Service x x x x x x x x x x Check Underbody for loose fasteners, hydraulic line connections, exhaust system / fuel Pipes for Damages or leakages if any. Attend if necessary. Every Service x x x x x x x x x x Apply grease on door latches, door lock, door check stop, striker, bonnet opening lever and lock plate, tailgate hinges and door lock inner ratchet. Every Service x x x x x x x x Check for proper tightening of Door latch & Striker screws, Tail gate latch and striker screws Every 15000 x x x x x x x x Check and ensure normal working of your vehicle using diagnostic equipment. Every Service x x x x x x x x x x 2.2L VARICOR ENGINE * Change engine Oil and Oil filter. (Every 15000 kms OR 1 year, whichever is earlier ) Every 15000 x x x x x x x Check All accessory Drive belts (Alternator & Compressor), adjust tension if required, change if damaged (Every15000 kms OR 1 year, whichever is earlier ) Every 15000 x x x x x x x

GENERAL 18 OPERATION Frequency (Km) PDI 1000-1500 5000-5500 15000-15500 30000-30500 45000-45500 60000-60500 75000-75500 90000-90500 105000-105500 Check accessory drive for power steering pump. Change if damaged Every 15000 x x x x x x x Change Accessory drive for Power Steering Pump Every 75000 x Change main fuel filter ( Every 30,000 OR 2 year, whichever is earlier) Every 30000 x x x * Replace air filter element Every 45000 x x Change coolant in the cooling system ( Every 60,000 OR 2 year, whichever is earlier) Every 60000 x Replace element of Prefilter cum Sedimenter (Every 15,000 OR 1 year, whichever is earlier) 15000 x x x x x x Change Timing Belt and Timing Belt tensioner Every 1,50,000 OR 5 years, whichever is earlier Check timing belt and if found damaged replace along with tensioner Every 1,20,000 Kms GEAR BOX * Change oil in gear box (First at 45,000 km and thereafter every 90,000 km) 45000 x Change oil in TOD (For 4x4 Only) Every 1,20,000 Kms PROPELLER SHAFT Grease propeller shaft with grease gun (at slip joint - splines end) and check Centre bracket mounting bolts for looseness. Tighten if necessary. 15000 x x x x x x x Check for rubber cracks on Torsional Vibration Damper (TVD), replace if necessary 15000 x x x x x x x Change TVD Every 60000 x FRONT AXLE (FOR4X4) / REAR AXLE Change oil in axle ( Front (For 4x4) / Rear) Every 75000 x Clean breather in front and rear axle Every 15000 x x x x x x x

GENERAL 19 OPERATION Frequency (Km) PDI 1000-1500 5000-5500 15000-15500 30000-30500 45000-45500 60000-60500 75000-75500 90000-90500 105000-105500 SUSPENSION AND STEERING Check wheel alignment and balancing, and adjust if necessary Every 15000 x x x x x x x Check condition of rubber bushes in the following and replace if necessary. 1)Top wishbone 2)Lower wishbone* 3)Anti roll bars 4)Rear links 5) Panhard rod * Lower wishbone bushes are not serviceable 30000 x x x Check shock absorber, bushes replace if necessary ( First at 30,000 km and there after at every service) 30000 x x x x x x Change oil in power steering system and change filter element 105000 x Change power steering belt 75000 x CLUTCH AND BRAKE Check parking brakes, adjust if necessary Every service x x x x x x x x x Check front brake pads and rear brake, regrease DIH liner resting points. Replace if necessary. Every 15000 x x x x x x x Change Clutch and Brake Fluid (45,000 Or 2 years whichever is earlier) 45000 x x ELECTRICALS Check headlamp low beam aiming and functioning of other electrical equip. Every 15000 x x x x x x x Check specific gravity of battery electrolyte (Battery is sealed. If it is refilled, use distilled water only) Every 30000 x x x HVAC Check the HVAC System for satisfactory performance, attend if required Every Service x x x x x x x x x

GENERAL 20 OPERATION Frequency (Km) PDI 1000-1500 5000-5500 15000-15500 30000-30500 45000-45500 60000-60500 75000-75500 90000-90500 105000-105500 Check and clean A.C. filter 15000 x x x x x x x WHEEL AND TYRES Tyre Rotation 15000 x x x x x x x • ( * ) Under severe driving conditions, additional maintenance is required. Please refer to “Additional Maintenance Schedule under severe driving conditions”: • Precautions to be taken while cleaning engine compartment: It is recommended to use dry low pressure air. Do not use pressurized water. ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS A. Driving in conditions such as Patrolling, Taxi, Pickup Van, Vehicle Towing, with Trailer Towing B. Driving on Dusty / Sandy roads C. More than 50% (in terms of kms) driving in heavy city traffic D. Frequently operating in mountainous area ITEM INTERVAL CONDITION A B C D Engine oil and oil filter Change every 7500 kms x x x x Air filter element Replace at 22,500 kms OR 1.5 years (whichever is earlier) x x Front (For 4X4) & Rear axle oil change Change at first 15,000 kms and thereafter at 45,000 kms x x x

GENERAL 21 1.9 LUBRICANTS, FLUIDS AND CAPACITIES 1.9.1 LUBRICANTS ENGINE OIL Recommended grade of engine oil confirming to APICH4+MB228.3 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. WINDSCREEN WASHER ANTI-FROST CONCENTRATION Ambient temp. in ºC Ratio (Washer : Anti-frost ) 00C 1:5 100C 1:1 160C 2:5 370C 1:0 1.9.2 RECOMMENDED LUBRICANTS AND FLUIDCAPACITIES ITEM SPECIFICATION COMPANY BRAND QUANTITY ENGINE OIL API- CH4+MB228.3 (15W40) CASTROL GTX (Diesel) 7.5 Liters HPCL HPCL MILCY no 1 TGO EXXON MOBIL Mobil Super 1000 TM 15W40 COOLANT 50:50 RATIO Premixed S-CCI Golden Cruiser Premium 1400M Approx. 9 Liters HPCL HP THANDA RAJA P TGO CASTROL Radicool SFO Premix GEAR BOX (G-76) Synthetic gear oil 75W90 GL4 HPCL HP GO XP 75W90 TGO 2.2 Liters CASTROL Castrol Syntro 75W90 GL4 EXXON MOBIL MOBILUBE 1 SHC 75W90 TRANSFER CASE – SHELL Spirax S3 ATF MD3 1.35 Liters POWER STEERING OIL ATF DEXRON-IID CASTROL Castrol TQD 1.6 Liters HPCL ATF Dex II EXXON MOBIL Mobil ATF 220

GENERAL 22 ITEM SPECIFICATION COMPANY BRAND QUANTITY REAR AXLE (Limited slip Differential 85W140 API –GL5 Anglomol 6043 HPCL HP Gear Oil XP 85W140 T2 1.68 Lt and 0.09 Lt (Friction modifier) CASTROL Extra Long Drain Rear Axle Oil 85W140 REAR AXLE (Standard Differential) HPCL HP Gear Oil XP 85W140 T2 1.68 Lt CASTROL Extra Long Drain Rear Axle Oil 85W140 LIVE FRONT AXLE HPCL HP Gear oil XP 85W140 T2 1.50 Lt CASTROL Extra Long Drain Rear Axle Oil 85W140 BRAKE / CLUTCH FLUID SAE J1703, DOT4 S-CCI Tata Genuine Brake Fluid (DOT4) As required CASTROL Universal Brake Fluid (DOT4) PETRONAS TUTELA TOP 4 TM WHEEL BEARING AND CHASSIS GREASE – HPCL Multipurpose Grease–2 As required CASTROL Castrol AP2 1.9.3 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. NOTE For BSIV vehicles it is mandatory to use Diesel fuel with sulphur contents less than 0.050%. Use of any other diesel fuel can increase the pollutants. Fit a cap to seal a hydraulic union and a plug to its socket after removal to prevent ingress of dirt. 1. Absolute cleanliness must be observed with hydraulic components at all times. 2. 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.

GENERAL 23 1.10 VEHICLE DIMENSIONS * Ground clearance: 200 mm for Pure Lx 4X2, Pleasure 4X2, Pride 4X2 & 4X4.

ENGINE ENGINE

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 TABLE OF CONTENTS 2.1.1 GENERAL INFORMATION ........................................................................................1 2.1.1.1 SPECIFICATION .............................................................................................................. 1 2.1.1.2 TIGHTENING TORQUES.................................................................................................. 2 2.1.1.3 SPECIAL TOOLS............................................................................................................ 20 2.1.1.4 GENERAL SYMPTOMS DIAGNOSIS ............................................................................. 21 2.1.2 MAINTENANCE, INSPECTION AND TESTS.......................................................24 2.1.2.1 PRELIMINARY INSPECTION......................................................................................... 24 2.1.2.2 REGULAR MAINTENANCE ........................................................................................... 26 A. ENGINE OIL REPLACEMENT. ........................................................................................ 26 B. OIL FILTER REPLACEMENT .......................................................................................... 27 C. AIR FILTER CLEANING................................................................................................... 27 D. FUEL FILTER REPLACEMENT ....................................................................................... 28 E. DRAINING WATER FROM PREFILTER CUM SEDIMENTOR. ........................................ 29 F. PREFILTER CUM SEDIMENTOR REPLACEMENT......................................................... 29 G. PREFILTER CARTIRDGE REPLACEMENT.................................................................... 30 H. COOLANT REPLACEMENT ............................................................................................ 34 2.1.2.3 ON VEHICLE PROCEDURES........................................................................................... 35 A. ENGINE REMOVAL......................................................................................................... 35 B. AIR FILTER ASSEMBLY REMOVAL................................................................................ 37 C. POWER STEERING PUMP BELT (STRETCH BELT) ...................................................... 38 D. ALTERNATOR AND AC BELT ......................................................................................... 38 E. INJECTOR REMOVAL..................................................................................................... 39 F. TIMING BELT REMOVAL................................................................................................. 41 F. TIMING BELT FITMENT................................................................................................... 43

ENGINE 2.1.3 OVERHAULING....................................................................................................45 2.1.3.1 ENGINE DISMANTLING:(ON STAND)............................................................................ 45 2.1.3.2 CYLINDER HEAD ........................................................................................................... 52 2.1.3.3 TIMING SYSTEM............................................................................................................ 64 2.1.3.4 ENGINE BLOCK ............................................................................................................. 67 2.1.3.5 ENGINE ASSEMBLY ...................................................................................................... 92 2.1.4 AIR INTAKE SYSTEM........................................................................................101 2.1.5 COOLING SYSTEM............................................................................................110 2.1.6 LUBRICATION SYSTEM....................................................................................118 2.1.7 FUEL SYSTEM...................................................................................................124 2.1.8 EXHAUST SYSTEM ...........................................................................................142 2.1.9 ENGINE MANAGEMENT SYSTEM (EMS) ........................................................161 2.1.10 DIAGNOSTIC USER MANUAL ..........................................................................192

ENGINE 1 2.1.1 GENERAL INFORMATION 2.1.1.1 SPECIFICATION Model 2.2 L VARICOR Type 16 valves, water cooled, Direct injection common rail, Turbo Charged, Intercooler Diesel Engine. No. Of Cylinders 4 In-line Bore / Stroke 85 mm x 96 mm Capacity 2179 cc Max. Engine Output 110 kW (150 Ps) at 4000 rpm Max. Torque 320 Nm at 1500 - 3000 rpm Compression Ratio 16:1 Firing Order 1-3-4-2 Engine Oil Capacity Max. 7.5 liters, Min 5.5 liters Weight Of Engine 235 kg (Dry) Special Items / Features 1) Centralized injectors 2) Fully electronic controlled common rail fuel injection system 3) 1600bar injection pressure 4) Variable geometry turbocharger with electric actuator 5) Electrically controlled EGR valve with pneumatic EGR cooler bypass 6) Hydraulic lash adjusters and roller finger followers for maintenance free quite operation and reduced friction 8) Closed Catalytic Converter

ENGINE 2 2.1.1.2 TIGHTENING TORQUES: SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 1 Main bearing cap mounting Bolt M12 X 1.5 5 ± 0.5 + 90o±10o 2 Cylinder head mounting Bolt* M12 X 1.5 ,12.9 Step 1 6 ± 0.5 Torque Step 2 90o ± 5o angle Step 3 90o ± 5o angle 3 Bearing frame mounting on cylinder head Bolt* M6 1.2 4 Oil sump Bolt M6 1+0.2

ENGINE 3 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 5 Sealing plug for oil gallery, front M14 X 1.5 3.5 6 Sealing plug for oil gallery, rear M14 X 1.5 3.5 7 Oil sump drain plug M18 x 1.5 5 ± 1

ENGINE 4 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 8 Injector claw Bolt M8 3 + 0.3 9 Cylinder head cover Bolt* M6 1 – 0.2 10 Rear cover (Crankcase) mounting Bolt M6 X 1, 8.8 1 + 0.2

ENGINE 5 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 11 Timing cover (Rear) Bolt M6 , 8.8 1 – 0.2 12 Timing cover (Front) Bolt M6 , 8.8 1 – 0.2

ENGINE 6 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 13 Vacuum pump mounting Bolt M6 , 8.8 1 + 0.2 14 Connecting rod big end Nut M9 X 1 Step 1 2.9 ± 0.3 Step 2 110O ± 10O angle 15 Flywheel mounting Bolt M10 X 1 Step 1 3.3 ± 0.3 torque Step 2 100o ± 5o angle 16 Exhaust manifold mounting Nut M8 2 + 0.3

ENGINE 7 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 17 Vibration damper pulley mounting Bolt M15 X 1.5 Step 1 9 ± 1 torque Step 2 110O ± 10O angle 18 Auto tensioner mounting Nut M8 3 19 Timing belt idler mounting Bolt M12 X 1.5, 12.9 8 + 0.5

ENGINE 8 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 20 Camshaft gear mounting on cam shaft Bolt M12 X 1.25, 10.9 11 ± 0.5 21 Touch idler mounting Bolt M8 2.5 + 0.3 22 HP pump bracket to Cylinder block Bolt M8, 10.9 2.2 + 0.3 23 HP pump mounting on Bracket Bolt M8, 10.9 2.2 + 0.3

ENGINE 9 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 24 HP pump bracket mounting Bolt M8, 10.9 2.2 + 0.3 25 HP pump gear mounting Nut M14 6.6 ± 0.5 26 Common rail mounting Bolt M8 2.2 + 0.3 27 H.P. line to rail, injector and pump Cap nut M14 X 1.5 3 ± 0.2

ENGINE 10 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 28 Inlet manifold mounting Nut M8 2.2 + 0.3 29 Intake pipe mounting on inlet manifold Bolt and Nut M6 1 + 0.2 30 Turbo charger mounting on exhaust manifold Nut M8 3 + 0.3 31 EGR cooler mounting Bolt M8 2 + 0.3

ENGINE 11 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 32 EGR cooler pipe (intake pipe side) Bolt M6 1 +0.2 33 EGR pipe mounting on EGR module Bolt M6 2 34 Starter motor mounting on clutch housing Bolt M10 3 35 Alternator bracket mounting Bolt M8 3 + 0.3

ENGINE 12 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 36 Alternator mounting Bolt M10 3 +0.3 37 Glow plug - 0.9 38 Crankshaft sensor mounting Bolt M6 1 ± 0.15 39 Oil pump mounting Bolt M6 X 1, 8.8 1 + 0.2

ENGINE 13 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 40 Oil strainer mounting Nut M8 2 + 0.3 41 Ladder frame mounting Bolt M6 X 18 1 +0.2 42 Oil pressure switch - 3

ENGINE 14 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 43 Adaptor Oil cooler mounting Bolt M8 2 + 0.3 44 Piston cooling nozzle mounting M6 1 +0.2 45 Turbo oil return tube (Turbo end) Bolt M6, 8.8 1 +0.2 46 Turbo oil return tube (Cylinder block end) Bolt M6, 8.8 1 +0.2

ENGINE 15 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 47 Oil cooler mounting Adaptor M20 x 1.5 4 48 Water pump mounting Bolt M6 X1, 8.8 1 ± 0.15 49 Temperature transducer - 1.5 50 Upper cooling line to water outlet elbow Bolt M6 2 ± 0.3

ENGINE 16 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 51 Engine mounting pad (On frame) Nut M10 4 52 Thermostat Cover mounting Screw M6 1 +0.2 53 ECU mounting Bolt M6 X 22 0.95 54 Lifting hook (Front) Bolt M8 2.2 + 0.3

ENGINE 17 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 55 Engine mounting bracket Bolt M10 4 56 Lifting hook (Rear) Bolt M8 2.2 + 0.3 57 Lifting hook (Front) Bolt M8 2.2 + 0.3

ENGINE 18 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 58 Lifting hook (Rear) Bolt M8 2.2 + 0.3 59 Power steering pump mounting bracket on crankcase Bolt M8 3 + 0.3 60 A/C compressor mounting Bolt M8 , class 10.9 3 + 0.3 61 Power steering pulley mounting Bolt M8 2.5

ENGINE 19 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 62 A/C Idler bolt (Slider bolt for tension adjustment) Bolt M10 2.5 63 Radiator mounting bolt M10 4.6 64 Engine mounting bolt (Front) Bolt M12 X 1.5 7 65 Engine mounting nut (Rear) Nut M10 4 NOTE • Please refer assembly procedure for tightening torque sequence mark as *. • Please refer the standard tightening torques for the components / fasteners which are not included in this torque table.

ENGINE 20 2.1.1.3 SPECIAL TOOLS SR. NO. DESCRIPTION PART NO. 1. Engine repair stand 2702 5890 24 04 2. Engine support stand 2653 5890 24 01 3. Valve spring compressor 2653 5890 06 02 4. Drift / dolly for camshaft oil seal 2653 5890 06 03 5. Flywheel locking pin 2870 5890 06 01 7. Cam shaft locking pin (Cam sensor hole) 2653 5890 06 09 8. Drift for crank shaft oil seal (Rear cover) 2653 5890 06 06 9. Spacer for valve guide Installation (Inlet/Exhaust) 2653 5890 06 01 10. Drift for Valve Guide Removal (Inlet/Exhaust) 2868 5890 06 05 11. Engine mounting bracket (LH) on stand 2653 5890 24 02 12. Engine mounting bracket (RH) on stand 2653 5890 24 03 13. Mandrel for aligning clutch disc 2870 5890 25 01 14. Injector puller 2868 5890 07 04 15. Adapter for compression testing 2868 5890 07 01 16. Spanner for holding HP Pump gear & Cam gear 2654 5890 05 01 17. Spanner for Oil filter (M/S FLEETGUARD) 2870 5890 18 04 18. Spanner for Oil filter (M/S MAHLE) 2870 5890 18 05 19. Flange for HP pump gear removal 2547 0713 71 03 20. Handle for Drift (Standard tool) 2640 5890 35 11 21. Drift for oil pump oil seal 2702 5890 18 01 22. Pin for locking HP pump gear 2653 5890 06 07 23 Crankshaft spigot bearing puller 2654 5890 03 06 24 Cam shaft locking plate 2653 5890 06 05 25 SF belt fitment tool 2702 5890 0622 26 SF belt removal tool 2702 5890 0623

ENGINE 21 2.1.1.4 GENERAL SYMPTOMS DIAGNOSIS NOTE It is always advisable to first use the diagnostic tool and rectify the electrical faults, before commencing with mechanical repairs/ troubleshooting. Refer EMS section in this group for procedure. SR. NO. COMPLAINT CAUSE REMEDY 1. Engine does not crank • Electrical connection loose/came out • Battery discharge • Starter Motor not working • Ignition switch defective • Correct them at proper place • Recharge/replace the battery • Repair/Replace the starter motor • Replace the main line switch 2. Engine Cranks but does not start • No Diesel • Fuse for engine stop blown • Fuel filters choked • Air filter choked • Engine seized • Exhaust system choked • Hydrostatic lock due to blown cylinder head gasket • Valve train failure due to timing belt failure/breakage • Glow plugs defective • Fill in Diesel • Replace the fuse. • Replace the fuel filters. • Replace the Air cleaner filter • Repair/Replace engine • Clean the exhaust system • Repair/Replace the engine • Repair/Replace the engine • Check / Replace • Clutch Switch faulty • Hold the Ignition key at crank position for 10seconds. This will help to crank the engine if starter motor is in fail-safe condition operation. • Further Investigation on Clutch Switch and Electrical Connection to be done • Clutch switch electrical connection faulty • Check the clutch switch electrical connection & rectify the same in case of unsuccessful / delayed engine start. • Clutch Switch Faulty • Check the fault codes in case of unsuccessful / delayed engine start and rectify the fault 3 Engine Seizure • Low coolant level • Cooling fan not working • Thermostat failure • Radiator hose leakage • Radiator leakage • Water pump defective/pump bearing damaged. • Replace affected parts • Check belt tension • Replace affected parts • Replace affected parts • Replace affected parts Replace affected parts.

ENGINE 22 SR. NO. COMPLAINT CAUSE REMEDY 4 Low compression pressure • Leakage of compression from engine valves • Cylinder head gasket blown between two cylinders • Leakage of compression past piston ring butt clearance (blow by) • Leakage of compression due to excessive cylinder bore/ring wear (excessive blow by). • Repair valve seats/Replace valve seat inserts • Replace gasket • Replace piston rings • Overhaul the engine 5 High Engine Oil Consumption • Oil leakage from: a) Camshaft front oil seal b) Camshaft rear oil seal c) Sump gasket d) Oil cooler e) Oil filter f) Crankshaft head front oil seal g) Cylinder head cover gasket h) Cylinder head cover war page i) Oil seal on valve guide j) Valve guide worn out • Excessive oil filling • Excessive piston ring butt/ Lateral clearance • Excessive cylinder bore wear (Excessive blow-by) a) Replace the oil seal b) Replace the oil seal c) Tighten sump screws/Replace gasket. d) Tighten the fastener / Replace oil cooler. e) Tighten the filter / Replace oil filter f) Replace the oil seal. g) Replace the gasket h) Replace cylinder head cover i) Replace the oil seal* j) Replace the valve guide • Fill the oil to correct level • Replace piston rings • Repair/replace the engine 6 Low Engine Oil Pressure • Defective instrument cluster • Low oil level in sump • Oil pump seized: a) Seized b) Oil pump relief valve stuck in open position • Main bearing /connecting rod bearings & journals excessively worn out • Bearing shells peeled off • Oil strainer inside oil sump broken • Wrong grade of oil • Diesel dilution • Check DTC and rectify • Top-up a) Replace b) Repair/Replace the valve and affected engine parts • Replace affected parts • Replace the bearing shell and affected parts, if any • Fill in correct grade of oil • Rectify

ENGINE. 23 SR. NO. COMPLAINT CAUSE REMEDY 7 Engine overheating • Defective temperature sensor • Less coolant in the system • If observed immediately after coolant refilling • Defective water pump • Radiator fan not working • Thermostat defective • Engine overloaded due to :- a) Brake binding b) Clutch slippage • Replace the temperature sensor • Top up • Perform deaeration • Replace the water pump • Check and rectify if required replace • Check and replace if necessary a) Adjust brake shoes b) Replace affected parts 8 Abnormal Noise from engine • Noise from bearings of bearing block • Noise from Alternator/ Power steering pump bearing • Timing belt loose • Water pump bearing failure • Connecting rod bush worn out • Big end/Main bearings & journals of crankshaft worn out • Piston Ring broken • Crankshaft broken • Silencer choked • Air Filter Element choked • Fuel Filters choked • Defective Injectors • Check for any loose connection or leakages in the air intake system and exhaust system circuit • Repair/Replace the bearing block • Repair/Replace the alternator /power steering pump • Adjust the belt tension/Replace the belt • Replace the bearings / water pump • Replace Connecting rod bushes • Replace bearings & affected parts • Replace piston rings & affected parts • Replace the affected parts • Clean the silencer • Replace the air cleaner element • Replace the fuel filters • Replace Injectors • Tighten loose connections and ensure for no leakage. 9 Poor pick up • MIL ON • Air filter element choked • Fuel filter choked • Low tyre pressure • Brake binding • Engine overheat • Water in fuel lamp glowing • ABS lamp ON • Check for Diesel leakage • Check for fault code and get it rectified • Clean air filter as per recommendations • Replace the fuel filter • Replace the fuel filter • Re-set the brakes • Top up coolant • Drain the water sedimentor • Rectify the ABS unit • Rectify the leakage

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