SAFARI

TATA STORME Service 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 2014 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 STORME family vehicles. 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 STORME” workshop manual. This manual provides information about the following groups: General. Engine. Clutch Steering Brake. HVAC Rear Axle Gear Box Electrical Schematics Diagnostic Trouble Code. 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 & 15A, PCNTDA, Chikhali, Pune-410 501 Maharashtra.

GENERAL GENERAL

GENERAL INTRODUCTION This Section provides workshop practices and repair procedures for the TATA STORME. 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 1 Technical Specifications: VARIANTS LX (4*2) EX (4*2) VX (4*2) / VX (4*4) 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 1700-2700 rpm as per CMVR 115 (9)1996. Compression ratio 16:1 Firing order 1 – 3 - 4 - 2 Engine oil capacity Max : 7.5 litres and Min: 5.5 litres Weight of engine 225 kg (Dry) Radial frontal area 2602 sq.cm minimum Special items / features 1) Direct injection, common rail 16 valves, centralized injector. 2) Fully electronic control fuel injection system. 3) Higher injection system pressure (1600 bar). 4) Variable geometry turbo charger with electric actuator. 5) Hydraulic lash adjusters and roller finger followers. 6) Auto Timing belt Tensioner. 7) EGR cooler with bypass option. 8) Gallery cooled pistons. 9) Single Mass Flywheel.

GENERAL 2 VARIANTS LX (4*2) EX (4*2) VX (4*2) / VX (4*4) CLUTCH Type Single plate dry friction diaphragm type Self Adjusting Clutch (SAC) with Concentric Slave Cylinder (CSC). Clutch Lining (Outside Dia.) 260 mm Total Friction Area 536.0 sq.cm (Approx.) GEARBOX Model GBS-76-5/4.10- MK-II-Gearbox with Overdrive. Type Synchromesh on all gears. No. of gears 5 Forward ; 1 Reverse Gear Ratios 1st 4.1 2nd 2.22 3rd 1.37 4th 1 5th 0.73 Reverse 4.22 TRANSFER CASE Type NA NA LH Drop from M/s Borg Warner. ECU Controlled electrical shifting Arrangement mounted on the gear box. (For 4X4 Only) Drive options NA NA 4x2 - High Ratio 1:1 4x4 - Low Ratio 1:2. 48

GENERAL 3 VARIANTS LX (4*2) EX (4*2) VX (4*2) / VX (4*4) REAR AXLE TYPE Single reduction Banjo type rear axle with hypoid gears and semi-floating axle shafts. Without limited slip differential for 4x2. Single reduction Banjo type rear axle with hypoid gears and semi-floating axle shafts. Without limited slip differential for 4x2. With limited slip differential for 4x4. Ratio 4 : 10 FRONT AXLE Independently suspended. Independently suspended with axle Disconnect. (For 4X4) Independently suspended. (For 4X2) STEERING Type Rack and Pinion steering with power assistance (Hydraulic). Ratio 17.5 : 1 Steering Wheel 380 mm dia. (New Gen) with "low pivot" tilt mechanism for adjusting height & collapsible column. BRAKES Service brake Vacuum assisted independent hydraulic brakes on front and rear through tandem master cylinder. Front Brakes Ventilated disc brakes. Disc Dia. 280 mm 298 mm 298 - VX(4*2) 302 - VX(4*4) Disc Thickness 26 mm Rear Brakes Drum Brake with auto adjuster. Drum dia. 295 mm with 26.99 wheel cylinder C48 single pot caliper with DIH (Drum In Hat, drum dia. 206mm,Disc dia. 316mm) Antilock Braking System NA 4 Channel,4 Sensors-For ABS Version (ABS 8.1 with Electronic Brake force Distribution (EBD)) Parking Brakes Lever type, console mounted, Cable Operated mechanical linkages acting On rear wheels through DIH.

GENERAL 4 VARIANTS LX (4*2) EX (4*2) VX (4*2) / VX (4*4) FRAME Depth 152 mm (max) Width 80 mm (max) SUSPENSION Front Double wishbone type with coil Spring 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 & rear. WHEEL AND TYRES Tyres PSR 235/70 R16 Passenger Radial - Tubeless Wheel Rims 6.5J x 16 - Stylised Steel Wheel rims. 6.5J x 16 - Stylised Steel Wheel rims. 6.5J x 16 - Alloy Wheel rims. Wheel rim cover Hub Cap for all versions. No. of wheels Front – 2 ; Rear - 2 ; Spare - 1(Spare wheel fitted on Chassis – under floor) FUEL TANK Capacity 63 lits. PERFORMANCE Max. speed with two occupants (Kmph) 170kph 180kmph Grade restartability (at rated GVW) 4x2 Mode – 38% at 1000 rpm 4x4 Mode – 78% at 1000 rpm Max. gradeability at rated GVW 56% 68% VX(4*2) 78% VX(4*4)

GENERAL 5 VARIANTS LX (4*2) EX (4*2) VX (4*2) / VX (4*4) MAIN CHASSIS DIMENSION AS PER ISO:612 in mm Wheel base 2650 mm Track Front 1580 mm Track Rear 1550 mm Front overhang 950 mm Rear Overhang 1055 mm over rear bumper. Overall Length 4655 mm over rear bumper. Max. Width 1965 mm (with footstep). Overall Height (Unladen / laden) 1922 mm (unladen) Approach angle ( º ) 29 degree Ramp over angle ( º ) 23 degree Departure angle ( º ) 26 degree Minimum turning circle dia. 10.8 m Minimum turning clearance circle dia. 11.8 m Ground Clearance 200 mm WEIGHTS (kg) Complete vehicle kerb weight (With spare wheel and tools) 1950 2000 2015 (4X2) 2110 (4X4) KERB WEIGHT (kg) Front 1070 1090 1099 (4X2) 1179 (4X4) Rear 880 910 916 (4X2) 931 (4X4) Gross Vehicle Weight 2505 2555 2570 (4X2) 2665 (4X4) Max. Permissible FAW 1200 1200 (4X2) 1280 (4X4) Max. Permissible RAW 1470

GENERAL 6 VARIANTS LX (4*2) EX (4*2) VX (4*2) / VX (4*4) PASSENGER CAPACITY Front Seat Driver + 1 Middle Seat 3 Rear Seat NA 1+1- Side Facing Seats Luggage Space 1000 mm wide x ~ 800 mm long (with 4 passengers + Driver)

GENERAL 7 CHASSIS TYPE AND SALES DESIGNATION : CHASSIS TYPE SALES DESIGNATION DESCRIPTION 617034 SAFARI STORME LX MUV,54077226R,TATA_SAFARI_STORME,LX,2.2L DICOR,BHARAT_STAGE_IV,DIESEL,SINGLE AC,4x2,7,ABS,HTG+DMST 617025 SAFARI STORME EX MUV,54077326R,TATA_SAFARI_STORME,EX,2.2L DICOR,BHARAT_STAGE_IV,DIESEL,ROOF AC,4x2,7,ABS,HTG+DMST 617009 SAFARI STORME VX 4X2 MUV,54077626R,TATA_SAFARI_STORME,VX,2.2L DICOR,BHARAT_STAGE_IV,DIESEL,ROOF AC,4x2,7,DAB+PAB+ABS,HTG+DMST 617010 SAFARI STORME VX 4X4 NORMAL CONTROL CHASSIS WITH ALL STEEL SHELL, SAFARI STORME VXP - 4X4 VERSION, M1 CLASS, 7(6+1) SEATER PASSENGER CARRIER, FRAME TYPE WITH HVAC WITH

GENERAL 8 Lubricants and Coolant Recommendations: Kindly use only following genuine oils, coolants, lubricants, anti-rust, branded by TATA motors for optimum performance of vehicle. Item Specification Company Brand Quantity Engine oil API CI4 Plus, (SAE 15W-40) CASTROL Castrol RX Super Turbo 15W40 7.5 lt EXXON MOBIL Mobil Delvac Tata Motors Geniune CI4 + oil 15W40 Petronas Petronas Urania TM CI4 + oil 15W40 HPCL HP Milcy No 1 Plus Coolant 50:50 ratio Premixed S-CCL Golden Cruiser Premium 1400 M Approx. 9 Lts HPCL HP THANDA RAJA P TGO CASTROL Radicool SFO Premix Gear Box (G-76 MKII) Synthetic gear oil 75W90 GL4 HPCL HP GO XP 75W90 TGO 2.2 Lt CASTROL Castrol SYNTRO 75W90 GL4 EXXON MOBIL MOBILUBE 1 SHC 75W90 Transfer Case ATF DEXTRON -IID SHELL Spirax S3 ATF MD3 1.2 - 1.4 Lt Power steering oil ATF DEXRON-IID CASTROL Castrol TQD 1.6 lt. HPCL ATF DEX II EXXON MOBIL Mobil ATF 220

GENERAL 9 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 Life Rear Axle Oil 85W140 Rear axle (Standard Differential) 85W140 API-GL5 Anglomol 6043 HPCL HP Gear oil XP 85W140 T2 1.68 Lt. CASTROL Extra Long Life Rear Axle Oil 85W140 Live Front axle 85W140 API-GL5 Anglomol 6043 HPCL HP Gear oil XP 85W140 T2 1.50 Lt CASTROL Extra Long Life Rear Axle Oil 85W140 Brake / Clutch Fluid SAE J 1703, DOT 4 S-CCI Tata Genuine Brake Fluid DOT 4 As required CASTROL Castrol Brake Fluid DOT 4 Petronas TUTELA TOP 4 TM

GENERAL 10 SERVICE AND MAINTENANCE SCHEDULE SR. NO. OPERATION Frequency (Km) PDI 4500-5500 9500-10500 19500-20500 295000-30500 39500-40500 49500-50500 59500-60500 69500-70500 79500-80500 89500-90500 99500-100500 GENERAL 1 Wash the vehicle & clean the condenser with compressed air. Every Service x x x x x x x x x x x x 2 Check & Top up Fluids if required: Coolant, Brake / Clutch Fluid, Battery Electrolyte, Power Steering Oil, Gear Box Oil, Transfer Case & Front Axle (4X4)/ Rear Axle Oil Every 10,000 x x x x x x x x x x 3 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 x x 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 x x x x x x x x x x x x 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 x x x x x x x x x x x x

GENERAL 11 SR. NO. OPERATION Frequency (Km) PDI 4500-5500 9500-10500 19500-20500 295000-30500 39500-40500 49500-50500 59500-60500 69500-70500 79500-80500 89500-90500 99500-100500 6 Apply grease on door latches, locks, check straps, strikers, bonnet opening lever, bonnet hinges & lock plate, tailgate hinges & door lock inner ratchet. Every 10000 x x x x x x x x x x 7 Check for proper tightening of latches & Striker screws for doors & Tail gate. Every 10000 x x x x x x x x x x 8 Check & ensure normal working of the vehicle using diagnostic equipment. Every Service x x x x x x x x x x x x 2.2L VARICOR ENGINE 1 Replace Engine Oil and Oil filter (Every 20,000 Km OR 1 year, whichever is earlier) 20K x x x x x 2 Replace element / cartriage of Prefilter cum Sedimentor (Every 20,000 Km OR 1 year, whichever is earlier) 20K x x x x x 3 Replace Main Fuel filter (Every 60,000 Km OR 3 year, whichever is earlier) 60K x 4 Replace Air filter element 40K x x

GENERAL 12 SR. NO. OPERATION Frequency (Km) PDI 4500-5500 9500-10500 19500-20500 295000-30500 39500-40500 49500-50500 59500-60500 69500-70500 79500-80500 89500-90500 99500-100500 5 Check accessory Drive belts ( Alternator & Compressor ) adjust tension if required, Replace if damaged Every 20K Km OR 1 year, whichever is earlier x x x x x 6 Check Timing belt and if found damaged , replace along with tensioner. Every 1,20,000 Kms 7 Replace Timing Belt & Timing Belt tensioner Every 1,50,000 Kms OR 5 years, whichever is earlier 8 Replace Engine Coolant (Every 60,000 km OR 2 year, whichever is earlier) Every 60,000 x 9 Check Accessory drive for Power Steering Pump. Replace if damaged Every 20,000 or 1 year, whichever is earlier x x x x x GEAR BOX 1 Replace Gear box Oil and Clean Breather (First at 40,000 km and thereafter every 90,000 km) Every 90000 kms x 2 Replace Transfer case Oil & Clean Breather (In 4x4 vehicles) Every 40000 Kms x 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 20,000 x x x x x

GENERAL 13 SR. NO. OPERATION Frequency (Km) PDI 4500-5500 9500-10500 19500-20500 295000-30500 39500-40500 49500-50500 59500-60500 69500-70500 79500-80500 89500-90500 99500-100500 2 Check for rubber cracks on Torsional Vibration Damper (TVD), replace if necessary Every 20,000 x x x x x 3 Replace TVD (Every 60,000 km) Every 60,000 x FRONT AXLE (FOR 4X4) / REAR AXLE 1 Replace Axle Oil ( Front (For 4x4) / Rear) (Every 70,000 km) Every 70,000 x 2 Clean Breather in front ( FOR 4x4 ) and Rear axle Every 70,000 x SUSPENSION & STEERING 1 Check wheel alignment / Steering wheel spoke alignment/ wheel balancing & adjust if necessary Every 20,000 x x x x x 2 Check shock absorber, bushes replace if necessary (First at 30,000 km and thereafter at every service) First 30,000 & then at every service x x x x x x x x 3 Check condition of rubber bushes in Top & Lower wishbones, Anti roll bars, Rear links, Pan-hard rod, rubber boots/dust cover/ bellow in Rack & pinion, steering ball joints & column. Replace if necessary. Every 30,000 x x x 4 Replace Power steering Oil & filter element Every 1,00,000 x

GENERAL 14 SR. NO. OPERATION Frequency (Km) PDI 4500-5500 9500-10500 19500-20500 295000-30500 39500-40500 49500-50500 59500-60500 69500-70500 79500-80500 89500-90500 99500-100500 BRAKES & CLUTCH 1 Check parking brakes, adjust if necessary Every Service x x x x x x x x x x x 2 Check front brake & rear brake pads, re-grease DIH liner resting points. Replace if necessary. Every 10,000 x x x x x x x x x x 3 Replace Brake & Clutch Fluid (Every 40,000 km Or 2 years whichever is earlier) Every 40000 x x ELECTRICALS 1 Check headlamp focusing & functioning of all electrical equipments. Every 20,000 x x x x x 2 Check for looseness of + Ve Terminals on Alternator and Starter motor Every 30,000 x x x HVAC 1 Check HVAC System for satisfactory performance, attend if required. Every Service x x x x x x x x x x x x WHEEL & TYRES 1 Tyre Rotation Every 20,000 x x x x x x x x x x

GENERAL 15 * 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 10,000 kms x x x x Air filter element Change at every 20,000 km or 1.5 year whichever is earlier x x Front (For 4X4) & rear axle oil change Change at first 20,000 kms & thereafter at 50,000 kms x x x

PRECAUTIONS PRECAUTIONS PRECAUTIONS

PRECAUTIONS PRECAUTIONS TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS ...........................................................................................1 1.2 SAFETY AGAINST PERSONAL INJURY......................................................................2 A. WORKING WITH VEHICLES FITTED WITH AIRBAG ...................................................2 B. WORKING WITH ENGINE 'ON' ......................................................................................3 1.3 AVOIDING DAMAGE .....................................................................................................4 1.4 USED OIL HANDLING AND DISPOSAL .......................................................................4 1.5 FUEL HANDLING PRECAUTIONS................................................................................5 1.6 HAZARDOUS MATERIAL..............................................................................................6

PRECAUTIONS 1 PRECAUTIONS 1.1 GENERAL PRECAUTIONS SAFE SERVICE During vehicle maintenance or service, the service technician may be exposed to certain components or conditions including, but not limited to: exhaust gas (carbon monoxide), fuel, oils, refrigerant, and materials under pressure, rotating components, and electrical current. Any of these components or conditions has the potential to cause bodily injury or death if proper precautions are not taken. The servicing technician is obligated and responsible for identifying and recognizing these inherent hazards to protect themselves, other personnel, and proceeding safely in order to complete their required tasks. Failure to comply with any of these requirements could result in serious damage to the vehicle and the property where the vehicle is situated, as well as severe personal injury or death to the service technician and other people at the site. The individual performing the vehicle repair procedures outlined in this manual must possess independent training that will enable them to perform their assigned tasks properly and safely. The technician must read and understand the content in this manual and any referenced materials before performing any work the vehicle. When performing any service, the technician maintains responsibility for knowing and complying with any applicable governing standards and regulations. The contents of this manual include suggested best working practices and procedures related to the servicing of the specified vehicle. Safety warnings show potential areas of hazards. These procedures in this manual are issued for guidance only and do not take precedence over the previously stated individual responsibility and local safety regulations. SAFETY AND WORKSHOP GUIDELINES PROTECTING THE ENVIRONMENT Protect the environment by using proper disposal procedures for engine oil, engine coolant, fuel, tyres, brake lining and batteries. Follow all governing regulations for proper disposal of these materials. PROPER ATTIRE Always wear proper attire when performing service on the vehicle. Proper attire guidelines to follow while servicing the vehicle include, but are not limited to, the following points:  Wear approved safety glasses.  If it is required to work near moving parts or when the engine is running, do not wear loosefitting clothing; keep clothing away from moving parts.  Never wear any jewelry, watches, rings, or necklaces to help protect yourself and your valuables.  Suitable clothing should be worn as metal buttons and zippers can damage the painted finish.  To protect the foot always wear steel-toe shoes.  Never work on vehicle without automotive work gloves to avoid burns, cuts, or other injuries. WORK AREA A proper work area is required to ensure safety while working on the vehicle. Follow the points listed below for a proper workspace:  Always engage the parking brake and/or use wheel chocks to prevent the vehicle from moving.  Before doing any job make sure that the work area (includes floors, workbenches, tools) is clean and free from debris and clutter.  Have adequate ventilation to disperse exhaust gases (carbon monoxide) and other fumes.  Inside the work area no animals or unauthorized person should be allowed. SUPPORTING THE VEHICLE Always make certain the vehicle is properly supported at the designated lift points for the method of lifting being used. A vehicle that is supported improperly may fall, causing damage to the vehicle, severe personal injury, or death. Refer to General Section in this manual for instructions on how to properly support the vehicle.

PRECAUTIONS 2 DURING REPAIRS 1. Disconnect the battery, before any repair, unless required. 2. To avoid serious burns, keep out of Hot metals like Radiator, Exhaust pipe, Catalytic converter and exhaust and intake manifold. 3. Apply handbrake, whenever working on a vehicle. 4. Do not smoke when working on the vehicle. 1.2 SAFETY AGAINST PERSONAL INJURY A. WORKING WITH VEHICLES FITTED WITH AIRBAG While working with Vehicles equipped with airbag special care should be taken to avoid accidental deployment, which may cause personal injury and also to avoid damage to the airbag which may result in its failure to deploy during a crash. Disconnect the battery negative and wait for a minute before proceeding with any repairs related to airbag. !! WARNING Since the airbag system has power back up for about 30 secs, it is essential to wait for at least a minute after disconnecting the battery to proceed with any repair in order to avoid air bag deployment. 1. Replace the Airbag modules if dropped from a height, even if no external damage is visible. 2. Only use the diagnostic tool to probe faults in the Airbag system, never use electrical probing instruments as the probing current may deploy the airbag. 3. Check if the airbag lamp comes ON to show any fault after conducting a repair and recheck for any errors using the diagnostic tool. 4. Do not try to dismantle the airbag module; there are no serviceable parts in it.

PRECAUTIONS 3 PRECAUTIONS 5. Place the Airbag modules such that the deployment side is placed facing upwards and away from any loose parts. 6. While carrying Airbag modules hold the deployment side away from face, to avoid personal injury. 7. To dispose an undeployed air bag module, follow the instructions given in the SRS section for disposal. 8. Follow the instructions given SRS section for all Air bag related repairs. 9. If the airbag is opened during transport or handling, the airbag should be returned to the supplier. 10.Do not carry the airbag modules by its wires. B. WORKING WITH ENGINE 'ON' It is recommended that the engine should be OFF during any repair procedures, however if it is required to keep the engine running during any repair or for testing purpose. Make sure the following precautions are observed: 1. Make sure that the vehicle is in neutral. 2. Make sure that the workshop has provision to artificially force out the exhaust gas (Exhaust fan), if not conduct the repair outdoors. 3. It is advisable to lift the rear wheels off ground to avoid personal injury in case of accidental gear engagement. !! WARNING  In case of vehicles fitted with transfer case it is recommended that all four wheels are lifted as there are chances the power may be transmitted to the front wheel as well.  Do not use Jack, use lifts instead. 4. Take special care to avoid putting hand into the engine bay, especially where the drive belt and radiator fan is located, it may lead to severe personal injury. 5. Ensure that you or your clothing is away from moving parts, especially drive belts. 6. Avoid placing tools on the engine, as the vibration may cause it to fall into running parts like belts, pulleys etc. causing damage to the components and may also result in personal injury. 7. Keep monitoring engine coolant temperature, since the vehicle is stationary, it may lead to coolant overheating.

PRECAUTIONS 4 1.3 AVOIDING DAMAGE 1. Always protect the vehicle paint and interiors where the technician might come in contact with the vehicle, using covers like fender cover, seat covers, steering cover, etc 2. Some lubricants, coolant and brake fluid can cause the paint to fade if it comes in contact with painted surface. If accidentally applied, wipe off immediately with clean dry cloth. 3. Remove all the ECU’s from the vehicle if any Arc Welding is to be done on the vehicle. In case of other welding (like Gas Welding) remember that the ECU should not be subjected a temperature of more than 800C. NOTE Precautions to be taken in order to avoid damage to components during repair are given in the section ‘GENERAL INFORMATION’ under ‘RECOMMENDATIONS – REPAIRS AND REPLACEMENT’. 1.4 USED OIL HANDLING AND DISPOSAL Used oil is a hazardous substance and should be handled as one. Special care should be taken while draining it from engine, storing it in the workshop and its disposal. HANDLING USED OIL Being a hazardous substance the following precautions should be taken 1. Avoid prolonged contact with any lubricant, especially used oil. 2. Avoid any open cuts, wounds and bruises coming in contact with the used oil. 3. If it possible to degrease the component before carrying out a repair, degrease before handling it. 4. Use soap to wash off used oil from skin, never use diesel, petrol, kerosene, thinner or any other fuel to wash. 5. Oily cotton waste or cloth should not be kept in pockets and discard unwashable clothing and footwear to which the oil has impregnated. DISPOSING USED OIL Since used automotive oil is a hazardous substance, Laws are being laid out on its disposal. In India, ‘The Hazardous Wastes (Management and Handling) Rules, 1989 (later amended in 2003)’, has detailed guidelines laid out for Waste generators, handler and disposing facility. Contact local State Pollution Control Board for awareness on your responsibilities. Contact the Government Environment or Pollution Control agencies for awareness on your responsibilities towards Disposing Used oil. !!WARNING Even in emergencies avoid disposing used oil to sewer or any water source.

PRECAUTIONS 5 PRECAUTIONS 1.5 FUEL HANDLING PRECAUTIONS Since fuel is highly inflammable following precautions should be taken when handling it. 1 Make sure you have the right kind of Fire extinguisher in case of any fire due to Fuel i.e. Dry chemical powder type or CO2 gas type extinguisher marked B & C. 2 Fuel vapours are highly inflammable and is toxic in an enclosed place. Hence even small fuel leakage should be treated seriously. 3 The battery terminal should be disconnected before conducting any Fuel system repairs. !! WARNING Never disconnect the battery terminal when a fuel system repair is already in progress as arcing at the terminals can have dangerous consequences. 4 Release the pressure of the fuel system before disconnecting any pipe. Refer ‘FUEL SYSTEM – Pressure Relieving Procedure’ procedure for instructions. 5 Never drain fuel when the vehicle is standing over a pit, always transfer or drain fuel in a well ventilated area. 6 Never try to repair the fuel tank, if any damage is found, replace it. 7 In case of leak never approach from below, as fuel vapours move downward. 8 Clear surrounding area of any combustible material during fuel system repair. 9 Avoid taking the lead lamp near the leaking fuel in case if it is necessary, use flame proof lead lamp. 10 Never gas cut any type of empty fuel container without purging the container. 11 The workshop area should be strictly maintained as NO- SMOKING AREA 12 No refueling of vehicle while engine is running 13 Switch off cell phone while repairing the fuel system of vehicle (Petrol/CNG/LPG) 14 Use metal container for emptying the vehicle fuel tank and keep the container on the ground to avoid the fire due to static charge FIRST AID In case of fire due to fuel: a. Remove all jewellery, watches, etc. from the victim’s body. b. Cool running water should be allowed to run on the burnt areas of the skin to reduce the pain. c. If blisters occur they should be protected and not burst. d. Protect the broken blisters using plastic bag, do not apply dry dressing on them.

PRECAUTIONS 6 1.6 HAZARDOUS MATERIAL A material is termed as Hazardous if it can harm people or the environment. These include substance that might be hazardous on contact or on consumption. The labels on these products give the required information issued by the manufacturer. Most of the materials used in Body shop and paint shop may carry a warning symbol, precautions for storing, handling and disposal and information on what has to be done in case of consumption or contamination. Protective equipment as recommended should be worn when working with hazardous material. Follow the following precaution when working with Hazardous material. 1. Use recommended protective gear like gloves, glasses and protective clothing. 2. Keep a separate rack/shelf Labeled “Hazardous” for all hazardous material. 3. Keep the tools and equipment used with such materials separate and under lock with clear labels to distinguish. 4. Such materials should not be allowed to come in contact with open cuts, bruises and wounds. FIRST AID The following first aid should be done as soon as a person is contaminated with such material before the help arrives. If poisonous materials are handled accidentally with bare hands or falls on skin: a. Remove all contaminated clothing and shoes. b. Remove all dry poison and pour excess of plain water in the hand or skin. c. Wash off skin, using a bar soap and water and rinse. d. Discard all contaminated clothing and shoes. If a poisonous material enters the eye: a. Keep the eye open and keep dropping room temperature water over the bridge of the nose for about 15 mins. b. Do not hold the eye under flowing water but drip water. c. Do not allow the person to rub the contaminated eye. d. No medicated drops should be used. IF A POISONOUS MATERIAL IS SWALLOWED a. Open the victim’s mouth and remove any material that may be present. b. Check for any cuts, burns, swellings, unusual colour and odor in the mouth. c. Rinse and wipe out the mouth with a cloth. d. Do not make the victim vomit. e. Refer victim to the nearest first aid center immediately. If poisonous fumes or gases are inhaled: a. Move the person immediately to fresh air, to reduce the exposure to the fumes / gases. b. In case the victim is not breathing, start artificial respiration immediately and continue it until the victim is breathing or help arrives. !! WARNING In all cases try to get medical assistance as soon as possible, even if the victim appears to have recovered.

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. DRAININGWATER 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) ...................................................... 37 D. ALTERNATOR AND AC BELT ......................................................................................... 38 E. INJECTOR REMOVAL..................................................................................................... 39 F. TIMING BELT REMOVAL................................................................................................. 40 G. TIMING BELT FITMENT .................................................................................................. 42

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....................................................................................117 2.1.7 FUEL SYSTEM...................................................................................................123 2.1.8 EXHAUST SYSTEM ...........................................................................................139 2.1.9 ENGINE MANAGEMENT SYSTEM (EMS) ........................................................157 2.1.10 DIAGNOSTIC USER MANUAL ..........................................................................188

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 150 Ps at 4000 rpm (320 Nm LET) Max. Torque 320 Nm at 1500 - 3000 rpm (320 Nm LET) 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 Power steering pump mounting bracket on crankcase Bolt M8 3 + 0.3

ENGINE 18 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 58 A/C compressor mounting Bolt M8 , class 10.9 3 + 0.3 59 Power steering pulley mounting Bolt M8 2.5 60 A/C Idler bolt (Slider bolt for tension adjustment) Bolt M10 2.5 61 Radiator mounting bolt M10 4.6

ENGINE 19 SR. NO. DESCRIPTION FASTENER TYPE TIGHTENING TORQUE (Kg-m) LOCATION 62 Engine mounting bolt (Front) Bolt M12 X 1.5 7 63 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 27 Front Damper Bottom Bush Fit / Removal 5407 5890 32 01

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 ENGINE 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

ENGINE 24 2.1.2 MAINTENANCE, INSPECTION AND TESTS: 2.1.2.1 PRELIMINARY INSPECTION: 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. GENERAL • Check for leakage of Oil, fuel, and Coolant. • Check for overheating of engine. • Check for unusual smoke. • If there is any fault in the Engine Management system (EMS) then the MIL indicator in the instrument cluster will come ON. In such a case connect the diagnostic tester. (For procedure refer EMS section). Before proceeding to carry out actual reconditioning of engine, it is desirable to have a preliminary inspection of engine to ascertain whether an engine reconditioning is necessary and if so, to what extent. Most common reasons for which engine is reconditioned are 1. Loss of power. 2. Excessive engine oil consumption. 3. Extremely low engine oil pressure. 4. Mechanical failures. To know exact reason and general condition of engine, proceed as follows 1. LOSS OF POWER Loss of engine power may be due to a. EMS is in limp-home mode due to some critical fault. b. Clogged air filter / clogged intercooler fins /loss of charge air pressure / choked exhaust passage / catalytic converter. c. Loss of engine compression d. Defective fuel system e. Clutch slippage f. Brake binding A. EMS is in limp-home mode If the EMS detects some major fault in the system it switches to limp-home mode, where it runs at a reduced torque. Connect the diagnostic tester and check if any faults are present in the Engine EMS, if found rectify them. (For details refer Engine Management Section) B. Clogged Air filter/Loss of Charge Air Pressure/ Choked exhaust system. Loss of power indicates lack of air or low air charging pressure to engine cylinders. Clean air filter & inter cooler fins. Check all joints for air leakage. If power loss still felt, check exhaust system for choking, rectify if ON as per procedure mentioned in owner’s manual. Clean and replace silencer if necessary. Check for kink formation in exhaust piping. C. Checking Engine Compression Pressure • If loss of power is not on account of defective fuel system, lack of air, choked exhaust system, clutch slipping and brake binding, check engine compression as follows. • Warm up engine preferably by road drive to get a coolant temperature of about 90ºC. Stop the engine. • Remove the air filter. • Remove the injector back-leak pipes and high pressure pipes from rail to injector .Disconnect rail pressure sensor. • Plug the common rail outlet with suitable caps. • Remove all injectors. • Fit adapter (Part no 2868 5890 07 01) in place of one injector. • Connect compression tester to adapter and tighten vent knob. • Crank the engine with starter motor by 200-350 rpm approximately. Pressure gauge needle will start rising. Continue cranking till gauge needle stops rising any further. Note down the reading. Loosen vent knob to make sure the tester needle returns to zero. Repeat this operation for remaining cylinders. • Minimum compression pressure in each cylinder should be 23 ± 1 bar. • Low compression pressure may be due to leakage past valves / piston rings / blown cylinder head gasket. To ascertain the point of leakage, spray small quantity of clean engine oil in to cylinder showing low pressure. If it improves, wear in piston rings / cylinder bore is indicated. If it does not, leakage past the valves is indicated. If compression pressure of adjacent cylinder is al-

Made with FlippingBook

RkJQdWJsaXNoZXIy MTIwNTUz