i WORKSHOP MANUAL RHD / LHD Mumbai Pune
ii All specifications are given in C.G.S. System (Metric System) unless otherwise specified. Published by Literature Development Cell, Customer Support, Passenger Car Business Unit, Tata Motors Pimpri, Pune - 411 018. Reproduction or translation of the whole or part of the workshop manual without our written approval is prohibited. Subject to modification in Design, Specification and Equipment. Printed by Sawkar Art Service, Pune. Tel.: (020) 4455739 SAS/M-2003/200
iii This manual brings to you the technical know-how on the repairs and overhaul of all versions of TATA SAFARI, assuming that the workman is fully conversant with general automobile practices. The repair procedures outlined in this manual emphasize the special aspects of the product. This will enable you to build and maintain a reputation of quality service. The manual includes instructions on aggregates manufactured by Tata Motors. For repair of proprietary aggregates such as Transfer Case, Rear Axle, Air Conditioning etc. please refer to the instruct ions of the respect ive propr ietary manufacturers included in this manual. The main idea behind incorporating these instructions in this manual is to enable workmen to understand their functions properly and thus judge the performance of the vehicle as a whole. All data contained in this manual is based on the latest product information available at the time of publication. This manual is also applicable to Tata Safari LHD versions as the basic aggregates are same. In case of LHD versions only the driving controls and vehicle electricals are different. For further technical advice, please contact your nearest Customer Support Office or write to : Tata Motors Customer Support, Passenger Car Business Unit, ‘K’ Block, Pune - 411 018. India INTRODUCTION: How to use this manual : This manual is divided into 18 groups. The first page of each group is marked with black tab & this lines up with one of the thumb index tab on the group index page. You can quickly find the first page of each group without looking through a full manual. The symbol printed at the top corner of each page can also be used as a quick reference system. Each group includes : l Technical specifications l Tightening torques l List of special tools l Disassembly / Assembly procedures l Use of special tools l Inspection of parts l Trouble shooting.
v Sr. No. Description 1. GENERAL 2. ENGINE - 4 DLT 3. ENGINE - 486 PETROL 4. CLUTCH 5. GEAR BOX 6. TRANSFER CASE 7. SUSPENSION (WHEELS AND TYRES) 8. FRONT LIVE AXLE (4X2) 9. FRONT LIVE AXLE (4X4) 10. REAR AXLE 11. PROPELLER SHAFT 12. BRAKES 13. ANTI-LOCK BRAKING SYSTEM 14. STEERING 15. ELECTRICAL 16. BODY 17. AIR BAGS 18. AIR CONDITIONING GROUP INDEX General Engine 4 DLT Engine 486 Petrol Clutch Gear Box Transfer Case Suspension Front Axle 4 x 2 Front Axle 4 x 4 Rear Axle Propeller Shaft Brakes Anti- Lock Braking System Steering Electrical Body Air Bag Air Conditioning G ABS SRS P ir B s
G 3 GENERAL INTRODUCTION : This manual provides the information on good workshop practices and safety precautions, chassis & aggregate numbering system, location of aggregate numbers, broad technical specification and filling capacities. It also provides information on fuel, lubricants and coolants required for TATA Safari Vehicles. All lubrication & maintenance work should be carried out as given in the service schedule chart. General
G 5 GENERAL CONTENTS Sr. No. Description Page No. 1. Good workshop practices and safety precautions 7 2. Lifting and jacking points 11 3. Tightening torques of standard bolts and nuts 12 4. Chassis numbering system 13 a. Chassis numbering system for domestic vehicles 13 b. Chassis numbering system for export vehicles 17 c. Chassis numbering system for CKD vehicles 17 5. Aggregate numbering system 18 6. Technical specifications 21 7. Filling capacities 25 8. Fuel, Lubricants & Coolants a. Fuel 25 b. Lubricants 26 c. Coolants 26 d. Genuine Co-Branded Items 27 9. Service schedule 28 General
G 7 GENERAL 1. GOOD WORKSHOP PRACTICES & SAFETY PRECAUTIONS Fol lowing are some safety precautions to be observed in the workshop. l Always ensure that all the repair / maintenance work carried out should be as per the instructions provided in the workshop manual. l Use protective clothing, apron, hand gloves, and safety shoes while working in the workshop. Do not wear watch, rings and belt while serving the vehicle. l Keep your work area, equipment and tools clean at all times. l Make sure you use the proper tool for the job and use it the rightway. The improper tool or its incorrect use can damage the par t you are working on or cause injury or both. l Never keep the tools on the floor/vehicle. The tools should be kept in the tool box after use. l Cover fenders, seats, steering wheel and any other parts those are likely to get scratched/ soiled before starting any service work (Fig. 1). l While servicing the vehicle in engine running condition make sure that the gear shifting lever is in neutral position and parking brake is fully applied. Never run the engine without proper ventilation and adequate means of getting rid of exhaust gases. l Prior to removing or disassembling parts, they must be inspected carefully to isolate the cause for which the service is called for (Fig. 2). l All the reusable dismantled components must be kept in a clean enamel coated white tray sequentially in an orderly manner to facilitate their accurate and proper reinstallation (Fig. 3). l Never reuse the parts like oil seals, gaskets, packing, O-rings, locking washers, split pins, self locking nuts and certain other parts. l Plug the ports / openings of aggregates such as FIP / Injectors, TMC, etc., whenever removed from the car. Fig. 2 Fig. 1 Fig. 3
G 8 GENERAL Fig. 4 Fig. 5 l For correct reinstallation of vacuum fuel hoses attach a tag describing the correct positions Fig. 4. l Make sure only the branded lubricants, coolant, corrosion protection coatings and sealants are used. l Check all the lines for leaks related to the systems like fuel, oil, coolant, vacuum, exhaust and brakes after servicing Fig. 5. l For vehicles equipped with fuel injection systems do not disconnect the fuel line between the injector and the fuel pump without releasing the fuel pressure or fuel can be sprayed out under pressure. Precaution for Catalytic Converter Fig. 6. Caution : If large amount of unburnt fuel goes into the converter, it may overheat and creat a fire hazard.To prevent this, observe the following precautions. l Use only unleaded gasoline for petrol vehicle & Low sulphur (<0.25%) Diesel for Diesel vehicles. l Engine compression checks should be carried out within the shortest possible time only. l If necessary then only conduct a spark jump test within the shortest possible time (Petrol version). l Do not run the engine when the fuel tank is nearly empty to avoid engine misfire and damage to catalytic converter. Fig. 6 VSV to EGR valve Boost controller backleak
G 9 GENERAL Precaution for Electrical circuit service : l Disconnect the negative cable of the battery while servicing the electrical parts that do not require battery power Fig. 7. l While removing the battery first disconnect the negative cable and then the positive cable. While reinstalling the battery, first connect the positive cable and then negative cable. Fig. 8 Fig. 9 Fig. 7 l Be sure to turn the ignition switch off before disconnecting and connecting coupler to avoid electronic parts damage Fig. 8. l Do not touch the electrical terminals of parts which use microcomputers (e.g. electronic control units like ECM etc.) to avoid damage to these parts from static electricity from your body Fig. 8. l Always use the correct voltmeter, ohmmeter for taking measurement to avoid damage to the electronic control unit and sensors. l Make sure to insert the probe from wire harness side of the connector for taking measurement. l Make sure the connector halves are mating properly and terminals seating precisely in the connector body Fig. 9.
G 10 GENERAL Fig. 10 Towing the Vehicle : Fig. 11. l For towing the best way is to use a wrecker. Alternatively use a rigid tow bar. l Avoid using a flexible cable or rope as your vehicle may crash into the towing vehicle when it stops suddenly. l Switch ‘ON’ the hazard warning signals of both the vehicles to warn other road users. l Where possible, keep the engine idling so that power steering assistance and brake vacuum are available. l Limit the speed to 20-30 Kmph. l In case of brake failure, use the parking brake to control the vehicle. l Dirt / corroded terminals result in improper contact. The terminals should be cleaned carefully. l Improper contact pressure between mating terminals disturbs the connectivity between them. l Replace the damaged connector body to avoid exposure of the terminals in case of inadequate contact pressure. l Ensure proper connection between the terminal to the wire. Rectify the loose connection by repairing / replacing the wire harness (Fig. 10). l Worn out insulation of the wire may result in short circuit. l Avoid water entering the connectors. Fig. 11 Rear tow hook Towing hook front
G 11 GENERAL 2. LIFTING AND JACKING POINTS Fig. 12 USING THE HOIST Make sure you follow the hoist manufacturers instructions while lifting the vehicle on two pole hoist Fig. 12. Always ensure vehicle balance in service while applying hoist to under body. Care should be taken that the hoist arm is not in contact with the bracket, brake or fuel pipes etc. Before servicing, make sure to lock the hoist after the vehicle is lifted up. When using the floor jack : Use the jacks at the locations indicated Fig 13. Do not apply the jack against any part which may get deformed. If front end or rear end of the vehicle is to be jacked ensure the wheels on ground are blocked with wheel chokes for safety. Fig. 13 Front Jacking Point Rear Jacking Point Front Lifting Points Rear Lifting Points
G 12 GENERAL 3. TIGHTENING TORQUES OF STANDARD BOLTS & NUTS Wherever the tightening torques are not specified use the following values for these fasteners. Grade Bolt or Nut Size Pitch (mm) Tightening N-m Torque kg-m M6 1.0 8.5 - 10 0.85 - 1.0 M8 1.25 21 - 25 2.1 - 2.5 M10 1.5 41 - 51 4.1 - 5.1 1.0 46 - 56 4.6 - 5.6 M12 1.75 72 - 88 7.2 - 8.8 1.5 75 - 91 7.5 - 9.1 M14 2.0 113 - 138 11.3 - 13.8 1.5 126 -154 12.6 - 15.4 M16 2.0 176 - 215 17.6 - 21.5 1.5 189 - 231 18.9 - 23.1 M6 1.0 12 - 14 1.2 - 1.4 M8 1.25 29 - 35 2.9 - 3.5 1.0 32 - 39 3.2 - 3.9 M10 1.5 58 - 70 5.8 - 7.0 1.0 64 - 78 6.4 - 7.8 M12 1.75 99 - 121 9.9 - 12.1 1.5 104 - 127 10.4 - 12.7 M14 2.0 162 - 198 16.2 - 19.8 1.5 176 - 215 17.6 - 21.5 M16 2.0 248 - 303 24.8 - 30.3 1.5 266 - 325 26.6 - 32.5 1. This standard is applicable to the bolts having the following marks embossed on the bolt head and punch mark on the nut head. Grade 8.8 For the Bolt 10.9 For the Bolt 8 For the Nut 10 For the Nut Note : Always use the calibrated torque wrenches. Bolt 8.8 Nut 8.0 Bolt 10.9 Nut 10.0
G 13 GENERAL 4. CHASSIS NUMBERING SYSTEM : a. CHASSIS NUMBERING SYSTEM FOR DOMESTIC VEHICLES Chassis number consists of 15 digits (5 barrels) as given below : 1 2 3 4 5 403 001 G SQ 9 00001 Location : Chassis number is punched on chassis frame LHS long members for RHD vehicles and RHS long member for LHD vehicles chassis type number is punched in a single line without any gap. Also a chassis number plate is fixed in the engine compartment. Barrel 1: 1st three digit indicates the Model 403 : for Safari Next three digit indicates type and wheel base. 001 : Safari Ex 4 x 4 version passenger carrier frame type normal control chassis with all steel shell, 483 DLTC diesel engine, Airconditioning, Heating and demisting and 2650 mm wheel base. 002 : Safari Ex 4 x 2 version passenger carrier frame type normal control chassis with all steel shell, 483 DLTC diesel engine, Airconditioning, Heating and demisting and 2650 mm wheel base. 011 : Safari Ex 4 x 4 version passenger carrier frame type normal control chassis with all steel shell, 483 DLTC diesel engine, Airconditioning, Heating and demisting, Bharat stage II and 2650 mm wheel base. 012 : Safari Ex 4 x 2 version passenger carrier frame type normal control chassis with all steel shell, 483 DLTC diesel engine, Airconditioning, Heating and demisting, Bharat stage II and 2650 mm wheel base. 013 : Safari L x 4 x 2 version passenger carrier frame type normal control chassis with all steel shell, economy version, 483 DLTC diesel engine, Airconditioning, Heating and demisting, Bharat stage II . 014 : Safari L x 4 x 4 passenger carrier, frame type normal control chassis with all steel shell, economy version, 483 DLTC Diesel engine, AC + Heating & dimisting, Bharat stage II 2650 mm wheel base. 015 : Safari Ex 4 x 4 version passenger carrier frame type normal control chassis with all steel shell, special version with VCD, 483 DLTC diesel engine, Airconditioning, Heating and demisting, Bharat stage II and 2650 mm wheel base. 016 : Safari Ex 4 x 2 version passenger carrier, normal control chassis with all steel shell, special version with VCD, 483 DLTC diesel engine, Airconditioning, Heating and demisting, Bharat stage II and 2650 mm wheel base. 017 : Safari 4 x 4 Normal control chassis with all steel shell Safari 4 x 4 special version with VCD system M1 class. 8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL INDIA 2000 Engine 2650 mmWB. 018 : Safari Normal control chassis with all steel shell Safari 4 x 2 special version with VCD system M1 class. 8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL INDIA 2000 Engine 2650 mmWB. 019 : Safari LX 4 x 4 Normal control chassis with all steel shell Safari LX-4 x 4 economy version M1 class. 5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE-II Engine 2650 mm WB. Fig. 14 Chassis Number on Cab
G 14 GENERAL 020 : Safari LX Normal control chassis with all steel shell Safari LX 4 x 2 economy version M1 class. 5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL BHARAT STAGE-II Engine 2650 mmWB. 101 : Safari EXi 4 x 4 Normal control chassis with all steel shell Safari EXi 4 x 4 version M1 class. 8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 PL Engine 2650 mm WB. 102 : Safari EXi Normal control chassis with all steel shell Safari EXi 4 x 2 version M1 class. 8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 PL Engine 2650 mm WB. 103 : Safari Normal control chassis with all steel shell Safari 4 x 2 version PMO’S ESCORT VEHICLE, M1 class. passenger carrier 4+1 seats frame type with A. C. + heating & demisting with 483 PL BHARAT STAGEII Engine, 2650 mm WB. 104 : Safari Normal control chassis with all steel shel l Safar i 4 x 2 version PMO’S ARMOURED VEHICLE, M1 class. passenger carrier 4+1 seats, frame type with A. C. + heating & demisting with 483 PL BHARAT STAGE-II Engine, 2650 mm WB. 105 : Safari EXi 4 x 4 Normal control chassis with all steel shell Safari EXi 4 x 4 version, M1 class. 5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 PL Engine, 2650 mm WB. 106 : Safari EXi Normal control chassis with all steel shell Safari EXi 4 x 2 version M1 class. 5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 PL Engine, 2650 mm WB. 151 : Safari EXi 4 x 4 Normal control chassis with all steel shell Safari EXi 4 x 4 version M1 class. 8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 486 PL BHARAT STAGE-II Engine, 2650 mm WB. 201 : Safari EX 4 x 4 Normal control chassis with all steel shell Safari EX 4 x 4 version M1 class. 8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DLTCIC INDIA 2000 Engine, 2650 mm WB. 202 : Safari EX Normal control chassis with all steel shell Safari EX 4 x 2 version M1 class.8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DLTCIC INDIA 2000 Engine, 2650 mm WB. 211 : Safari EX 4 x 4 Normal control chassis with all steel shell Safari EX 4 x 4 version M1 class.8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mmWB. 212 : Safari EX Normal control chassis with all steel shell Safari EX 4 x 2 version M1 class.8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mmWB. 213 : Safari EX 4 x 4 Normal control chassis with all steel shell Safari EX 4 x 4 version M1 class.8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with air bag with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mm WB. 214 : Safari EX Normal control chassis with all steel shell Safari EX 4 x 2 version M1 class.8(7+1) seater passenger carrier, frame type with A. C. + heating & demisting with air bag with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mm WB. 230 : Safari EX 4 x 4 Normal control chassis with all steel shell Safari EX 4 x 4 version M1 class.5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mmWB. 231 : Safari EX Normal control chassis with all steel shell Safari EX 4 x 2 version M1 class.5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mm WB.
G 15 GENERAL 250 : Safari EX 4 x 4 Normal control chassis with all steel shell Safari EX 4 x 4 version (limited edition-2003) M1 class. 5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mm WB. 251 : Safari EX Normal control chassis with all steel shell Safari EX version (limited edition2003) M1 class. 5(4+1) seater passenger carrier, frame type with A. C. + heating & demisting with 483 DL TCIC BHARAT STAGE - II Engine, 2650 mm WB. 101 : Safari 4 x 4 version passenger carrier frame type normal control chassis with all steel shell, 483 PL engine, Airconditioning, Heating and demisting and 2650 mmwheel base. 102 : Safari 4 x 2 version passenger carrier frame type normal control chassis with all steel shell, 483 PL diesel engine, Airconditioning, Heating and demisting and 2650 mmwheel base. Barrel 2: Indicates the manufacturing month (code) Month Code Month Code Jan. A July G Feb B Aug H March C Sept. J April D Oct. K May E Nov. L June F Dec. M Barrel 3: Indicates the manufacturing year (code) 1997 SQ 2002 XZ 1998 RQ 2003 WZ 1999 QQ 2004 VZ 2000 ZZ 2005 UZ 2001 YZ Barrel 4: Indicates the plant location. 0 & 4 for Lucknow (I & II) 1 & 2 for Jamshedpur (I&II) 5 for CKD vehicles, 6 for Dharwad 7 for D block, Pune, 8 for H black, Pune 9 for J block, Pune - 1st assy. Line N for J block Pune - 2nd assy. Line Barrel 5 : Indicates cumulative serial number of chassis produced during the year at each plant location.
G 16 GENERAL RUNNING SERIAL NOS. NUMBER TO BE PUNCHED SIGNIFIES THE RUNNING CHASSIS NO. 0001 TO 09999 00001 TO 09999 10000 TO 19999 10000 TO 19999 20000 TO 29999 20000 TO 29999 30000 TO 39999 30000 TO 39999 40000 TO 49999 40000 TO 49999 50000 TO 59999 50000 TO 59999 60000 TO 69999 60000 TO 69999 70000 TO 79999 70000 TO 79999 80000 TO 89999 80000 TO 89999 90000 TO 99999 90000 TO 99999 A0000 TO A9999 100000 TO 109999 B0000 TO B9999 110000 TO 119999 C0000 TO C9999 120000 TO 129999 D0000 TO D9999 130000 TO 139999 E0000 TO E9999 140000 TO 149999 F0000 TO F9999 150000 TO 159999 G0000 TO G9999 160000 TO 169999 H0000 TO H9999 170000 TO 179999 J0000 TO J9999 180000 TO 189999 K0000 TO K9999 190000 TO 199999 L0000 TO L9999 200000 TO 209999 M0000 TO M9999 210000 TO 219999 N0000 TO N9999 220000 TO 229999 P0000 TO P9999 230000 TO 239999 R0000 TO R9999 240000 TO 249999 S0000 TO S9999 250000 TO 259999 T0000 T0 T9999 260000 TO 269999 U0000 TO U9999 270000 TO 279999 V0000 TO V9999 280000 TO 289999 W0000 TO W9999 290000 TO 299999 X0000 TO X9999 300000 TO 309999 Y0000 TO Y9999 310000 TO 319999 Z0000 TO Z9999 320000 TO 329999 Note : Letters I, O & Q, not used as per iso 3779
G 17 GENERAL b. CHASSIS NUMBERING SYSTEM FOR EXPORT VEHICLES Chassis number consists of 17 digits (6 barrels) chassis number is punched in a single line without gap on frame LHS long member - RHD vehicles and on RHS long member in case of LHD vehicles. 1 2 3 4 5 6 MAT 414XXX X X X XXXXX Barrel 1 : MAT indicates chassis produced in Tata Engineering, India. Barrel 2 : 414XXX Indicates chassis type no. where in 414 indicates model i.e. Safari Ex & next three digits ‘XXX’ indicates the version i.e. 414053 : Safari Ex 4 x 4 - For Normal control chassis with all steel shell, Safari Ex 4 x 4 version, M1 class, passenger carrier 7(6+1) seater, frame type, with 483DLTCIC Euro III Diesel Engine with A.C. + heating and demisting, with air bags, 2650mmWB. Barrel 3: Indicates year of production as below RHDVehicle :Year Code 1 - 1 - 2003 to 31 - 12 - 2003 : 3 1 - 1 - 2004 to 31 - 12 - 2004 : 4 1 - 1 - 2005 to 31 - 12 - 2005 : 5 1 - 1 - 2006 to 31 - 12 - 2006 : 6 1 - 1 - 2007 to 31 - 12 - 2007 : 7 1 - 1 - 2008 to 31 - 12 - 2008 : 8 1 - 1 - 2009 to 31 - 12 - 2009 : 9 LHDVehicle :Year Code 1 - 6 - 2003 to 31 - 5 - 2004 : 4 1 - 6 - 2004 to 31 - 5 - 2005 : 5 1 - 6 - 2005 to 31 - 5 - 2006 : 6 1 - 6 - 2006 to 31 - 5 - 2007 : 7 1 - 6 - 2007 to 31 - 5 - 2008 : 8 1 - 6 - 2008 to 31 - 5 - 2009 : 9 Barrel 4 : Indicates Plant location 9 for J block, Pune, First Assy. line N for J block Pune - Second assy. Line Barrel 5 : Indicates Drive type. R - for RHD Vehicle L - for LHD Vehicle Barrel 6 : Indicates Serial No. to starts every year with 00001 on first Jan. for RHD vehicles at each plant location. For LHD vehicles, it starts with 00001 on first June at each plant location (Separate sequence) c. CHASSIS NUMBERING SYSTEM FOR CKD VEHICLES : CKDVehicle (RHD/LHD) XXXXXX X 5 R X XXXX 1 2 3 4 5 6 Barrel 1 : Indicates chassis type no., model, execution, wheel base, etc. Barrel 2 : Indicates year of production As given in chassis numbering. Barrel 3 : Indicates CKD vehicles. 5 is reserved for CKD. Barrel 4 : Indicates drive type R - for RHD Vehicle L - for LHD Vehicle Barrel 5 : Indicates plant location Barrel 6 : Indicates serial no. starts with 00001 on first Jan. for RHD vehicles and first June for LHD vehicles every year. Fig. 15 Chassis Number on Frame (RHDVehicle) 4 4 4 4 4
G 18 GENERAL 5. AGGREGATE NUMBERING SYSTEM : Q Transfer Case Number Q Front Axle Number Chassis Number Engine Number Rear Axle Number Gear Box Number FRAME Aggregate number for Fame consists of Five barrels X XXX XX X XXXXX Barrel 1 : Indicates basic model, T for Safari Barrel 2 : Indicates variation in basic model as below 405 - For Safari, 2650mmWB, Diesel 4 x 2 406 - For Safari, 2650mmWB, Diesel 4 x 4 Barrel 3 : Indicates year of production 2002 - XZ 2003 - WZ 2004 - VZ 2005 - UZ 2006 - TZ Barrel 4 : Indicates plant location 8 for J Block, Pune Barrel 5 : Indicates cumulative serial number of frame. ENGINE : Aggregate number for Engines consists of six / seven barrels XXXXXXX XX X X XX X XXXXX 1 2 3 4 5 6 7 Engine model Engine No. Barrel 1 : Indicates engine model 483 DLTC Barrel 2 : Indicates variation in basic model of engine i.e. 55 :- 483 DL Turbocharged intercooled diesel engine 64 kw@4300 rpm, linered, meeting Euro III emission norms with catalytic convertor and EGR Barrel 3 : Indicates ‘L’ for LHD application only. Fig. 16 Location of aggregate numbers
G 19 GENERAL Fig. 18 Gear box number location Barrel 4 : Indicates month of production as below : Month Code Month Code Jan. A July G Feb. B Aug. H March C Sept. J April D Oct. K May E Nov. L June F Dec. M Barrel 5 : Indicates year of production 2002 - XZ 2003 - WZ 2004 - VZ 2005 - UZ 2006 - TZ Barrel 6 : Indicates plant location 0 for Lucknow 7 & 8 for D Block, Pune 8 will be used if serial number reaches 99,999 under plant code 7 in that year. Barrel 7 : Indicates cumulative serial number of engine. GEARBOX Gear box is numbered in 5 barrels 2684 710 XZ 8 00001 1 2 3 4 5 Barrel 1 : Indicates model i.e. G-76 Barrel 2 : First digi t indicates type of gear engagement & shift. 7 for synchromesh. Second digit indicates type of vehicle control. 1 for normal control vehicle. Third digit indicates first gear ratio. G-76 gear box (2684) 0 for first gear ratio 3.87 1 for first gear ratio 3.87 with second gear ratio 2.36 2 for first gear ratio 4.1 Fig. 17 Engine Number plate (483 DL) Barrel 3 : Indicates year of production 1997 SQ 2002 XZ 1998 RQ 2003 WZ 1999 QQ 2004 VZ 2000 ZZ 2005 UZ 2001 YZ 2006 TZ Barrel 4 : Indicates plant location 0 for Lucknow 5 & 6 for Pune 6 will be used if serial number reaches 99,999 under plant code 5 in that year.
G 20 GENERAL Barrel 5 : Indicates cumulative serial number of gear box. For LHD : Gear box for Left Hand drive vehicle vehicle execution will have an additional letter 'L' punched after first two barrels. Note For transfer case, front axle & rear axle aggregate number location is indicated in the fig. CAB Cab is numbered in 5 barrels J 403 SQ 9 0000 1 2 3 4 5 Barrel 1 : Indicates basic model safari type steel shell, normal control. Barrel 2 : 403 - Indicates model of Cab i.e. Safari Barrel 3 : Indicates year of production 1997 SQ 2002 XZ 1998 RQ 2003 WZ 1999 QQ 2004 VZ 2000 ZZ 2005 UZ 2001 YZ 2006 TZ Barrel 4 : Indicates plant location 9 for J block, Pune 1st assy. Line N for J block, Pune 2nd assy. Line Barrel 5 : 00001 - Indicates cumulative serial number of cab produced. LHD : Lef t hand dr ive execut ion wi l l have vehicle an additional letter 'L' stamped after first two barrels. Fig. 20 Front axle number location Fig. 21 Rear axle number locations Fig. 19 Transfer case number location
G 21 GENERAL 6. TECHNICAL SPECIFICATIONS TATA SAFARI (DIESEL) TATA SAFARI (PETROL) Engine Engine Model : TATA 4DL Turbo Diesel Engine Model : TATA 486 PL Petrol Engine Type : Water cooled indirect injection, Type : Water cooled, Motronic turbo charged, inter cooled multipoint sequential fuel diesel engine injection, 4 valves/ cylinder No. of cylinder : 4 in-line No. of cylinders : 4 in-line Bore/Stroke : 83 mm / 90 mm Bore/stroke : 83 mm / 90 mm Capacity : 1948 cc Capacity : 2092 cc Max. engine : 90PS at 4300 rpm as per Max. engine : 99.5 kw (135 PS) @ 5630 output as per Din 70020 output rpm as per 14599 or ISO 1585 64 kw at 4300 rpm as per 92 kw (125 PS) @ 5630 rpm CMVR 115(9) 1990 as per IS 10004 Max . torque : 19 mkg at 2500 rpm as per Max. torque : 195 Nm@ 3750 rpm DIN 70020 as per IS 14599 or ISO 1585 190 Nm at 2000 - 3000 rpm 192 Nm@ 3750 rpm as per IS 10004 Compression ratio : 21.0:1 Compression ratio : 9.6 : 1 Firing order : 1-3-4-2 Firing order : 1-3-4-2 Air filter : Dry (paper) type Air Filter : Dry (paper) type Oil filter : Spin on full flow paper type Oil Filter : Spin - on full flow paper type Fuel filter : Two stage, fine filtration Fuel Filter : Single full flow, fine filtration Fuel injection : Rotary type with electric stop Fuel pump : In-tank type, 12V electrically pump solenoid operated Governor : Mechanical Engine Oil : Max. 6.0 liters for 4 x 4 capacity 5.7 liters for 4 x 2 Engine oil : Max. 7.7 litres Weight of Engine : 192 Kg. (Dry) capacity Min 5.7 litres Weight of engine : 220 kg. (dry) Radiator : 2345 sq. cm. Radiator : 2277 sq. cm. frontal area frontal area
G 22 GENERAL Special items/features of petrol engine 1. EngineManagementSystem-MotronicM2.10.3 2. MPSFI (Multi point sequential fuel injection) 3. Dual overhead cam shaft (16 valves) 4. Exhaust gas recirculation valve 5. HFMFS (Hot film Air Mass Flow Sensor) 6. Dynamic Knock control 7. Idle speed control 8. Evaporative Emission control 9. Distributorless Electronic ignition 10. Automatic cold start control 12. Close Loop Lambda control 13. Intank fuel pump 12V electrically operated. CLUTCH Single plate dry friction diaphragm type Outside diameter of clutch lining : 228 mm Friction area : 463 sq. cm. (approx.) Clutch actuation : Hydraulically GEARBOX Model : GBS 76 5/3-87 with overdrive Type : Synchromesh on all gears No. of gears : 5 Forward, 1 Reverse Gear ratio : Diesel Petrol 1st : 3.87 4.1 2nd : 2.36 2.22 3rd : 1.37 1.37 4th : 1.00 1.00 5th : 0.82 0.82 Rev. : 3.40 3.40 TRANSFER CASE (For 4 × 4 configuration) With electric shift mounted on gear box 4 x 2 : High Ratio 1 : 1 4 x 4 : High Ratio 1 : 1 4 x 4 : Low Ratio 1 : 2.48 REAR AXLE For 4 x 4 : Single reduction, salisbury type rear axle, hypoid gears, semi floating axle shafts with limited slip differential For 4 x 2 : Same as above, l imi ted sl ip differential is optional Ratio : Standard 4.55 (50/11) Diesel 5.375 (43/8) Petrol FRONT AXLE For 4 x 4 : Independently Suspended with automatic hub locks Ratio : 4.56 (41/9) Diesel 5.375 (43/8) Petrol For 4 x 2 : Independently suspended STEERING Type : Power steering Ratio : 18.9 : 2 (For ZF steering) Steering wheel : 380 mm dia. with tilt mechanism for adjusting height and collapsible column. BRAKES Service brakes : Vacuum assisted independent hydraulic brakes on front and rear through tandem booster and tandem master cylinder. Front : 281 dia. ventilated disc brakes with twin pot caliper Rear : 282 dia. drum brakes with Auto adjuster 25.4 mm wheel cylinder. Parking brake : Lever type console mounted cable operated mechanical linkages acting on rear wheels. Vacuum servo : 9"+8" Tandem booster with 25.4 mmTandem master cylinder. Load conscious : Provided for rear brakes Pressure reducing valve (No LCRV for ABS versions)
G 23 GENERAL FRAME : Ladder type cranked frame with boxed section long members and welded cross members. Depth : 110 mm. (max.) Width : 60 mm. SUSPENSION Front : Double wishbone type with torsion bar springs Rear : Coil spring type 5 link suspension. Shock absorber : Hydraulic double acting telescopic type at front and rear. Anti-roll bar : At both front and rear. WHEELS & TYRES Tyres : 235 / 75R R 15 - Passenger radial Wheel rim : 6.0 J × 15 steel / alloy wheel rims No. of wheels : Front 2, Rear 2, Spare 1 FUELTANK Capacity : 65 liters (made out of Terne coated sheets) BODY Normal control all steel with five doors ELECTRICAL SYSTEM System voltage : 12 volts (-ve earth) Alternator : 135 Amps Battery : 12V, N 70Z Capacity : 75 Ah (20 Hr Rate) PERFORMANCE : Diesel engine vehicles Max. speed at : 123 kmph (with cd = 0.6 rated GVW and cn = 0.018) Max speed with 2 occupants 150 kg : 130 kmph Max geared speed : 154 kmph Max gradeability at : 80% at 14 kmph rated GVW - 4 x 4 version : 30% at 34 kmph - 4 x 2 version Petrol engine vehicles Max. speed at rated GVW : 141 kmph (with cd = 0.6 & crr = 0.018) Max speed with 2 occupants (150 kg.) : 146 kmph Max geared speed : 172 kmph Max gradeability GVW : 87% at 14 kmph rated - 4 x 4 version : 34% at 34 kmph - 4 x 2 version MAIN CHASSIS DIMENSIONS Wheel base : 2650 Track front : 1500 Track rear : 1470 Overall length : 4650 over rear bumper Max. width : 1810, 1918 (With foot step) Overall height : 1925 (Unladen) Front overhang : 945 Rear overhang : 1055 over rear bumper Min. turning circle dia. : 12 m Min. turning clearance : 13 m Circle dia. Ground clearance : 205 mm
G 24 GENERAL Fig. 22 Main Chassis Dimensions
G 25 GENERAL 8. FUELS, LUBRICANTS & COOLANTS FUEL (FOR 483 DLTC ENGINE) High Speed diesel conforming to Is 1460 or DIN 51601 or equivalent is recommended to be used as fuel. At very low temperatures 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 supplementary fuel and diesel are shown in table : Ambient Percentage temperature upto summer suppl. Deg c. Grade diesel fuel upto 0 100 0 0 to -10 70 30 -10 to - 15 50 50 Ambient Percentage temperature upto summer suppl. Deg c. Grade diesel fuel upto - 15 100 0 -15 to -20 70 30 -20 and below 50 50 Care should be taken that diesel and supplementary fuel are thoroughly mixed before filling. For vehicles fitted with catalytic converter use only the diesel with Sulphur content less than 0.25% WEIGHT (kg.) For M1 For N1 4x4 4x2 4x4 4x2 Complete vehicle kerb weight as per ISO : 1176 2040 1920 2040 1920 (with spare wheel and tools) Gross vehicle weight 2670 2550 2780 2780 Max. permissible FAW 1180 1100 1180 1180 Max. permissible RAW 1580 1540 1700 1700 Max. mass of unbraked trailer 750 750 750 750 Max. mass of braked trailer 2000 2000 2000 2000 (Centre axle trailer) Kerb weight Front 1080 1000 1080 1000 Rear 960 920 960 920 7. FILLING CAPACITIES : Engine : 483 DL TCIC : 7.7 liters max. 4 PL Petrol : 6.0 liters max. (4 × 4) 5.7 liters max. (4 x 2) Gear Box : 1.5 liters Rear Axle : 2.2 liters Front Axle : 1.2 liters Transfer case : 1.2 liters Hub grease front : 92 gms per hub Rear : 25 gms per hub Power Steering : 1.4 liters Clutch release bearing sleeve, Release fork support bearing groove : As required Chassis : As required Propeller shaft U-Joints, & sliding yoke, vacuum booster : As required Brake Hydraulic system : As required Clutch Hydraulic System : As required
G 26 GENERAL FUEL (FOR 486 PL PETROL ENGINE) VEHICLESWITHOUT CATALYTIC CONVERTER Leaded premium grade petrol Confirming to Is 3796 - 1994 or DIN 5 1600 (or equivalent) or unleaded premium grade petrol confirming to DIN 51607 (or equivalent) and RON not less then 87 is recommended to be used as fuel. VEHICLESWITH CATALYTIC CONVERTER Unleaded regular grade petrol confirming to Is 2796 - 1994 / DIN 51607 (or equivalent) and RON not lower then 87 is recommended to be used as fuel. (RON means Research Octane Number) Caution : Do not use leaded petrol in the vehicle fitted with catalytic converter. Even single use / fill of lead fuel will seriously damage the catalytic converter. LUBRICANTS ANDOILS Recommended lubricants conform to the following specifications : ENGINE (483 DLTC ENGINE) SAE 15W40 to APl CF4 + Grade (up to -100 c ambient temperature) SAE 10 W 30 to APl CF4 + Grade (For ambient temperature between - 200 c & 00 c) SAE5 W 20 to APl CF4 + Grade (For ambient temperature below - 100 c) ENGINE OIL (486 PL PETROL ENGINE) Recommended grade of engine oil confirming to APl - SF/ CC or SG specification and range of ambient temperature at which these can be used are given in table. Ambient temp. Engine oil grade in deg. c -10 deg. & above SAE20W - 40 or 20W 50 -15 deg. to 40 deg. SAE15W- 40 SAE 15W - 50 -20 deg. to 40 deg. SAE10W- 40orSAE10W-50 -35 deg. to 40 deg. SAE5W - 50 In the initial operation (first 2000 km.) of a new or recondi t ioned engine, also use the above recommended oils. GEARBOX AND TRANSFERCASE General motors ATF Type A, Suffix A REAR AXLE (with LSD *) APlGL 5 with friction modifier REARAXLE (without LSD *) and FRONT LIVEAXLE APIGL 5 Without friction modifier (*Limited Slip Differential Only On 4 WD model) GREASE FOR AXLE BEARINGS Lithium based grease BRAKE ANDCLUTCH FLUID IS 8654 / DOT 3 POWER STEERING ATF Type A, Suffix A PROPELLER SHAFT NLGI - 2 grade grease 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. Coolant should be drained and replenished every two years or at every 50,000 km whichever is earlier.
G 27 GENERAL GENUINE CO-BRANDED ITEMS : ITEM COMPANY BRAND QTY ENGINE OIL CASTROL GTD 15W/40 (DIESEL) HP HP Milcy 15W/40 7.7 LITRES ENGINE OIL CASTROL GTX 20W40 6.0 LITRES FOR 4 X 4 (PETROL) HP HP ESMO 20W/40 5.7 LITRES FOR 4 X 2 SUNSTAR Golden cruiser Premium 1400 NA COOLANT ANCHEMCO (HENKEL TEROSON) Frostox SFD 12 Approx. 9-10 Litres HPCL Thanda Raja P. GEARBOX HPCL HP ATF 1.5 Liters TRANSFER CASE HPCL HP ATF 1.2 Liters REAR AXLE HPCL HP Gear oil XP 85 W 140 202 Liters FRONT AXLE POWER STEERING HPCL HP ATF 1.4 Liters OIL BRAKE FLUID HPCL HP Super Duty Brake fluid DOT 3 As required ANTIRUST DINITROL Dinitrol - TREATMENT & WUERTH Wuerth - SOUNDDEADENING WIND SCREEN ANCHEMCO Terostat 8590 Kit form - SEALANT METAL & PLASTIC ANCHEMCO Terostat 930 310 ml Cartridge ADHESIVE DIESEL ADDITIVES* IFTEX Iftex clear system D 250 ml pack PLEASE USE ONLY FOLLOWING GENUINE ENGINE OILS, COOLANTS, LUBRICANTS, ANTI RUST & SOUND DEADENING COATS,WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM PERFORMANCE OFYOURTATA SAFARI. *Add to diesel as per the dosage recommended by M/sIftex for vehicles fitted with Delphi TVS FIPs.
G 28 GENERAL SR. OPERATION FREQUENCY NO. IN KM 9. SERVICE SCHEDULE TATA SAFARI GENERAL 1. Wash the vehicle 5,000 l l l l l l l l l l l l l l l l l l l l DIESEL ENGINE 1. Clean air cleaner filter element, change if red band appears on service indicator, even after cleaning 5,000 l l l l l l l l l l l l l l l l l l l l 2. Check coolant level, top up if necessary Frequently l 3. Change coolant in cooling system 50,000 km. or two years whichever is earlier 4. Check oil level in sump, top up if necessary Frequently l 5. Change engine oil and filter cartridge 10,000 l l l l l l l l l l 6. Change fuel filter element (tank side) 10,000 l l l l l l l l l l 7. Change both fuel filter elements (main) 20,000 l l l l l 8. Check timing belt, adjust tension if necessary, replace if defective 20,000 l l l l l 9. Replace timing belt 100,000 l 10. Check fan belt, adjust tension if necessary, replace if defective (at every 40,000 km) 10,000 l l l l l l l l l l 11. Check injection nozzles for opening pressure & spray characteristics Check if any problem is noticed. PETROL ENGINE (If fitted) 1. Check the tightness of fastners 5,000 l l l l l l l l l l l l l l l l l l l l 2. Check coolant level, top up if necessary Frequently l 3. Change Coolant in cooling system 50,000 or two years which ever is earlier 4. Check oil level in sump, top up if necessary Frequently l 5. Change engine oil and filter cartridge 10,000 or 1 Yr l l l l l l l l l l whichever is earlier 6. Check gasket / hoses for leakages 5,000 l l l l l l l l l l l l l l l l l l l l 7. Rectify fuel leakages Frequently l 8. Change assy. fuel filter 20,000 or 1 yr whichever is l l l l earlier 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000
G 29 GENERAL 9. Clean air cleaner filter element Periodically l 10. Replace Air filter element 10,000 or 1 Yr whichever is earlier (Earlier for vehicles operating under dusty / off road conditions.) 11. Check timing belt, adjust tension if necessary repalce if defective 20,000 l l l l l 12. Replace timing belt 100,000 l 13. Check AC, Power steering belt, adjust tension if necessay, replace if defective 5,000 l l l l l l l l l l l l l l l l l l l l 14. Check spark plug gap 10,000 l l l l l l l l l l 15. Replace carbon Canister 50,000 or 2 year whichever is earlier 16. Replace all four spark plugs 30,000 l l l 17. Check/Inspect PCV valve, Replace if necessary 10,000 l l l l l l l l l l GEAR BOX 1. Check oil level in gear box, top up if necessary 10,000 l l l l l l l l l l 2. Change oil in gear box # (ATF) 20,000 & also at 1st 10,000 l l l l l 3. Check oil level in transfer case, top up if necessary 10,000 l l l l l l l l l l 4. Change oil in transfer case 45,000 l l 5. Clean breather on gear box 70,000 l PROPELLER SHAFT 1. Grease propeller shaft with grease gun 5,000 l l l l l l l l l l l l l l l l l l l l FRONT* AND REAR AXLE 1. Check oil level in axle,top up if necessary 10,000 l l l l l l l l l l 2. Change oil in axle (First 20,000 km) 40,000 l l l 3. Grease idler arm, 10,000 l l l l l l l l l l SUSPENSION & STEERING 1. Grease steering spindle and sleeve 10,000 l l l l l l l l l l 2. Check wheel alignment, chassis height & adjust if necessary 15,000 l l l l l l 3. Change grease in front hub& adjust bearing play 40,000 l l 4. Check & adjust steering wheel free play 30,000 l l l 5. Check oil level in power steering tank 10,000 l l l l l l l l l l and top up if necessary SR. OPERATION FREQUENCY NO. IN KM * For 4 x 4 version # For G-76 with Dual synchrocone package use synthetic oil (75 W 90). Oil change period (first at 40,000 kms) & then after every 80,000 kms. 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000
G 30 GENERAL 6. Change oil in power steering system and 80,000 l change filter element 7. Check belt tension of power steering 10,000 l l l l l l l l l l and adjust if necessary 8. Check condition of rubber bushes in the 30,000 l l l following & replace if necessary. 1) Top wishbone 2) Lower wishbone 3) Anti roll bars 4) Rear links 5) Panhard rod. 9. Check shock absorber, Its bushes and 15,000 l l l l l l steering damper bushes, replace if necessary CLUTCH AND BRAKES 1. Check level of clutch & brake fluid in 10,000 l l l l l l l l l l containers, top up if necessary 2. Check service & parking brakes, adjust if necessary 5,000 l l l l l l l l l l l l l l l l l l l l 3. Check front brake pads & rear brake linings. 15,000 l l l l l l Replace it necessary 4. Overhaul the following brake components & change the brake fluid in the system 30,000 l l l 1) Tandem Master Cylinder 2) Front Caliper, 3) Rear Wheel Cylinders, 4) Clutch Master cylinder & Slave Cylinder. 5. Overhaul Vacuum booster & change the felt & 40,000 l l Polyurethane filters along with rubber bellow. ELECTRICALS 1. Check electrolyte level in battery, add 15,000 l l l l l l distilled water if necessary. 2. Check specific gravity of electrolyte and the charge of battery. 30,000 l l l 3. Check headlamp focussing & functioning 15,000 l l l l l l of other electrical equipment. 4. Check glow plugs for continuity/short circuits 15,000 l l l l l l replace if required (For Diesel model only) 5. Check water level in windscreen washer Weekly l container & top up if necessary For cold region application, use antifreeze mixture (1:1 of water & glycol) 6. Apply grease on door latches, door lock, door check 10,000 l l l l l l l l l l stop, striker, bonnet opening lever and lock plate. SR. OPERATION FREQUENCY NO. IN KM 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000
G 31 GENERAL 7. Apply grease on tail gate hinges & door lock inner ratchet. 30,000 l l l 8. Tighten all fastners of front grill, oil sump, 10,000 l l l l l l l l l l oil & fuel filter & mounting bracket, exhaust manifold & pipe, air filter engine clutch housing, radiator mounting, propeller shaft centre bearing bracket mounting bolts, joints of pitman arm, idler arm, centre link, tie rods, upper ball joints of top wishbone, upper wishbone & lower wishbone, steering gear box & its mounting bracket, vacuum & hydraulic line connections, head lamp mounting, wheel mounting nuts, Body mountings, axle shaft mounting, anti-roll bar mounting, vacuum booster & tandem master cylinder mountings, clutch master &stave cylinder mounting, rear anchor plate mounting, front disk brake mounting, fuel tank mounting, front suspension top rubber mounting nut. AIR CONDITIONING SYSTEM 1. Check torqueof boltsonbrackets, &compressor, 15,000 l l l l l l 2. Check compressor belt, adjust tension, Replace if necessary (at every 40,000 kms) 10,000 l l l l l l l l l l 3. Check for leak of gas/oil from pipes, joints, 10,000 l l l l l l l l l l compressor shaft seal & cylinder head 4. Clean condensor with high pressure water 5,000 l l l l l l l l l l l l l l l l l l l l 5. Check fan speeds for proper air flow 30,000 l l l 6. Check clutch operation 5,000 l l l l l l l l l l l l l l l l l l l l 7. Check system pressure with gauges, 10,000 l l l l l l l l l l 8. Clean evaporator from its face to remove dust, foreign objects etc. 30,000 l l l WHEELS & TYRES 1. Tyre rotation, check tyre pressure 10,000 l l l l l l l l l l SR. OPERATION FREQUENCY NO. IN KM 1000 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 55000 60000 65000 70000 75000 80000 85000 90000 95000 100000
3 4 DLT ENGINE TATA 483 DL TC IC is a turbocharged engine with intercooler, and indirect fuel injection system. The aluminium cylinder head incorporates glow plugs, combustion chambers, and overhead camshaft. A rubberised timing belt drives the overhead camshaft, water pump and rotary fuel injection pump from crankshaft. Element type heat exchanger is fitted on the right hand side of the engine and it can be easily removed for access to water jackets. The oil pump is chain driven from the crankshaft and oil filter is spin-on-throw away type. An oil separator is provided in the crankcase ventilation system to separate the gases and oil droplets in the system. The engine has a three point mounting with two mounting points in front of engine and one under the rear of the gear box. INTRODUCTION : Engine 4 DLT
5 4 DLT ENGINE CONTENTS Sr. No. Description Page No. 1. Technical specification 7 2. Schematic circuits of various systems on engine 8 a) Lubrication system 8 b) Cooling system 8 c) Fuel system 9 d) EGR system 9 e) Engine Breathing System / Oil separator sectional view 10 3. Viscous fan drive 11 4. Special tools 12 5. Preliminary inspection of engine 13 6. Removal of engine from vehicle 15 7. Engine dismantling procedure 17 8. Checking viscous fan drive 18 9. Cylinder head dismantling 30 10. Tightening torques 32 11. Repair data 34 12. Inspection and cleaning 40 13. Service instruction for aluminium radiators 42 14. Cylinder Block assembly 44 15. Removal, installation and machining of cylinder liner 47 16. Engine assembly procedure 63 17. FIP timing setting procedure (MICO) 74 18. Fuel injection equipment schematic layout & function (LUCAS) 78 a) Lucas DPC FIP - Hydraulic Circuit 79 b) Lucas FIP Euro - III 80 c) Lucas DPC FIP - Feautres 81 d) Air Venting 82 e) Idle Speed Setting 83 f) Antistall Setting 84 g) Fault Diagnosis fuel injection system 85 h) Fault Diagnosis injectors 86 i) Fault Diagnosis smoke 87 19. FIP Timing Setting Procedure (LUCAS) 88 20. Fuel Tank & Hoses 90 21. Turbocharger 98 22. Exhaust system 99 23. EGR system (For Euro III) 101 Catalytic converter care & maintenance 101 24. Accelerator Cable 104 25. Engine testing 106 26. Trouble Shooting 107 Engine 4 DLT
7 4 DLT ENGINE TECHNICAL SPECIFICATIONS Engine model : TATA 4DLTC IC Type : Water cooled, indirect injection, turbo charged, and intercooled diesel engine with crank case breather (& exhaust gas recirculation system for Euro III engine) No. of cylinders : 4 in line Bore/stroke : 83 mm / 90 mm. Capacity : 1948 CC Max. Engine output : 64 kw at 4300 rpm (DIN 70020) (90 Ps at 4300 rpm) Max. Torque : 190 Nm at approx 2000-3000 rpm. (19 mkg at approx. 2000-3000 rpm) Compression ratio : 21:1 firing order : 1-3-4-2 Air filter : Dry (paper) type Oil filter : Spin-on full flow paper type Fuel filter : Two stage, fine filtration Fuel injection pump : Rotary type with electric stop solenoid Governor : Mechanical Engine oil capacity : Max. 7.7 liters / Min. 5.7 liters Weight of engine : 220 kg (dry) Radiator frontal area : 2345 sq. cm.
8 4 DLT ENGINE SCHEMATIC CIRCUITS OF VARIOUS SYSTEMS ON 4 DLT ENGINE Lubrication System Cooling System A. Strainer in sump B. Oil pump C. Oil pump relief valve D. Full flow oil filter (paper type) Fig. 1 Fig. 2 E. Filter bypass valve F. Heat exchanger H. Turbocharger I. Crankshaft Journals etc. J. Piston cooling nozzles K. Oil sump No Loss Tank Overflow Bypass pipe Thermostat Return pipe Cylinder Block / Head Additional Venting Timing Belt Cover Radiator Cap with pressure release valve Water pump Cooling Fan
9 4 DLT ENGINE Fig. 3 Fig. 4 Injector Hand Priming Pump Secondary Fuel Filter FIP HP lines Tank Cap With Breather Fuel return line Fuel Tank Fuel Supply line Primary Fuel Filter Fuel System EGR System (On Euro III Engine)
10 4 DLT ENGINE OIL SEPARATOR FITTED ON ENGINE (SCHEMATIC LAYOUT) Oil Separator for Air Breather : Astep towardsdevelopingenvironment friendlyproducts, to eliminate the engine blow by being emitted to atmosphere, the engine breather / oil separator has been fitted. The oil separator, separates oil from the blow by of the engineandsends it back toengineoil sump.The remaining air, carbon particles and other gases are sent to the inlet manifold. There is alsoa spring loadeddiaphragmvalveprovidedon the oil separator outlet to the inletmanifold.This prevents the flow of excessive blow-by from the oil separator to inlet manifold in case the air filter is choked and high suction starts acting on outlet port of oil separator. Fig. 5 Oil Separator fitted on 4 DLTC Engine No leakagepast diaphragmor top cover of oil separator is permitted. Replace the assembly if there is any leakage. ENGINE BREATHING SYSTEM : OIL SEPARATOR (OIL SEPERATOR SECTIONAL VIEW) (TOP VIEW) CRANK CASE
11 4 DLT ENGINE VISCOUS FAN DRIVE Operation of the viscous fan drive. The viscous drive unit for the engine cooling fan provides a means of controlling the speed of the fan relative to the temperature of the engine.The viscous fan unit, see Figure 6. is a type of fluid coupling, which drives the fan blades by means of 'silicon fluid'. Operation : There are two main components of the viscous fan drive : An input (drive) member (1) consisting of a threaded shaft passing through a bearing into the clutch plate and secured to the water pump, see Figure 7. An output (driven) member (2) comprises the main body to which the fan attaches, wi th the temperature sensing 1. Input (drive) member. 2. Output (driven) member. 3. Running clearance. 4. Pump plate 5. Valve (closed) 6. Sensing mechanism (bi-metal coil) 7. Fluid seal 8. Bearing, input member 9. Fluid chamber 10. Fluid reservoir Fig. 6 Fig. 7 Viscous unit disengaged (engine at normal operation temperature) mechanism (bi-metal coil) (6) and pump plates (4). The fan drive has to be engaged only periodically, between 5% and 10%, during normal operating conditions because the rest of the time the vehicle cools itself by ram air cooling. To engage and disengage the fan drive the bimetal coil senses air temperature behind the radiator.When a pre-determined temperature is reached, the coil opens a valve (5) which allows fluid to enter the drive area and due to centrifugal force circulates to the annular drive area. There are two sets of annular grooves (3), one in the drive clutch and the other in the drive body, a specific clearance being provided between the two sets of grooves.When this clearance is filled with viscous fluid a shearing action, caused by the speed differential between the two drive components, transmits torque to the fan.The fluid is thrown to the outside of the unit by centrifugal force from where it is then re-circulated to the reservoir (10) via the pump plate 4 adjacent to the drive member. If the engine speed is increased the amount of slip will also increase to limit the maximum fan speed. When the air temperature from the radiator drops sufficiently, the bi-metal coil closes the valve and prevents fluid entering the drive area, See Fig. 8 The fluid that is in the drive area will gradually pump out into the reservoir (10) and the fan will return to an idle condition. Fig.8 Viscous unit engaged (hot running temperature) Bi-metal coil (6) expanded, valve (5) open. 1. Input (drive) member 2. Output (driven) member 3. Sensing mechanism (bi-metal coil)
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