tata sumo grande

TATATATATATTTTTAAAAA SUMO GRANDESUMO GRANDESUMO GRANDESUMO GRANDESUMO GRANDEOwner's Manual & Service Book

Passenger Car Business Unit (PCBU)Mumbai Pune

This owner’s manual should be considered as a permanent part of the vehicle and must remain with the vehicle.

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This Owner’s Manual is advised to be kept in the vehicle at all times.

This book will help you to understand the vehicle better, maximise uptime of the vehicle & obtainbetter performance at optimum cost.

The recommended routine maintenance servicing along with any running repairs that may be required, shouldbe entrusted to TATA Authorised Workshop to ensure that only latest methods and genuine TATA MOTORSreplacement parts are used for the continued reliability, safety and performance of the vehicle.

Some of the items / accessories / features shown / given in this book may not be fitted on your vehicle, butthey are applicable for other versions of Sumo Grande.

(C) Copyright 2004 TATA MOTORS

All rights reserved. The material in this manual may not be reproduced or copied, in whole or in part, in anyform without written permission from TATA MOTORS.

The information and specifications given in this book are valid as on the date of printing. TATA MOTORSLimited reserves the right to make changes in design and specifications and/or to make additions to orimprovements in this product without obligation to install them on products previously sold.

In the event of the Vehicle being sold, please ensure that this manual is left in the vehicle for the reference ofthe new owner.

A NoteA NoteA NoteA NoteA Note

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DDDDDear Cear Cear Cear Cear Custustustustustomeromeromeromeromer,,,,,

Thank you for selecting Tata Sumo Grande - the vehicle of your choice

We welcome you to the world of advanced automotive engineering in a form especially suited toyour operating conditions.

This book gives you all the information necessary for making your ownership of this vehicle athoroughly satisfying experience.

To assist you in maintaining your vehicle as per recommended schedule, we have a widespreadnetwork of dealers and service centres. The list is included in this book for your convenience.

Should you need any special assistance, please call on our Regional / Zonal level offices whichare also listed in this book.

Please note that by adhering to the correct operating procedures and by availing the scheduledmaintenance services at our authorised service centres, you can obtain the maximum performancefrom your vehicle.

We request you to go through the book and derive many miles of motoring pleasure.

We wish you good luck and prosperity

F o r e w o r dF o r e w o r dF o r e w o r dF o r e w o r dF o r e w o r d

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Customer AssistanceCustomer AssistanceCustomer AssistanceCustomer AssistanceCustomer Assistance

Safety and vehicle damage warningsIn this manual, you will see CAUTION and NOTICE warnings.

CAUTIONThis is a warning. May cause injury to people if the warningis ignored. You are informed what you must or must not doin order to avoid or reduce the risk to yourself and otherpeople.

NOTICEThis is a warning. May cause damage to the vehicle or itsequipment if the warning is ignored. You are informed whatyou must or must not do in order to avoid or reduce the riskof damage to your vehicle and its equipment.

WARNINGIndicates a strong possibility of severe personal injury ordeath if the instructions are not followed.

Safety symbolIn this manual, you will also see a circle witha slash. This means "Do not", "Do not dothis", or "Do not let this happen".

IMPORIMPORIMPORIMPORIMPORTTTTTANT INFORMAANT INFORMAANT INFORMAANT INFORMAANT INFORMATION ABOUT TION ABOUT TION ABOUT TION ABOUT TION ABOUT THIS MANUTHIS MANUTHIS MANUTHIS MANUTHIS MANUALALALALAL

1800 209 6688

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ContentsContentsContentsContentsContents

Getting StartedKey & Door Lock 48

Child Lock 49

Seats, Seat Adjustments & Seat Belts 50

Steering Wheel Adjustment 54

DrivingChecks Before Driving 55

Safety Checks 56

Fuel Saving Tips 58

Starting & Stopping the Engine 59

Gear Shifting 61

Braking 64

Driving In Adverse Conditions 65

Incase Of EmergencyJack Locatation / Warning Triangle 67

Flat Tyres replacement 68

Spare Wheel 69

Spare Wheel & Limp Home Mode 70

Starting The Engine with Jump Leads 71

Know your Sumo Grande 6Environmental Care 8

Sumo Grande At A GlanceDriving Controls 10

Instrument Cluster 12

Steering Lock cum Ignition Switch 18

Combi Switch 23

Head Lamp Leveling 24

Transfer case Switch 26

Music System, Antenna & Clock 27

Heating, Ventillation & Air Conditioning 28

Grab Handle & Cigarette lighter 29

Lamps 34

Sun visor & Mirrors 34

Glove Box, Cup holder & Utility Pockets 36

Window Glass Operations 37

Fuel flap opening 38

Gear Shift Lever & Parking Brake 39

Anti Theft / Immobiliser system 40

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ContentsContentsContentsContentsContents

Tyre Rotation 97

Wheel Alignment, Balancing & Catalytic convertermaintenance 98

Battery 99

Important Technical InformationFuel, Lubricants & Coolants 100

Oil Filling & Drain Points 104

Technical Specification 105

Information At a Glance (Dimensions) 110

Vehicle Identification

Loctation of Aggregate Number 111

PDI Service 113

Service Schedule 115

Service Maintenance Schedule 117

Record of Services Performed 123

Record of Repairs Carried Out 125

Towing the Vehicle 72

Routine Service 73

Preliminary Trouble shooting 74

Electrical MaintenanceFuses & Relays 80

Bulb Specification 82

Bulb Replacement 83

Vehicle CareWashing & Cleaning 85

General Precautions 87

MaintenanceOpening & Closing The Bonnet 88

Engine Compartment 89

Air Filter, Engine, Oil & coolant 90

Brake & Steering 91

Clutch & Sedimenter 93

Filter & Priming Pump 94

Windshield washer & Tyre 95

Tyre Inspection 96

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KKKKKnononononow w w w w YYYYYour Sumo Gour Sumo Gour Sumo Gour Sumo Gour Sumo Grrrrrandeandeandeandeande

Your Tata Sumo Grande is a new generationmulti utility vehicles and is a result of extensiveresearch and development by Tata MotorsLimited. This vehicle also incorporates all thewell known and proven features of Tata Motorsprecision and advanced technology.Easy maneuverability and economic life cyclecost makes Sumo Grande ideal for operating inboth urban as well as rural areas.

This vehicle is powered by a new generation 2.2LDICOR BS-III engine which is in turn mated to a5 speed fully synchromesh gearbox withoverdrive for excellent fuel efficiency andtubeless tyres for better road holding and grip.

Your Sumo Grande’s 2.2L DICOR engine is arefined power plant employing a sophisticatedcommon rail fuel system. The engine’s ECU(Electronic Control Unit), basically a 32 bitmicroprocessor, controls the engine’s fuelinjection, operation of the Variable GeometryTurbocharger (VGT) and other related parametersfor it to perform optimally.

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KKKKKnononononow w w w w YYYYYour Sumo Gour Sumo Gour Sumo Gour Sumo Gour Sumo Grrrrrandeandeandeandeande

Your Sumo Grande has Vacuum assistedindependent hydraulic brakes on the front andrear wheels through tandem master cylinder andtandem booster, ventilated front disc brakes withtwin pot calipers on front wheels for better brakingand safety. The front independent suspensionsetup has telescopic shock absorbers and an antiroll bar. The rear suspension is via parabolicsprings. This suspension setup ensures good roadholding and stability.

An ergonomically designed cab with addedfeatures like collapsible power steering, centrallocking, power windows, highly effective HVACfor comfort, music system, state of art headlampand rear lamps, good all-found visibility and easyaccess to areas of daily maintenance is some ofthe other user-friendly features of the SumoGrande.TATA vehicles are backed by well establishedservice network with trained and skilledmanpower ensuring proper maintenance. Timelymaintenance and servicing as recommended inthis manual ensure trouble free operation overlong year.

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We WARRANT each TATA SumoGrande vehicles & parts thereofmanufactured by us to be free fromdefect in material and workmanship,subject to the following terms &conditions :

1. This warranty shall be for 24months OR 75000 kms,whichever is earlier from the dateof sale of the vehicle, However,for the vehicles used forcommercial applications(including those used for hire orreward viz those operating witha yellow number plate), thewarranty shall be limited to 24months or 50,000 kms,whichever occurs earlier.

2. Our obl igation under thiswarranty shall be limited torepairing or replacing, free ofcharge, such parts of the vehiclewhich, in our opinion, aredefective, on the vehicle beingbrought to us or to our dealerswithin the warranty period. Theparts so repaired or replacedshall also be warranted forquality and workmanship but

such warranty shall be co-terminus with this originalwarranty.

3. Any part which is found to bedefective and is replaced by usunder the warranty shall be ourproperty.

4. As for such parts as tyres,batteries, transfer case, rubberparts, electrical equipment andfuel injection equipment, powersteering equipment, A.C.equipment not manufactured byus but supplied by other parties,this warranty shall not apply, butbuyers of the vehicle shall beentitled to, so far as permissible

by law, all such rights as we mayhave against such parties undertheir warranties in respect ofsuch parts. Our Dealers/TASC’swill assist the purchaser in takingup the complaint with therespective manufacturers andtheir decision on the warranty willbe final.

5. This warranty shall not apply if thevehicle or any part thereof is

repaired or altered otherwise thanin accordance with our standardrepair procedure, or by anyperson other than our sales orservice establishments, ourauthorised dealers or servicecentres or service points in anyway so as, in our judgementwhich shall be final and binding,to effect its reliability, nor shall itapply if, in our opinion which shallbe final and binding the vehicle issubjected to misuse, negligence,improper or inadequatemaintenance or accident orloading in excess of suchcarrying capacity as certified byus, or such services asprescribed in our Owner ’sManual and Service Book are notcarried out by the buyer throughour sales or serviceestablishments, our authoriseddealers or service centres orservice points.

6. This warranty shall not covernormal wear and tear or anyinherent normal deterioration ofthe vehicle or any of its partsarising from the actual use of the

KKKKKnononononow w w w w YYYYYour Sumo Gour Sumo Gour Sumo Gour Sumo Gour Sumo GrrrrrandeandeandeandeandeWWWWWARRARRARRARRARRANTANTANTANTANTY - Y - Y - Y - Y - TERMS & CTERMS & CTERMS & CTERMS & CTERMS & CONDITIONSONDITIONSONDITIONSONDITIONSONDITIONS

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vehicle or any damage due tonegligent or improper operationor storage of the vehicle. Thiswarranty shall not apply to normalmaintenance services viz. oils &fluid changes, head lampsfocussing, fastener retightening,wheel balancing, tyre rotation,adjustment of valve clearance,fuel timing, ignition timing andconsumables like bulbs, fuelfilters and oil filters etc. Thiswarranty shall not apply to anydamage or de ter io ra t ioncaused by envi ronmenta lpollution or bird droppings. Thiswarranty shall not apply to V-belts, hoses and gas leaks incase of air conditioned vehicle.Sl ight i r regular i t ies notrecognised as affecting thefunction or quality of the vehicleor parts such as slight noise orvibration and defects appearingonly under par t icu lar orirregular operations or itemsconsidered characteristic ofthe vehicle.

7. This warranty shall be null andvoid if the vehicle is subjected

to abnormal use such asrallying, racing or participationin any other compet i t ivesports. This warranty shall notapply to any repai rs orreplacement as a result ofaccident or collision.

8. This warranty is expressly inlieu of all warranties, whetherby law or otherwise, expressedor impl ied, and a l l o therobligations or liabilities on ourpart and we neither assume norauthor ise any person toassume on our behalf, anyother liability arising from thesale of the vehicle or anyagreement in relation thereto.

9. The buyer shall have no otherrights except those set outabove and have, particular, noright to repudiate the sale, orany agreement or to claim anyreduct ion in the purchasepr ice of the vehic le, or todemand any damages orcompensat ion for losses,inc identa l or ind i rect , orinconvenience or consequential

damages, loss of vehicle, orloss of t ime, otherwise,incurred or accrued.

10. Any claim arising from thiswarranty shall be recognisedonly if it is notified in writing tous or to our concerned dealerwithout any delay soon aftersuch defect as covered andascer ta ined under th iswarranty.

11. This warranty shal l s tandterminated if the vehicle ist ransferred or o therwisealienated by the buyer withoutour prior written consent.

12. We reserve our rights to makeany change or modification inthe design of the vehicle or itspar ts or to in t roduce anyimprovement therein or toincorporate in the vehicle anyadditional part or accessory atany time without incurring anyobligation to incorporate thesame in the vehicles previouslysold.

KKKKKnononononow w w w w YYYYYour Sumo Gour Sumo Gour Sumo Gour Sumo Gour Sumo GrrrrrandeandeandeandeandeWWWWWARRARRARRARRARRANTANTANTANTANTY - Y - Y - Y - Y - TERMS & CTERMS & CTERMS & CTERMS & CTERMS & CONDITIONSONDITIONSONDITIONSONDITIONSONDITIONS

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KKKKKnononononow w w w w YYYYYour Sumo Gour Sumo Gour Sumo Gour Sumo Gour Sumo GrrrrrandeandeandeandeandeENVIRENVIRENVIRENVIRENVIRONMENTONMENTONMENTONMENTONMENTAL CAREAL CAREAL CAREAL CAREAL CARE

TATA MOTORS LTD. iscommitted to produce the vehiclesusing environmentally sustainabletechnology. A number of featureshave been incorporated in TataMotors passenger vehicles whichhave been designed to ensureenvironmental compatibilitythroughout the life cycle of thevehicle. We would like to informyou that your vehicle meetsemission norms and this is beingregularly validated at themanufacturing stages.

As a user you too can protectthe environment by operatingyour vehicle in a proact ivemanner. A lot depends on yourdriving style and the way youmaintain your car. We havegiven few tips below for yourguidance.

DRIVINGAvoid frequent and violentaccelerations.Do not carry anyunnecessary weight on thevehicle as it overloads theengine. Avoid using devicesrequir ing high powerconsumption during slow citytraffic condition.Monitor the vehicle’s fuelconsumption regularly and ifshowing rising trend get thevehicle immediately attendedat the Company’s AuthorisedService Outlets.

Switch off the engine duringlong stops at traffic jams orsignals. If you need to keepthe engine running, avoidunnecessary revving it up orstopping and starting.

It is not necessary to rev up

the engine before turning itoff as it unnecessarily burnsthe fuel.

Shift to higher gears as soonas it is possible. Use eachgear upto 2/3rd of i t ’smaximum engine speed. Achart indicating gear shiftingspeeds is given in this book.

MAINTENANCEEnsure that recommendedmaintenance is carried outon the vehicle regularly at theAuthorised Service Outlets.

As soon as you see anyleakages of oil or fuel in thevehicle we recommend to getit attended immediately.

Use only recommendedgrades and quanti ty oflubricants and clean/uncontaminated and correctfuels.

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KKKKKnononononow w w w w YYYYYour Sumo Gour Sumo Gour Sumo Gour Sumo Gour Sumo GrrrrrandeandeandeandeandeENVIRENVIRENVIRENVIRENVIRONMENTONMENTONMENTONMENTONMENTAL CAREAL CAREAL CAREAL CAREAL CARE

Get your vehicle checked foremission periodically byauthorised dealerEnsure that fuel filter, oil filterand breather are checkedperiodically and replaced, ifrequired, as recommendedby Tata Motors.Do not pour the used oils orcoolants into the sewagedrains, garden soil or openstreams. Dispose the usedf i l ters and batter ies incompliance with the currentlegislation.Do not allow unauthorisedperson to tamper withengine settings or to carrymodifications on the vehicle.Never allow the vehicle to runout of fuel.Parts l ike brake l iners,clutch disc should bevacuum cleaned. Do not use

the compressed air forcleaning these parts whichmay spread the dust in theatmosphere.While carrying out theservicing or repairs ofyour vehicle you shouldpay keen attention tosome of the importantengine aggregates andwiring harness whichgreatly affect emission.These components are :-

1. Fuel injection equipments- pump, rail , Injectors,Nozzles and high pressurepipes.

2. Air Intake & Exhaustsystem especially forleakages.

3. Cylinder head for valveleakage.

4. All filters such as air, oil &fuel f i l ters (checkperiodically).

5. Turbocharger & VacuumModulator OR it’s vacuumhoses.

6. EGR System &components.

7. Electrical connections8. ‘Service’ lamp

contineously glows, pleasetake the vehicle to ServiceStation.

9. Catalytic Convertor10. EMS wiring harness i.e.

electrical connections toall sensors and actuators.

This owner’s manual containsfurther information on drivingprecautions and maintenancecare leading to environmentprotection. Please familiariseyourself with these aspectsbefore driving.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a Glance DRIVING CONTROLS DRIVING CONTROLS DRIVING CONTROLS DRIVING CONTROLS DRIVING CONTROLS

1. Steering Wheel2. Instrument Cluster3. Mirror Adjustment Switch4. Horn Pads5. Operating Switches6. Bonnet Opening Lever7. Gear Shifting Lever8. Parking Brake9. Cigar Lighter (Rear)

10. Cigar Lighter (Front)11. Music System12. A.C.Controls13. Glove Box14. A.C. Air Vents15. Analog Clock16. Central Air Vents

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a Glance INSTR INSTR INSTR INSTR INSTRUMENT CLUMENT CLUMENT CLUMENT CLUMENT CLUSTER (GX)USTER (GX)USTER (GX)USTER (GX)USTER (GX)

10913 12 11

14

16

231524 19 201718

2221

1

2

3

4

6

7

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9

All indicators may not be provided on some instrument cluster and may not be applicableto all models.ca

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INSTRINSTRINSTRINSTRINSTRUMENT CLUMENT CLUMENT CLUMENT CLUMENT CLUSTER ( EX )USTER ( EX )USTER ( EX )USTER ( EX )USTER ( EX )

Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a Glance

910913 12 11

14

16

2315 1718

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1

2

6

7

8

All indicators may not be provided on some instrument cluster and may not be applicableto all models.ca

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3

4

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceINSTRINSTRINSTRINSTRINSTRUMENT CLUMENT CLUMENT CLUMENT CLUMENT CLUSTERUSTERUSTERUSTERUSTER

1. SERVICE Indicator (Red)

2. Door Open Indicator (Red)

3. Lock Indicator Warning Light

4. Hazard Warning Indicator

5. Position Lamp Indicator

6. MIL Indicator (Amber) If fitted

7. High Water level Indicator in Sedimenter (Amber)

8. Glow Plug “ON” Indicator (Amber) - If fitted

9. Direction Indicator (Green)

10. Head Lamp Main Bean Indicator (Blue)

11. Low Engine Oil Pressure Indicator (Red)

12. Battery Charging Indicator (Red)

13. Brake Fluid Level Check/Parking Brake Indicator(Red)

14. Seat Belt Indicator (Red)

15. Trip Odometer

16. Cumulative Odometer

17. Mode Selector Knob (Odometer)

18. Set Knob (Odometer)

19. High Temperature Warning

20. Low Fuel warning

21. Speedo Meter

22. RPM Meter

23. Fuel Gauge

24. Temperature Gauge

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one of the doors is partially open,the door open indicator will comeon. In addition to this, in case driverside door is not properly closedan audio beep will come for fewseconds, when the key is inserted.

Hazard Warning:This can be operated withoutignition ‘ON’. Press the hazardwarning switch (red knob) on thecentre of the dash board, all turnindicator lights will f lashsimultaneously to warn the otherroad users about any hazardouscondition of the car. Press theknob again to switch ‘OFF’ thehazard function.

NOTEIf lights do not blink or blinkrapidly, it is an indication ofproblem in the blinker electricalsystem or the indicator bulb atfront or rear has fused. Get itrectified immediately.

Position LampIndicator :Symbol lights up when the positionlamps are switched ‘ON’.(instrument cluster illuminationlamps when the position lamps are‘ON). Position lamps can be usedas parking lamps.

Malfunction IndicatorLamp - MIL (if installed)This indicator comes ‘ON’ when theignition is turned on and goes OFFonce the engine is cranked. Theindicator remains on for any enginesensor related fault due to whichemissions of the vehicle may crossthe regulatory limit.

CAUTIONMIL illuminates / flashes when amalfunction occurs in the engineemission system. Do not drivethe vehicle if this indicatorremains ‘ON’ or Flashes. Get theproblem attended to immediately

SERVICE Indicator :

This lamp indicates your vehicle’sengine condition when amalfunctioning occurs in theengine, wiring harness, EMS, etc.this lamp indicates as below:1. Comes ‘ON’ when key is in

‘IGN’ position and goes ‘OFF’when engine is running.

2. Remains “ON” while the engineis running if malfunctioningoccurs.

CAUTIONWhen “Service” lamp is ON whilethe engine is running, theengine’s performancedeteriorates marginally andsometimes drastically. .Please getthe malfunctioning rectified at anearest authorized service outlet.

Door Open Warning:Prior to driving ensure that all thedoor are properly closed. If any

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Low Oil PressureIndicator:When the ignition key is turned tothe ‘IGN’ position, symbol lights upand goes off as soon as therequired engine oil pressure isdeveloped after starting the engine.

If the low oil pressure indicator doesnot glow or remains ‘ON‘ with the‘IGN’ on and engine is running, itindicates a fault in the electricalcircuit/lubrication system. Check &get the problem attended to at anAuthorised Service outlet.

Lock Indicator WarningLight :This system disables the startermotor circuit, ignition supply andfuel cutoff solenoid supply. Thevehicle can be unlocked onlypressing the “Unlock” button of thecorresponding vehicle remote.

It will blink when vehicle isimmobilised condition. Unlock withremote and start vehicle.

Turn Signal:

Turn signal lamps can be operatedonly when the ignition supply is‘ON and by using the turn indicatorswitch on the combi switch. Thedirection indicator arrow (LHS)and (RHS) on the instrumentcluster flashes along with externalindicator lights as selected.

High Beam Indicator:

Symbol lights up when theheadlamp high beam is ‘ON’.

at a TATA Authorised ServiceOutlet. Driving the car in thiscondition may cross theregulatory emission limit and / ordamage the catalytic convertor.

Water in fuel sedimenterindicator :This light indicates excess wateraccumulation in the sedimenter. Itwill come on when ignition is turned‘ON’ and will go off in approximatelyfive seconds. When this lampremains ON, water needs to bedrained from sedimenterimmediately.

CAUTIONIf water is not drained from thesedimenter, it can cause seriousdamage to the fuel injectionsystem.

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• When ignition key is turned to“IGN” position, this indicatorlights up and goes off whenengine starts in normalcondition. If it continueously ONwhile engine is running, get theproblem attended to anAuthorised Service Outlet.

Seat Belt Indicator:

The indicator initially flashes whenthe ignition is ON and seat belt isnot fastened. It will continue to flashuntil the vehicle exceeds a speedof 20 kmph. After that, it will remaincontinuously ON accompanied bya buzzer that will buzzapproximately for 100 seconds.After that, the buzzer goes OFF butthe indicator continues to remainON.

NOTENOTENOTENOTENOTE

Battery Indicator:Symbol lights up when the ‘IGN’ isturned ‘ON’ and should go ‘OFF‘after the engine starts.

If it remains ‘ON’ while theengine is running. It indicatesthat the battery is not gettingcharged. Switch off allunnecessary electricalequipment and get theproblem attended to at anAuthorised Service outlet.

Parking Brake Indicatorcum Low Brake FluidWarning Light :This indicator has multiplefunctions as follows :• It lights up when the parking

brakes is applied and goes offwhen parking brake isreleased.

• It also lights up when brake fluidlevel is low.

Odometer and Trip meter (onLCD):The odometer records the totaldistance the vehicle has beendriven. The trip meter can be usedto measure the distance traveledon each trip or between fuel fillings.Keep track of the odometer reading& follow the maintenance scheduleregularly for meeting servicerequirements.

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NOTENOTENOTENOTENOTE

Odometer, Trip meter andIllumination intensity control oninstrument panel (LCD):The instrument panel has an LCDto display the following :Main Odometer (Non- resettable)- Counts up to 999999 kms• Trip meter A (Resettable) -

Counts up to 1999.9 kms• Trip meter B (Resettable) -

Counts up to 1999.9 kms• Intensity level of instrument

panel illumination – selectionamong preset levels.

LCD has two line display. The firstline displays the Odometer count.The second line displays either ofTrip meter A, Trip meter B,Intensity level of panel illumination.The selection and control offunctions are done through‘MODE‘ and ‘SET’ push buttons(knobs) provided on either side of

the LCD. The ‘MODE’ knob is usedto select one of the Trip meter A,Trip meter B OR Intensity level ofpanel illumination. Switchingamong the above three functionscan be done by pressing the knob.

The ‘SET’ knob is used to controlthe chosen function. Pressing theknob for a few seconds resets thechosen trip meter and varies theintensity level of instrument panelillumination.

The panel illumination intensityvaries among preset levels asfollows:

Intensity Level IndicatorIntensity Level IndicatorIntensity Level IndicatorIntensity Level IndicatorIntensity Level Indicator

= Min

= = = = Max

This display returns to Trip meterA after a few seconds of intensitylevel selection, if left in this mode.

Main odometer and trip meter ‘A’indication will remain on displayeven if the ignition key isremoved.

Low Fuel Indicator:

(Amber/Orange) :

It comes on when fuel level in lowand needs refill at the earliest.

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RPM meter (if provided) :

The meter indicates engine speed in revolutions perminute (rpm) Change gears at appropriate engine rpmand vehicle speed to get optimum fuel economy. Thepermitted engine rpm upper limit is the start of RedZone on the dial.

Fuel Gauge:

The fuel gauge indicates the approximate fuel level inthe tank. Refill the fuel tank at the earliest, before theneedle touches the red band on the gauge. At thispoint, fuel level in tank is low and it is advised to getfuel filled immediately

Temperature gauge:The gauge indicates the temperature of the enginecoolant. The red zone at ‘H’ indicates temperaturehigher than the normal. Avoid driving, when the pointeris in the red zone. It indicates engine overheating,which may be due to insufficient coolant in the radiatoror due to any other defect. At this stage take the car tothe nearest Authorised Service outlet for necessaryattention.Caution: Never remove the radiator pressure cap fromthe radiator when the engine is hot. Do not restart theengine until the problem has been duly attended.The speedometer: The speedometer indicates thevehicle speed in km/hr.

SpeedometerGX EX

TTTTTempempempempemperererereraaaaaturturturturture Ge Ge Ge Ge Guageuageuageuageuage

HighTemperature

Warning

RPM meterGX EX

Fuel GuageFuel GuageFuel GuageFuel GuageFuel Guage

Low FuelWarning

Fuel GuageFuel GuageFuel GuageFuel GuageFuel Guage

TTTTTempempempempempGuageGuageGuageGuageGuage

GAGAGAGAGAUGESUGESUGESUGESUGES

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceOPEROPEROPEROPEROPERAAAAATING SWITTING SWITTING SWITTING SWITTING SWITCHESCHESCHESCHESCHES

OPERATING SWITCHES :

Four operating switches areprovided on the console.

1 2 3 4

1. Rear Windshield Demister2. Hazard Warning Switch3. Rear Fog Lamp Switch4. Front Fog Lamp Switch

Rear WindshieldDemister :( Unlatched switch)This switch can be operatedwhen Ignition is ON. Demister isprovided to clear the visibility ofRear Windshield on tail gatewhen required. Push the rearwindshield demister operatingswitch to turn the demister ON.The demister will switch offautomatically after 15 minutes.Rear Wind Shield Demister willwork effectively when battery isfully charged.

NOTICEClean the rear windshield glasscarefully from inside to avoiddamage to demister heaterelement.

Hazard WarningSwitch:

Hazard warning is used in case ofbreakdown especially during nightand vehicle has to be parked at theside of the road or vehicle beingoperated in adverse condition.This can be operated withoutIgnition ON. Press hazard warningswitch to switch ON. All outside turnsignal lights and indicators oncluster will flash simultaneously towarn the other road users abouthazardous condition of the vehicle.Depress the switch to switch OFFthe hazard function.

CAUTIONEnsure that all turn signalindicators are working properly.Get it rectified in case ofproblem.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceOPEROPEROPEROPEROPERAAAAATING SWITTING SWITTING SWITTING SWITTING SWITCHESCHESCHESCHESCHES

Rear Fog Lamps :(Unlatched switch)

The fog lamps are provided on rearbumper to improve the visibility andwarning in foggy weather or duringheavy rains. The rear fog lampscan be switched on with parkinglamp and front fog lamps ON andcan be remain ON till the parkinglamp is switched OFF. The rear foglamps can also be switched ONeven if only headlights are ON.

NOTICEUse only during foggy conditionsor heavy rains if required.

Front Fog Lamps :( Unlatched switch)

The fog lamps are provided onfront bumper to improve thevisibility in foggy weather or duringheavy rains. The front fog lampscan be switched ON with parkinglamp ON and can be remain on tillthe parking lamp is switched OFF.

NOTICEUse only during foggyconditions or heavy rains ifrequired.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSTEERING LOCK CUM IGNITION SWITCHSTEERING LOCK CUM IGNITION SWITCHSTEERING LOCK CUM IGNITION SWITCHSTEERING LOCK CUM IGNITION SWITCHSTEERING LOCK CUM IGNITION SWITCH

Steering Lock cum IgnitionSwitch:Key of ignition switch is commonfor door lock, steering lock andglove box lock.The ignition switch is on the rightside of the steering column. It hasfour positions. Turn the keyclockwise for further functions.

LOCK - Steering LockedOFF - ‘KEY IN’ position.IGN - All electricals ‘ON’START - Engine crank

LOCK:You can insert or remove the keyonly in this position. The steeringcolumn is locked when the key isremoved.

WARNINGDo not remove the key whiledriving. It will lock the steeringand can cause loss of control.Remove the key only when thevehicle is parked.

OFF (key IN):By turning key to OFF (key in)position. ‘KEY IN’ driven load likemusic system will be ‘ON’.IGN:All electricals and accesories ON.START :Turn the key further clockwise tothe START position (spring loaded)to start the engine. As soon as theengine starts release the ignitionkey to ON position. While

cranking, all accessories will bemomentarily ‘OFF’.

NOTICENOTICENOTICENOTICENOTICE

Do not crank the engine morethan 10 secs. continuously. Ifthe engine does not start waitfor 30 secs. before cranking itagain. Release the keyimmediately after starting theengine otherwise starter motor/flywheel ring may getdamaged.

By turning the ignition key from‘IGN’ position to ‘OFF’ position,engine can be stopped.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceCCCCCOMBINAOMBINAOMBINAOMBINAOMBINATION SWITTION SWITTION SWITTION SWITTION SWITCHCHCHCHCH

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceCOMBI SWITCHCOMBI SWITCHCOMBI SWITCHCOMBI SWITCHCOMBI SWITCH

A) RIGHT HAND STALK

1) Head lamp leveling rotaryswitch:

Inner rotary switch on right handstalk is provided for head lampleveling. Setting is done by rotatingthe knob to select one of the 3 levelpositions depending upon theloading of the vehicle. Head lampleveling can be done with headlamp in Low Beam and in ONposition.

Setting should be done onlywhen vehicle is stationary

NOTICESince the leveling switch takescare of headlamp focus patternunder varying load conditions, itis advisable to select the correctposition before starting a trip(depending on load)

2) Light stalk:

Outer rotary switch on right handstalk is provided for selectingPosition or Head lamp High/Lowbeam. It operates with Ignitionswitch in “IGN” position.

a) Head / Position lamp OFF.

Head lamp, position (Parking) lampand tail lamp will be OFF in thisposition.

b) Position lamp in ON.

Position (Parking) lamp and taillamp will be ON in this position.

c) Head / Position lamp ON.

Head lamp, position (Parking) lampand tail lamp will be ON in thisposition. Toggling the lever (Stalk)

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceCOMBI SWITCH

Turn (Self cancellation / Manualreturn type)LEFT HAND STALK :

1) Rear windshield - Wipe &Wash rotary switch:

Outer rotary switch on left handstalk is provided for rear windshieldwipe & wash. The top (1st) positiondenotes wash, which is springloaded. After releasing, the switchreturns to the OFF position. Firstposition below OFF position is forWipe and second position is forWash + Wipe which is springloaded.

A

BC

in upward direction changes theLow beam to High beam and viceversa. For High beam flash, pull thelever halfway. For keeping the inHigh beam position pulls up thelever further up to latch.

3) Light stalk (Side Indicator):

Push the stalk upwards forchanging lane or turning to Left anddownwards for changing lane orturning to Right according torequirement. It has three positions.A) Side indicator OFFB) Lane change for Left or RightTurn (Spring Return)C) Lane change for Left or Right

2) Intermittent front wiper delay:

Inner rotary switch on left hand stalkis provided for intermittent frontwiper delay. The switch has 5 delaytimers for intermittent function.

3)Front windshield-Wipe & Washrotary switch:

Pull the stalk upwards to operateintermittent wipe (- - -), Slow wipe( ) or fast wipe ( ). Pull the

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceANALANALANALANALANALOG CLOG CLOG CLOG CLOG CLOCK & MUSIC SYOCK & MUSIC SYOCK & MUSIC SYOCK & MUSIC SYOCK & MUSIC SYSTEMSTEMSTEMSTEMSTEM

Tweeter Location on dash board

Speaker Location on doors

Antenna: The antenna is locatedover the inner rear view mirror.

Music System :The music system is provided onthe facia & the speakers are fittedon doors and tweeters ondashboard.

Music System

stalk down for wipe and wash. Pulltowards driver for Flick Wipe(spring return).

NOTICEAfter wash function is activated,there will be three wipes of wiper.There will be one more wipe after5 seconds to clean traces ofwater on wind screen.

Analog Clock :

The vehicle is fitted with an analogclock on the center console. It hasa knob at the bottom of the dial forresetting the time.

SettingKnob

For operation and moreinformation of music systemplease refer manufacturer ’smanual.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceHEATING, VENTILATION & AIR CONDITIONING

Central Console

A.C. Controls

A B CD E

A - Air Direction Control KnobB - Temperature Control KnobC - Blower Speed Regulation KnobD - A.C. ON/OFF SwitchE - Air Recirculation / Fresh Air Switch

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceHEATING, VENTILATION & AIR CONDITIONINGA. Air Direction Control Knob :

The air flow can be changed byturning the knob (A) to the desireddirection.

B. Temperature-Control Knob :

The air temperature in the vehiclecan be controlled by operating thetemperature control knob (B) onthe control panel. The temperaturecan be increased by rotating theknob towards the red segment anddecreased by rotating it towardsthe blue segment.

C. Blower Speed RegulationKnob :

The HVAC system has a fourspeed blower. The blower speedscan be regulated to any one of thefollowing speeds by operating theblower knob (C) centre of thecontrol panel.

Towards face

Towards face and feet

Towards feet

Towards feet & windshield(Recommended for clearingmist on windshield)

Air demist/defrost windshield(Recommended for clearingheavy fog or snow

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceHEATING, VENTILATION & AIR CONDITIONING

D. A.C. ON/OFF Switch :The A.C. can be switched ‘ON’ bypressing the switch (D) on the A.C.control panel provided the bloweris ÒN’ and the engine is running.The indicator lamp will show thatthe A.C. is ÒN’.

IndicatorIndicatorIndicatorIndicatorIndicator

E. Recirculation / Fresh AirSwitch :

● In HVAC version to put aircirculation mode inrecirculation, press switch 'E'.The indicator lamp will show aircirculation is in recirculation.To put vehicle in Fresh moderelease switch 'E'. Indicatorlamp will be 'OFF'.

In recirculation mode, air insidethe vehicle is circulated againand again. In Fresh mode, airis taken from atmosphere andcirculated in the vehicle.

Recirculation mode can be usedWhile driving in dusty conditionTo avoid traffic pollutionTo get quick cooling/heating asrequired.

Whenever discomfort is felt switchair circulation mode to fresh.


The A.C. can be switchedÒN' only if the blower is 'ON'and engine is running. WhenA.C. is switched 'ON' engineidling RPM increasesmarginally, to adjust to theA.C. compressor load. Whendesired temperature isachieved A.C. trips 'OFF'automatically.

The A.C. compressor getsswitched 'OFF' automaticallywhen engine gets overheated.The A.C. is automaticallyswitched 'ON' when theengine cools down.

IndicatorIndicatorIndicatorIndicatorIndicator

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Normal Heating :

(For vehicles fitted with HVAC &Heating system only)

Knob 'A' - Towards face & feetKnob 'B' - Suitable temperaturepositionKnob 'C' - Suitable blower speedA.C. - OFFAir Circulation - Fresh switch

Quick Heating :All settings as explained beforeexcept air circulation switch torecirculation.Once vehicle is heated, switch backto fresh mode.

Normal Cooling :

A.C. - ONKnob ‘C’ - desired speed positionKnob ‘A’ - towards faceSwitch ‘E’ - suitably as explained

Quick Cooling :Switch ‘ON’ the A.C. and keep theblower at maximum speed. Keepair direction in face mode. Allvents should be openedcompletely. Keep the aircirculation switch in therecirculation mode andtemperature control switch in themaximum cooling (Blue) position.At maximum cooling, A.C. trips offautomatically when the desiredtemperature is achieved.

In case you find reduction inair flow or foul smell in thepassenger compartment cleanthe evaporator

Demisting :In rainy season or in areas of highhumidity, mist formation insidewindshield glass is observed. Toclear mist dehumidified air ispassed on the windshield glass.

HEATING, VENTILATION & AIR CONDITIONINGThe position of control knobsshould be adjusted as follows :A.C. - ONKnob 'C' - Desired speed positionKnob 'A' - Towards windshieldKnob 'B' (for vehicles fitted withHVAC) - at suitable temperatureAir circulation - at suitable position


When mist gets cleared switchthe knob "A” position to Facemode.

In high humidity areas, if coldair continues to flow overwindshield, it may cause suddenfogging on outside surface ofwindshield.

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Defrosting :(For vehicles fitted with HVAC unit& HD)In low temperature areas, to clearfrost formation outside thewindshield glass, this setting isused.First start the engine andaccelerate to warm up.Knob 'B' - Maximum hot positionKnob 'C' - Very HighKnob 'A' -Towards windshieldSwitch 'E' - Fresh air modeconditionOnce the windscreen has becomeclear, move the fan switch todesired speed.

Ventilator :The air flow can be adjustedcontinuously with the rotary controlknob at the vents on the dashboard. The air vents can beadjusted upward and downward.


••••• Refrigerant charged in the airconditioning circuit has beenidentified on the label overfront body member. Use onlyrefrigerant as given in thelabel for topping up orrecharge, i.e. do not chargeR12 (CFC) in the vehicleearlier charged with R134a(Non CFC) or vice versa.

••••• Fresh air is taken from thegrill opening provided atbase of windshield glassoutside the vehicle. Keepthese openings clear andfree from fallen leaves etc.

HEATING, VENTILATION & AIR CONDITIONING

Front Ventilators

Side Ventilators


••••• AC Gas charging Quantityshould be 780 + 20 gms.(R 134a-Non CFC)

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Rear AC:Rear AC is provided for rearseats passengers. When frontAC is ON, it will provide cool airfrom front AC. When front AC isOFF, it can be used as blower(supplying normal air). Rear ACswitch is provided on roof andcan be used to switch ON theblower and select the blowerspeed. four adjustable air ventsare provided on roof. Air flowand direction can be adjustedon each air vent.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceLAMPS

Head Lamp:Head lamps are clear lens typehaving multi focal reflector and are

1 Main/Dip Beam2 Position/Parking Lamp3 Direction Indicatorprovided with H4 halogen lamp withdouble fitment for providing straightahead illumination of the road forthe long distance or deep beamwhich il luminates the roadimmediately ahead for shortdistance visibility. It also containsside indicator lamp and a parkinglamp.

Tail Lamp:The tail lamp assemblyincorporates the following

1 Reverse Lamp2 Direction Indicator3 Tail / Brake LampSide Repeater Indicator Lamp

FFFFFrrrrrononononont Ft Ft Ft Ft Fooooog Lampg Lampg Lampg Lampg Lamp

RRRRRear Fear Fear Fear Fear Fooooog Lampg Lampg Lampg Lampg Lamp

Fog Lamp :Front and rear fog lamps areprovided for your convenience andthey can be operated by rotatingthe Selector on Combi switch.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceLAMPSHigh Mounted Stop Lamp:High mounted stop lamp isprovided on the tail gate, and itglows whenever service brake isapplied.

Registration Plate Lamps:Two concealed lamps are providedfor il lumination of the rearregistration number plate.

Door Lamp :

These are provided on the innerside of the front and rear doors towarn the traffic coming from therear that the door is open.

Door Puddle Lamp :

This is provided on the bottom sideof the doors to assist the user foreasy entry and exit during night.

Engine Compartment Lamp :

This lamp is provided for yourconvenience.

High Mounted Stop LampHigh Mounted Stop LampHigh Mounted Stop LampHigh Mounted Stop LampHigh Mounted Stop Lamp

Registration Plate LampsRegistration Plate LampsRegistration Plate LampsRegistration Plate LampsRegistration Plate Lamps

Engine Compartment LampEngine Compartment LampEngine Compartment LampEngine Compartment LampEngine Compartment Lamp

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Front interior light with readinglamps:Interior roof lighting and readinglamps with inbuilt switches areprovided on the roof near the rearview mirror.

The central rectangular switch hasthree positions:ON - The lamp will come ‘ON’ aslong as switch is in this position.DOOR - In this position the lampcomes on when either of the doorsare opened. When the door isclosed, the lamp will not go ‘OFF’immediately, but remain ‘ON’ for5-8 sec. This helps settling in the

seat and inserting the key in theignition switch. When the key isturned to the ‘IGN’ position, thelamp goes ‘OFF’ immediately.OFF - In this position the lamp willnot come ‘ON’ at all. Tworectangular shaped push type ‘ON/ OFF’ switches are providedseparately for the right and leftreading lamps.Rear roof lamp :A roof mounted lamp is providedabove the rear seat. It has followingthree positions :ON, DOOR & OFFThe function of this switch is similarto front interior light.

LAMPS

Left RightMiddle

“Follow me home” Headlamps :After closing the door, your car’sheadlights remain ON forapproximately 30 seconds to helpyou reach your destination in thedark.

If the car’s headlamps remain ONfor five minutes or more and whenswitched off, ignition key removedand the door locked or kept open,the headlamp’s Low-beam comesON automatically for approximately30 seconds to help the car occupantreach his / her destination safely.If, within 15 minutes, the car islocked using a remote key, theheadlamp will come ON for a further30 seconds. If the remote key isused again within 15 minutes, thisprocedure is repeated. If theoccupant returns to the vehiclewithin 15 minutes after lastswitching it off, the headlamp againcomes ON when the door isunlocked.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSUNVISORS & GRAB HANDLESun visors:Two adjustable sun visors areprovided inside the cab above thewindshield to prevent sun glare.Lower the sun visors to protect theeyes from bright sunlight. The sunvisors can also be moved sidewaystowards the door.A vanity Mirror has been providedon the back of the Co-driver’ssunvisor.

Roof Grab Handle :

These are provided on all seatsexcept driver seat. This helps incomfortable positoning ofpassengers during journey.

NOTEWhen not in use keep thesunvisors in their original positionotherwise they may block thedriver’s vision.

Sunvisor

Vanity Mirror

Goggle Case :

A goggle case is provided nearinner rear view mirror for keepingthe goggle. Pull the cover to open,place the goggle (keeping glassfacing towards antidust cloth) andpress to lock.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceREAR VIEW MIRRORS

Motorised Outer Rear ViewMirror :

Motorised Rear View Mirrors arefitted on both front doors and canbe adjusted to the desired positionwith the help of a switch providedon the driver side door. The switchfacilitates the driver to adjust themirrors without lowering the windowglasses and without moving fromhis/her position.

1. Move the main switch to L (foradjusting left side mirror) andR (for adjusting right sidemirror)

2. Use the 4 positions of the knobto adjust the rear view mirrorsto correct angles.

NOTE : Manually adjusted outerrear view mirror are also availablein few version

Inner Rear View Mirror:

Antiglare mirror The antiglaremirror is fitted inside the cab.Provision has been made for twopositions:1. Normal position2. Antiglare positionUse antiglare position only whennecessary, as it reduces rear viewclarity.

1. Inner Rear View Mirror2. Operating Knob

Motorised Outer Rear ViewMirror

Mirror Adjustment Switch

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceGLOVE BOX, CUP HOLDER & UTILITY POCKET

Glove Box:The glove box is located on thedash board in front of the co-driver’s seat. The glove box canbe locked with the ignition key.

Cup holder :

Two cup holders are provided inthe glove box lid for yourconvenience.

Cup holderCup holderCup holderCup holderCup holder

Utility pocket / box :Utility pocket is provided to all thedoors to keep magazines / booksetc.

Front utility pocket / box

Glove BoxGlove BoxGlove BoxGlove BoxGlove Box

Rear utility pocket / box

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a Glance CIGARATTE LIGHTER & CUP HOLDERS

Floor Console :A) Cigarette Lighters:Two cigarette lighters are providedon floor console at front and rear.Press the cigarette lighter in thesocket to heat up. When it reachesthe desired temperature, it will popup and can be used. These lighterswill operate only when Engine isON or Ignition key in ON position.

CAUTIONHandle the lighter carefully toavoid personal injury.If lighter does not pop out,remove it to avoid overheating.Avoid smoking inside thevehicle; it may spoil insideambience, interiors, upholsteryetc.

Cigarette Lighter for front passengers

Cigarette Lighter for Rear passengers

B) Cup Holder:

Two cup holders are provided in thefloor console lid at the rear end forthe convenience of the rear seat(2nd Row Seat) passenger. Openthe lid to use the cup holders. Keepit closed when not in use.

Cup Holder for rear passengers

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceWINDOW GLASSPower WindowsGlasses on all four windows of yourvehicle can be operated by switchesprovided on the main control panellocated on the driver’s arm rest.They work only when the key is inthe “IGN” position.Glasses are wound up by pullingthe switch and are lowered bypressing it down.If you would preferto have the glass at its lower mostposition, press the switch down alittle longer and the glass glidesdown. This feature is known as“Express Down”.A safety locking arrangement hasalso been provided and can beactivated by a push type switchlocated at the centre, below thewindow switches. It has twopositions:LOCK – When switch is pressedUNLOCK – When switch isreleased

WARNINGWhile raising the glass, takecare to avoid fingers / handsgetting trapped between glassand the frame.

Power window switch (On RearDoors): Individual window windingswitches have been provided onlyon the rear doors.To close the door window glass pullthe knob up and to open, push theknob down

When the switch is in “LOCK”position, the rear window switches(located on rear doors) do notfunction. The rear window glassescan still be operated by using theswitches on the console.Illumination on the rear windowswitch goes off when the switch isin locked condition. Press down thelock button to unlock.Individual window windingswitches have been provided onlyon other doors.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceWINDOW GLASS & STEERING ADJUSTMENT

Manual window winding :

In few versions, power windows arenot provided. In such vehicle, usewinder handle manually forlowering down or raising up windowglasses.

Rear Side Window Glasses :

Butterfly windows are provided onboth rear sides of vehicle to provideventilation for 3rd row occupantswhen required. Pull the toggle tounlock and open the window. For

Toggle

locking, pull toggle lever and pressit to lock.

NOTICEIt is advisable not to open thewindows when AC is ON. This willadversely affect the ACperformance.

Steering Wheel PositionAdjustmentYou can adjust the steering wheelposition to suit your convenience.Adjust the steering wheel positionas follows before you start driving.1. Adjust the seat to a comfortable

position.2. The lever to tilt the steering

wheel is under steering column.Pull the lever up and hold in thatposition.

3. Move the steering wheel up ordown to the desired position.

Position the wheel such a waythat all the instrument panelgauges and warning lights arevisible.

4. Release the lever. Make surethat steering wheel is securelylocked by moving up and down.

CAUTIONSteering wheel should beadjusted only when the vehicleis stationary.

Steering Adjustment Lever

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceFUEL FLAP OPENING

Fuel Tank flap opening:The fuel flap is located on the leftrear side of the vehicle. The fuelflap can be opened by pulling theopening lever located at the righthand side of the driver’s side forRHD vehicle & left hand side forLHD vehicle

WARNINGFuel vapour is extremelyhazardous. Always stop theengine before refueling andnever refuel near sparks or openflames.

CAUTIONRemove the fuel filler cap slowly,and wait for any hissing to stop,then remove it. The fuel may beunder pressure & may sprayout, causing injury if the cap isopened suddenly.

Fuel Flap Openning Lever

Always use only originalspecification fuel cap or anapproved equivalent, available atAuthorised Dealers. The wrongcap can result in a seriousmalfunction of the fuel systemand the emission controlsystem.

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Gearshift lever & shiftingpattern:

The gearshift lever is mounted onthe center console between the twofront seats. The gearshift patternis shown on the gear lever knob.

The reverse gear should beengaged only when the vehicleis stationary. Wait for 5 secondsafter declutching to ensuresmooth engagement of thereverse gear.

Parking brake:Mechanical parking brake actingonly on the rear wheel is providedon your vehicle. The parking brakelever is located behind thegearshift lever. To apply theparking brake, pull the lever upfully. The indicator light on theinstrument panel will become ‘ON’.To release it, pull the lever upslightly, press the release buttonand push the lever down. Theparking brake indicator on theinstrument panel will go ‘OFF’ whenthe parking brake lever is fullyreleased.

1. Release Button2. Parking brake leverA. Applied ConditionB. Released Condition

GEAR SHIFT LEVER & PARKING BRAKE


Apply the parking brakeproperly before leaving thevehicle & release it beforemoving.When parking on a steepslope, do not rely on the handbrake alone to hold thevehicle. Leave the vehicleparked with gear box in lowforward gear when facinguphill and reverse gear whenfacing downhill.

46

Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceAnti Theft/ Immobiliser cum Keyless Entry System (If fitted)ANTI THEFT / IMMOBILISER CUMKEYLESS ENTRY SYSTEM :

This system is essentially an anti-theft security system, which has akeyless operation for door unlock/lock. It immobilizes the vehicle bydisabling starter motor, ignition andfuel supply in case of unauthorisedentry.The system consists of follow-ing :1. One User "Remote" with LOCK

and UNLOCK button fornormal use.

2. Body Control Module (BCM).3. "Lock Indicator Warning" on

instrument cluster for indicationof "mode" of the system.

Features :Locking/ unlocking the vehiclefrom distant place. (Refer armmode)

Immobilisation of vehicle andcontinuous flashing of turnindicators and hooting, if theftis detected (Refer ArmedPanic).Protection when user forgets tolock using remote.(Refer AutoArm Mode).Immobilisation of vehicle if theftis detected in Auto Arm mode.(Refer Auto Arm immobilised)Finding the vehicle. (Refer carseek).Manual central door locking/unlocking (Refer central doorlocking feature).Unlocks all doors in case of anaccident. (In case of vehiclecrash)Continuous flashing of turnindicators and hooting (ReferForced Panic).

UnlockLock

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceAnti Theft/ Immobiliser cum Keyless Entry System

Auto lock and unlock optionalfeature on some vehicles.(Refer Auto lock and unlock).Additional/ new remote can beadded. Stolen remote can bedisabled. (Refer LearningAdditional Remote / UnlearningLost Remote).

Modes of the system :

State of Immobiliser Meaning / Function of the state

Disarmed Vehicle can be drivenArmed Vehicle cannot be driven. Immobiliser is

sensing for unauthorised entry.Armed Panic/ Vehicle cannot be driven.Immobilised Fuel,starter supply is cut and

EMS interface state is inverted.Auto Armed Vehicle cannot be driven. Immobiliser is

sensing for unauthorised entry.Auto Armed Vehicle cannot be driven.Immobilised Fuel,starter supply is cut and

EMS interface state is inverted.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceAnti Theft/ Immobiliser cum Keyless Entry System (If fitted)DESCRIPTION OF MODES ANDUSAGE OF "REMOTE" ARMMODE:Used to lock the vehicle from Dis-tant place (Do not use Mech. Key).Press "LOCK" on User Remote.

Gives two flashes. Locks alldoors.Gives delayed flashthrough turn indicators afterlocking.Lock Indicator on instrumentcluster starts blinking (typicallyonce in 1.5 sec)The vehicle arms (i.e. Vehiclecannot be driven.If attempted,the system goes to ArmedPanic Mode). Press UNLOCKto disarm the vehicle.If any of the doors, bonnet orhatchback is not properly closedbefore locking, system goes toArmed Panic mode. PressUNLOCK to disarm the vehicle.

UNLOCK/ DISARM MODE :Used to UNLOCK the vehicle fromDistant Place. (Do not use Me-chanical Key)Press “UNLOCK” on User Remote.

Gives one flash on turnindicators.Unlocks drivers door (Press“UNLOCK” again to unlock otherdoors.Lock Indicator on dashboardstops blinking.The vehicle disarms (User candrive the vehicle).When Lock Indicator on dashboard is blinking the vehiclecannot be driven. PressUNLOCK to disarm the vehicle.

ARMED PANIC MODE :

In Armed Mode, if Theft is detected(door opened/Key inserted inignition switch/cranking attempted)vehicle immobilises and flashes theturn indicators for about 25 to 30seconds (To stop the flashing pressany button on the user Remote).

AUTO ARM MODE :

Protection when user forgets to lockthe vehicle using remote.

In Unlock mode, after the keyis taken out of the Ignition switchand leaving the vehicle (door isopened and closed), vehiclearms automatically in 55 sec.,(i.e. Vehicle cannot be drivenwithout pressing UNLOCKbutton on the User remote. Ifattempted, vehicle goes to autoarmed immobilised mode)

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceAnti Theft/ Immobiliser cum Keyless Entry System (If fitted)

As an additional securitymeasure, the system has abackup facility. In Unlock modeafter taking the key out ofIgnition switch, the vehicle armsautomatically in 55 sec., even ifno door activity is detected.The Lock Indicator on theinstrument cluster startsblinking once in 1.5 seconds.When Lock Indicator oninstrument cluster is blinking,the vehicle cannot be driven.Press UNLOCK to disarm thevehicle.

AUTO ARMED IMMOBILISEDMODE :In Auto Armed Mode if Theft isdetected (Key inserted in ignitionswitch/or attempt to crank)Lock Indicator on the dashboardstarts blinking at faster rate and thevehicle immobilises. When Lock

Indicator on instrument cluster isblinking the vehicle cannot bedriven. Press unlock to disarm thevehicle.CAR SEEK :Used to find the vehicle.Press “LOCK” on User Remotewhen the vehicle is locked. (Range7.5 meters max.)

Gives three flashes on turnindicators and remains armed.

CENTRAL DOOR LOCKINGFEATURE :All doors can be locked/unlockedby manually locking / unlocking thedriver’s door (using mechanicalkey/knob)FORCED PANIC MODE :

Press “LOCK” and “UNLOCK”on User Remote simultaneously.Hooting and flashing will startcontinuously.

Press any button on the remoteto stop flashing.AUTO LOCK AND UNLOCK : (Iffitted)(When driving the vehicle)1. New locking strategy : When

ever vehicle is cranked andengine is fired, all doors will belocked automatically once vehiclereaches above 10 kmph providedthey are closed properly. If anyone of the doors is open, thenlocking will not take place.

2. After the key is taken out fromthe Ignition switch, the systemautomatically unlocks theall doors.

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Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceAnti Theft/ Immobiliser cum Keyless Entry System (If fitted)EMERGENCY DISARMINGPROCEDURE :THIS PROCEDURE ISAPPLICABLE IN CASE OF LOSTREMOTE & SYSTEM IN ARMED /AUTO ARMED / IMMOBILISEDSTATE I.E. CLUSTER LED ISBLINKING1. Enter the vehicle by opening

the door through physical key& close the door.In case thevehicle is in armed condition,the system will enter armedpanic in immobilised state-willhoot (if provided) and flash formax. 27 seconds.

2. Open driver door or turn on hazard switch.

3. Turn ignition ‘ON’ and ‘OFF’ 3times within 5 seconds.

4. On successful completion ofstep 3, the sysytem will comeout of the immobilised state toenter emergency dis-arming

state. (This state is similar tothe immobilised state withoutthe hooting and side indicatorflashing).The left and rightindicators will remain ON for 5sec. and will go OFF after that.

5. If step 3 is not completed within5 seconds the system willremain in immobilised stateand the left & right indicatorswill not come ON as in pointno.4. Close the driver’s doorand follow the step no. 2onwards

6. After step 5 the left and rightindicators start flashing (ON/OFF) for max. 9 counts theuser. Must count the numberof flashes and turn ignition ‘ON’as soon as this count matchesthe first digit of secret code.The left and right indicators willstop flashing.

7. Switch ‘OFF’ the ignition.

8. The user must enter the 2nd,3rd and 4th digit of the secretcode in a similar fashion asdescribed in step 6 & 7 above.

9. After successful entry of all thefour digits of secret codes thecluster left and right indicatorsstops flashing. The system willdis-armed and vehicle will getmobilised.

10. Close driver door or turn ‘OFF’hazard switch.

11. In case of any error inentering the secret code digitsthe left and right indicatorscontinue to flash and thesystem remains in immobilsedstate to re-enter secret code.Perform step 10 and start theprocedure from step2 onwards.

12. All previously learned remoteswill get unlearnt.

13. vehicle engine is released for5 cranks (configurable) only.

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14. The vehicle can be crankedand driven.

LEARNING OF NEW REMOTE :THIS PROCEDURE IS APPLI-CABLE IN CASE OF LOSTREMOTE & SYSTEM IN ARMED/AUTO ARMED/IMMOBILISEDSTATE I.E. CLUSTER LED ISBLINKING.Step 1-12 mentioned above, shouldbe completed successfully andthen follow steps 1,2 below, within30 sec. (Configurable)1. Open driver door (OR turn ‘ON’

hazard switch).2. Parking light should be ‘OFF’.3. Turn ignition ‘ON’ & ‘OFF’ 5

times within 10 sec.4. The system enters the learn

mode. The left and rightindicators remain ‘ON’ for30 sec. (Configurable)

5. Press any key on the remoteonce within 5 sec.

6. On successful learning of theremote, system gives singleflash.

7. Repeat step 4 & 5 above forlearning other remote (Max.4remotes)

8. Learning mode will be exited in30 seconds, if any of theremotes is not learnt during thistime. The learning process hasto be repeated.

CHANGING OF SECRET CODE :THIS PROCEDURE ISAPPLICABLE IN CASE WHENTHE USER WANTS TO CHANGETHE SECRET CODE.

CHANGING OF PIN WILL BEPOSSIBLE WHEN IMMOBILISERIS IN UNSET STATE OR REMOTEKEY ENTRY IN UNLOCK STATE

1. Press UNLOCK button from theremote.

2. Switch ‘ON’ the parking lights.

3. Turn ignition ‘ON’ and ‘OFF’ 3times within 5 sec.

4. If step 3 is not completed withinfive seconds, the left and rightindicators will not become ONas is case 4. Switch OFF theparking light and follow step 2onwards.

5. The Left and right indicatorsstart flashing (0.5 sec. ON / 0.5sec. OFF) for max. 9 counts.

6. The user has to enter theexisting secret number. Theuser must count number ofleft and right indicators flashesand turn the ignition switch ONas soon as the count matchesthe '1st' digit of the existingsecret code. On successfulentry, the right and leftindicators will stop flashing.

7. Switch OFF the ignition.

52

Sumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceSumo Grande At a GlanceAnti Theft/ Immobiliser cum Keyless Entry System (If fitted)8. The user must enter the 2nd,

3rd and 4th digit of secret codein similar fashion as describedin step 6,7 and 8 above.

9. After successful entry of all the4 digits of existing secret code,the left and right indicatorsstops flashing for 10 sec.

10. If a wrong secret code isentered, the LED continues toflash and the system remainsin immobilised state. To re-enter secret code, switch OFFthe parking lights and startprocedure from step 2 on-wards.

11. Repeat steps 7, 8 and 9 butwith the new 4 digit number.The digits to be entered can befrom 1 to 9. After successfulentry of all 4 digits of newsecret codes the left and rightindicators stops flashing for 10sec.

12. Again repeat the steps 7,8 and9 with the same new 4 digitnumber. After successfulentry of all the 4 digits of newsecret code, the left and rightindicators stops flashing for 10sec.

13. If the new secret code enteredtwice is not matching then theflashing of side indicators willstart for 5 sec. To restart theprocedure of entering newcode, steps from 12 onwardsto be performed. The left andright indicators starts flashingafter 10 sec.

14. If secret code entered twice ismatching then the system givesinformation of newly enteredcode with the equivalentnumber of left and rightindicators flashes for eachdigit, with a 5 sec. gap betweentwo digits.

15. Switch OFF the parking lights.16. The newly entered secret

number to be used here afteremergency dis-arming andremote learning.

NOTE : No remote will get unlearntwith this procedure.During this procedure any keypressed from the remote will beignored.REPLACEMENT OF REMOTEBATTERY :(replace every year for normal use)1. Place the remote button-side

facing down and removescrews.

2. Change the battery withGOLDEN POWER Battery GP23A or equivalent (eg:- DuracellMS21/ MN21).

3. Put back the screws.4. Press any button and check

that the LED on the remoteglows.

53


5. Change the default PINnumber using aboveprocedure.

GUIDELINES FOR USER :The vehicle does not start(Engine does not crank/fire)Check the Lock Indicator onthe dashboard. If it is blinkingthen the vehicle is not supposedto start ( Arm Mode/Auto ArmMode). Press UNLOCK buttonon the User Remote and thenstart the vehicle.If the turn indicators areblinking, pressing the UNLOCKbutton of the User Remote willstop the blinking of the lamps.The next pressing of theUNLOCK button of the UserRemote will unlock/disarm thevehicle and then the vehicle canbe driven.Contact the dealer ifthe vehicle still could not bestarted.

Pressing UNLOCK/LOCKdoes not UNLOCK/LOCK thevehicle.If the turn indicators areblinking, pressing UNLOCK/LOCK will stop the blinking oflamps. The next UNLOCK/LOCKpress will actually unlock/disarmthe vehicle and the vehicle canbe driven.Battery Low Indication :1. Operating Distance has comedown2. LED on user remote flasheswhenever UNLOCK / LOCKbutton is pressed on the remote(under normal batteryconditions, the LED on the userremote lights continuously when-ever UNLOCK / LOCK button ispressed).3. Replace the battery to get increased range.

Press any of keys on remote, ifLED of the remote iscontineously 'ON' means batteryis OK. If it is blinking, thenremote battery is to be replaced.

NOTE : Remote may not beoperative in near transmissionvicinity of high power antenna (LikeTV)

54

KEYS & DOOR LOCKFront Doors (Driver & Co-driver)Locking / unlocking doors withkey from outside :Both front doors (drivers & co-driver) have separate lockingfacility. Front doors can be lockedor unlocked from outside with key.

Insert the key and turn it anti-clockwise to open or clockwise tolock the door. Pull the Door handleto open an unlocked door.

Keys:The key operates all locks andIgnition switch.

A code number is stamped on theplate attached to the key set.Detach this plate and store at safeplace (Not in the vehicle). Thisreference number is necessarywhile getting duplicate keys fromyour Authorised Dealer. Itadvisable to keep another key atsafe place for use in case ofemergency.

NOTICEDo not use locally made keys,get duplicate key through yourauthorized dealer.

Locking without a key frominside:All the doors can also be locked orunlocked independently frominside by pressing or pulling theknob (1).

NOTEWhen locking doors this way, donot leave the key inside thevehicle.

Getting Started

5555

Opening the doors from inside :All doors can be opened frominside. To open pull the dooropening lever / latch (2).

Childproof lock :Both the rear doors of the vehicleare provided with child proof lock.Push the lock lever located onvertical face near the lockdownward before closing the door.The door which has been lockedcannot be opened from inside, itcan be opened only from theoutside.

Tail gate Locking / Unlocking :Insert the key and turn it anti-clockwise to open or clockwise tolock the door. Pull the Door handleto open an unlocked door and justby closing the tail gate to its originalposition, it gets locked.

DOOR LOCK & CHILD LOCK

Getting Started

Location of door opening lever/latch

Tail gate Swing Handle

CAUTIONDeactivate the childproof lockwhen not required.

56

SEAT ADJUSTMENTS

Getting Started

Seats :Bucket type seats are providedwith a lever and recliner handleknob, to adjust seat positions.Lumbar Support :The lumbar support is provided togive you maximum driving comfort.and adjusted by the lever (1)provided at the side of the seatbackrest.

1. Lumbar Support2.Seat Back Recliner

Seat Back Recliner :To change the seat back angle,lean forward slightly and raise thelever (2). Then lean back to theposition you want and release it.Make sure that lever return to itsoriginal position.Moving the Seat Forward &Backward:To adjust the seat position, lift thelever under the seat cushion front,then slide the seat to the desiredposition and release the lever.Once the desired position isachieved release the lever to lockthe seat. Make sure the seat islocked in position. 1. Lumbar Support

2. Seat Back Recliner3. Handrest4. Lever for forward/backward movement5. Utility Tray (C0-driver Side)

2

3

4

5

1

5757

Poor Adjustment Good Adjustment

Head restraint :Adjustable head restraints areprovided for bucket seats in front.Neck rest for rear bench seat(Crew cab) cannot be adjusted. Toincrease the height lift up and leaveat desired click position. To reducethe height, press the unlock button& push the head restraint downwards.

CAUTIONAvoid driving the car with thehead-rest removed as it is asafety item. Do not attempt toadjust the head-rest while drivingthe vehicle.

SEAT FOLDING

Getting Started

Utility Tray

Utility Tray (Co-driver Seat) :A Sliding tray is provided below co-driver’s seat. Important papers /documents can be kept inside.Always ensure that, this tray isproperly closed after use.

58

REAR SEAT ADJUSTMENTSMiddle row seatsMiddle row seat is in 2 parts i. e.60 / 40 split. Two adjustable neckrestraints are provided on themiddle row seat. Foldable arm restis provided in centre of the seat.Pull out the arm rest when neededand fold back when not required.

These seats can be independentlyfolded as and when required whileentering and getting down from thevehicle for the third row seat

passenger or for carrying extraluggage.Folding of middle row seats fromoutside the vehicle.Latches are provided on both seatson outer side for folding the seatbackrest. Operate the seat latch‘A’ to fold the seat back on seatbase.

Pull the seat release strap ‘B’provided on seat base and tilt theseat base up so that it is verticaland touching front seat.

To unfold the seat, slide the knob‘C’, drop the seat. Operate latch‘A’ to unfold back rest.

1.Head Restraint 2. Foldable Handrest

1

2

REAR SEAT ADJUSTMENTS

Getting Started

5959

Folding of middle row seats frominside the vehicle (from third rowseat).Operate the seat latch ‘A’ to foldthe seat back on seat base.Pull the seat release strap ‘D’provided on seat base rear sideand tilt the seat base up so that itis vertical and touching front seat.To unfold the seat, slide the knob‘D’, drop the seat. Operate latch‘A’ to unfold back rest.

Third row seatThe third row seat is also frontfacing. It can be accessed afterfolding one of the middle row seats.Two adjustable neck restraints areprovided on the third row seat.This seat can be folded and alsocan be removed as and whenrequired for more luggages.

Folding of third row seatLatch is provided on back rest forfolding the seat backrest. Open thetail gate to access the latch. Pull

the seat latch ‘1’ to drop the seatback on seat base.

Lift the handle ‘2’ and tilt the seatbase up so that it is vertical andtouching middle row seat.

REAR SEAT ADJUSTMENTS

Getting Started

60

SEAT FOLDING

Getting Started

Hook the straps provided on seatbase rear side into middle row seatneck restraints. This will hold theseat firmly.

Removal of third row seatOnce the seat is folded, it can betaken out from the vehicle. Operatethe levers to release the seat andcare fully takes out seat fromvehicle.

Seat Release Lever

6161

SEAT BELTS

Getting Started

Seat BeltsThe safety of the occupants is ofprime importance to us.

This vehicle is equipped with seatbelts as a part of occupantrestraint system.

Why Seat BeltsWearing seat belts properly canprotect you from being thrownagainst the inside of the vehicle,against other occupants or out ofthe vehicle, in case of an accidentor sudden braking. It will reducethe chances of severe injury.

How to use seat beltsThis vehicle has three point inertiareel type front and rear seat beltsin the out board positions and alap belt for middle passenger onrear seat. In normal driving the beltlets you move freely in your seat.In case of an accident or suddenbraking inertia reel automatically

tightens the belt to help restrainyour body.

The anchor end of the shoulder beltis adjustable to suit the height ofthe passenger wearing it. The lapbelt has one manually adjusted beltthat fits across the hip bone. It issimilar to safety belt used inaeroplanes.

Make sure that your seat isadjusted to a good driving positionand the back of the seat is upright.

1. Pull the tongue across your bodyand insert it into the buckle.

1. Seat Belt 3. Lock Buckle2. Tongue 4. Lap Belt

2

1

3 4

2. Check and ensure that the beltis not twisted.

WARNINGTwisted seat belts can causeinjury, in a collision, the full widthof the belt isn’t available toabsorb the impact. This putsmore force on the bonesbeneath the belt, which couldbreak them or cause otherserious injury. Don’t weartwisted seat belts.

3. Position the lap portion of thebelt as low as possible acrossyour hip bone.

4. Pull up the shoulder part of thebelt to remove the slack. Makesure that the belt goes over yourcollar bones and across chest.

5. To unlatch the belt, press the redbutton on the buckle. Guide thebelt to the pillar as it retracts.

62

SEAT BELTS

Getting Started

WARNINGImproper positioning of theshoulder portion of the seat beltis dangerous. An improperlypositioned belt will provide littleor no protection in a collision.Always make sure the shoulderportion of the seat belt ispositioned across your shoulderand near your neck, but neverunder your arm. on your neck,or on your upper arm.

6. Each belt should be used byone occupant only . The beltmust not be put round a child,seated on passengers lap.

7. When the belt has been in usein a serious accident or showssigns of severe fraying or ofhaving been cut, replace with anapproved belt kit.

8. The belt must not be altered ormodified during use.

WARNINGUsing one seat belt for morethan one person at a time isdangerous. A seat belt used Inthis way can’t spread the impactforces properly and the twopassengers could be crushedtogether and seriously injured.Never use one belt for morethan one person at a time.

9 The belts are meant (intended)for adult occupants only.

10.The belts if required should bereplaced, by Authorisedpersonnel only.

11.The belt should not bedisassembled. If required,authorised personnel onlyshould carry out disassemblyand assembly.

12 Clean the webbing with a mildsoap solution recommended forupholstery or bleach or dye thewebbing this may weaken it.

Lap beltPull the tongue to the desiredlength.

Insert it into the buckle until youhear a click.

Adjust the belt length. To lengthenthe belt, hoId the tongue at a rightangle to the webbing and pull. Toshorten, pull the loose end of thewebbing.

To unfasten, depress the button inthe buckle.

WARNINGPositioning the lap portion of theSeat Belt too high can bedangerous, in a collision, thiswould concentrate the impactforce directly on the abdominalarea, causing serious injury.Wear the lap portion of the beltsnugly and as low as possible.

6363

SEAT BELTS

Getting Started

TATA MOTORS strongly urgesthat the driver and passengers inthe vehicle be properly restrainedat all times with the seat-belts.Failure to do so could increase thechance of injury and / or theseverity of injury in accidents.

Baby or Small Child :Use child restraint systemappropriate for the child until thechild becomes large enough toproperly wear the vehicle’s seat-belts.

If a child is too large for a childrestraint system, the child shouldsit in the seat and must berestrained using the vehicle’s seat-belt.

Also use the seat-belt while thechild is in the rear seat. Accordingto accident statistics, the child issafer when properly restrained inthe rear seat than in the front seat.

Child restraint systems areavailable. TATA MOTORSrecommend the use of a typewhich fits to your vehicle. Beforeinstallation, always read themanufacturer’s instructions.

Pregnant Woman :TATA MOTORS recommends theuse of a seat-belt. Doctors adviseis recommended. The lap beltshould be worn securely and aslow as possible over the hips andnot to waist.

Injured person :TATA MOTORS recommends theuse of a seat-belt for injured person.Depending on the injury, consultyour doctor for specificrecommendations.

64

DrivingSAFETY CHECKSBefore Driving, please ensure tocheck (Refer maintenance)1. Tyre pressure and condition of

tyres. Inflate recommended tyrepressure if required.

2. Coolant level to Max level.3. Engine oil level up to Max mark

on dipstick.4. Brake fluid level .5. Water in windshield washer

reservoir. Top up if required.6. Power steering oil level.7. Battery electrolyte level.8. Fuel level. Ensure sufficient

Fuel.

Adjust1. Check position of seat. If

required adjust to yourconvenience.

2. Check adjustment of all rearview mirrors.

Ensure1. Bonnet is fully closed.2. All doors are properly closed &

locked.3. Check that any items you may

be carrying inside with you arestored properly or fasteneddown securely.

4. Seat belts are fastened5. Ensure all mirrors, windows and

outside lights are clean andunobstructed. Remove dust,frost, snow or ice if any, onthese.

6. All switches & lamps are working7. Check and ensure that all the

gauges and indicators in theinstrument cluster are working.

8. Gear shift lever is in neutralposition

9. Parking brake is released.10.Adjust steering wheel position.

SAFETY CHECKSWindshield/wiper/windshieldwasherAlways keep windshield glass cleanto avoid any distraction in visibility.Ensure proper working of wipersand condition of wiper blade.Ensure that windshield washerreservoir is full. Do not operatewiper alone when the windshieldglass is dry, this would damage thewindshield.

HeadlightsKeep headlight lenses clean. Checkfor operation of headlamps in bothhigh/low beam condition. Check forcorrect focusing of headlamps. Useonly recommended type of bulbs.Do not use the high beam unless itis inevitable. Its dazzle may glarethe driver of the oncoming car thecondition thus causing an accident.

6565

DrivingDRIVING SAFETY

Side indicators / Hazard warningEnsure that all side indicators/hazardwarning lights are always in workingcondition and they are used whenrequired.HornEnsure the horn is working properly.Horn provides safety to other roadusers by alerting your presence.BrakesEnsure brakes are working properly.Check brake fluid level in reservoir.Do not drive the car when brakewarning lamp is 'ON'.TyresCheck the condition of tyres for anyabnormalities. Maintain correct tyrepressure, it is very importantparticularly when subjected toextreme conditions, such as highspeed, high load and high outsidetemperature. Do not use worn or baldtyres specially on the front wheels.

First Aid KitFirst aid kit is provided in your vehicle.This is for use in case of minorinjuries. It is to be regularly checkedfor any disintegration and should beupdated regularly.

DocumentsAlways carry vehicle registrationpapers, insurance, valid PUC certificateand driving licence with you.

DRIVING SAFETYSeat BeltSeat-belts are life saving equipment,use of seat-belt reduces the chanceof injury and severity of injury in caseof an accident. It is stronglyrecommended that all the caroccupants should always wear seat-belt, while vehicle is in motion.

Influence of AlcoholAvoid driving under the influences ofalcohol or drugs. Alcohol and drugswill severely impair your control of the

vehicle and increase the risk of injuryyourself and others.

Mobile phones

Avoid using mobile phones whiledriving a vehicle. This could divertyour attention from the road and resultin an accident.

Fatigue 'Rest Revive survive'Do not attempt driving when you feeltired, sleepy. Long distance drivingcan tire you very much and fatiguecan dull your reflexes and judgment.Take a rest and get refreshed atintervals.

66

FRIENDLY TIPS TO IMPROVEFUEL ECONOMY :

Your vehicle's fuel economy ismainly dependent on your style ofdriving.To operate your vehicle aseconomically as possible, use thefollowing driving suggestions.

Avoid Excessive Idling :

Stop the engine and start it again,if you have to wait for more than aminute while you are stopped.

Avoid fast starts & unnecessarystops :

Start off slowly from traffic lights orstop signs to prevent increased fuelconsumption and shortening ofengine life. Avoid unnecessarydeceleration (stopping or slowingdown) and then acceleration whichuses more fuel.

Fuel economy speeds :

Gear Speed (kmph)

1st 152nd 303rd 454th 605th 80

DrivingFUEL SAVING TIPS

NOTICE

Always maintain clean air-filter:

The amount of air supplied willreduce due to clogged air-filter,resulting in wastage of fuel due toincomplete combustion.

Avoid incorrect tyre pressures :

Under-inflated tyres result inincreased running resistance of thetyres, leading to wastage of fuel.(Refer tyre maintenance section)

Proper Driving Practices :

Keep a safe distance from othervehicles to avoid braking suddenly.

Do not rest your foot on theclutch pedal. It does not allowfull engine power to betransmitted to the vehicle andreduces clutch life.

6767

Starting the EngineBefore starting1. Apply parking brake.2. Ensure gear lever in neutral.A. Insert the key in steering cum

ignition lock and turn it to ‘ON’position.

B. Press the clutch pedal fully.C. Now crank the engine.D. If the engine does not start turn

the key to off position and tryafter 30 seconds.

NOTICEAfter starting run the engine inidle speed for at least 30seconds. Do not pressaccelerator pedal while startingthe engine to avoid damage toturbocharger.

Stopping the Engine

Before switching off the engine,run the engine in idle condition foratleast 30 seconds and then switch

STARTING, STOPPING THE ENGINE

Driving

Gear Km/ph

1st 202nd 403rd 654th 905th 110

off. This will allow the engine oil tolubricate the turbocharger, till itsspeed is fully reduced and alsoallow the unit to cool down.Above precautions will ensuresatisfactory life and performancefrom the turbocharger.Running-in PeriodAvoid rapid acceleration andprolonged high speed running ofthe engine while using the newvehicle for the first 1500-1800 kmof operation.Do not exceed the following vehiclespeed during running in period.

Gear boxGear box has all synchromeshgears including reverse. The 5thgear is an over drive.When shifting the gear up or downmake sure you press the clutchpedal fully and shift to the next gearand then release the clutch pedalgradually.

68

STARTING, STOPPING THE ENGINE

Driving

Before shifting in to reverse gearbring your vehicle to a completestop and depress the clutch pedalfully.

Do not shift into reverse gear withvehicle moving forward.

While shifting the gears it isrecommended to shift at thespeeds given in the table.

You can get extra braking from theengine when slowing down byshifting to a lower gear.

This can help you to maintain asafe speed and prevent yourbrakes from overheating whilegoing down a steep hill.

CAUTIONAvoid excessive revving up ofengine rpm.

CAUTIONRuning Engine under idlecondition for long duration andalso in high idle (fly-up rpm)should be avoided

Gear Shifting :Gear Change Speeds duringupshift :

Gear Change Speeds duringdownshift :

Gear Km/ph1-2 202-3 453-4 704-5 90

Gear Km/ph2-1 153-2 254-3 455-4 60

6969

Put your foot on brake pedal toapply brake. Do not ride thebrakes as they may overheat andthe performance may be impaired.The brake lights may confuse theother road users behind you.Use engine to assist the brakes byshifting to a lower gear and liftingyour foot from accelerator pedal.Constant application of brakeswhile going down the hill buildsheat and reduces brakingefficiency.Check your brakes after drivingthrough deep water. Apply thebrakes moderately to feel that theyare normal. If not, apply them gentlyand frequently until they do. Withwet brakes you should be extracautious and alert in your driving.

BRAKINGBrakes

The brake system on yourvehicle is an advanced vacuumassisted hydraulic brakesystem, equipped with:Brake booster : This assists thedriver in braking with anergonomic pedal force onbrake pedal;Tandem Master Cylinder, for failsafe braking.Twin pot calipers, for efficientenergy absorption.Load Sensing ProportionatingValve, to avoid rear wheellocking in extreme loadcondition.Auto adjusted rear brakeswhich are designed for troublefree performance.

The system is designed with an Hcircuit, this has an advantage ofproviding minimum braking even ifone circuit fails, however the pedalwill be harder to press and stopping

CAUTION

distance will increase. At the sametime brake indication light wouldglow on dash board.If you observe any abnormality inbrake system contact your nearestTATA Motors authorized workshop.In case of failure of vacuum supplyto the brake booster the vehicle canstill be stopped with a higher pedaleffort. In case of vacuum failureor brake circuit failure, slow downthe vehicle by shifting to lower gearand lifting your foot from theaccelerator pedal. Pull the side ofthe road as soon as it is safe.

Brake system failure is veryhazardous. It is best to haveyour vehicle towed, but if youdrive the vehicle in thiscondition, be extremelycautious.Have your vehicleattended immediately.

70

DrivingDRIVING IN ADVERSE CONDITIONSDriving Through Water :

Never venture to drive throughwater when it flows over guardstones.Engine may get seriously damagedif attempted to cross over throughdeep water.If at all the situation demands thatyou have to drive through waterthen;- Keep engine in fast idling and

crawl the vehicle in low gear.- After driving through water

apply brakes several times todry liners and to regain originalbraking.

Do not attempt to start the engineif vehicle gets flooded due to water.Tow the vehicle to a safe place.Take the vehicle to nearestAUTHORISED Workshop to checkentry of water in cylinders.It will also be necessary to replacelubricants of engine, gearbox,transfer case, front axle and rearaxle if water has entered.Get the starter and alternatorchecked.Driving on a Rainy Day :

Check brakes, steering andwindows.Check tyres for wear and tyrepressure.

Check wiper blades for properfunctioning.Avoid harsh braking and sharpturns. It may cause loss of controland lead to a skid.For slowing down, shift to lowergears and brake gently.Keep lights ON if visibility is poor.

Night Driving :

Dip the head lamp for oncomingtraffic during night driving.Maintain a speed such that you canstop within illuminated distance ofhead lamps.Use head lamp main/dip beam toalert other road users on turns/

7171

DrivingDRIVING IN ADVERSE CONDITIONS

cross roads etc.Use side indicators for lanechange or turning.

• Put on hazard warning switchin case of hazardous parking or ifyour vehicle is disabled to warn thepassing traffic.

Climbing Sharp Gradients onLoose Surfaces :

Start off smoothly in any suitablegear. Apply power smoothly so thatthere is no loss of traction by over-revving of the engine.Choose as smooth a slope aspossible and select the appropriate

gear so that gear changing in themiddle of the climb is not required.Changing gears in the middle ofthe climb can cause loss ofmomentum and engine stalling.Shifting to lower gear has to bedone cautiously to avoid loss oftraction.Under no conditions should thevehicle be moved diagonallyacross a hill. The danger is in lossof traction and sideways slippage,possibly resulting in tipping over.If unavoidable, choose as mild anangle as possible and keep thevehicle moving.If the wheels start to slip within fewfeet of the end of the climb, motioncan be maintained by swinging thesteered wheels left and right,thereby providing increased grip.If the vehicle stalls or lossesheadway while climbing a steephill, make a quick shift to reverseand allow the vehicle to move back

with the control of enginecompression.

Descending Sharp Gradients :

Depending on the severity of thegradient, shift into appropriategear. Use engine brakingjudiciously without over-revving theengine.Brake application under suchsituations should be done verysmoothly to avoid loss of control.Select appropriate gear so thatgear changing or clutchdisengagement is not involvedwhile descending the gradient.

72

Incase Of EmergencyJACK LOCATATION, WARNING TRIANGLE & FLAT TYRE REPLACEMENTAdvance Warning Triangle

There is an advanced warningtriangle provided along with yourvehicle. In case there is abreakdown and or the vehicle is tobe parked at the side of road, thenthe triangle is to be used as perinstructions given below:

1) Remove advance warningtriangle from case and assemble.

2) Place the triangle on the roadbehind the vehicle where it isstranded.

3) The triangle must be at least 50meters behind the vehicle in thesame lane of traffic.

4) Increase the distance to 150meters on a highway or if a bad/hill top obscures the view.

Hazard Warning Switch :

Use Hazard Warring lights besidesadvance warning triangle in caseof breakdown specially duringnight time and vehicle has to be

parked at the side of the road orvehicle is being operated in adversecondition.

This can be operated withoutignition 'ON'. Press the hazardwarning switch (red knob) on theleft side of the dash board, all sideindicator lights will flashsimultaneously to warn the otherroad users about any hazardouscondition of the vehicle. Depressthe knob again to switch 'OFF' thehazard function.

CAUTIONIf lights do not blink or blinkrapidly, it is an indication ofproblem in the blinker electricalsystem or the indicator bulb atfront or rear has fused. Get itrectified immediately.

7373

Incase Of Emergency

IF YOU HAVE A FLAT TYRE

Reduce vehicle speed graduallykeeping it is a straight line. Movecautiously off the road to safe placeaway from traffic. Park the vehicleon a level and firm ground. Applyparking brake & engage 1st gear.Turn on Hazard warning switch.Keep advance-warning triangle atleast 50 meters behind the vehicleas an indication of breakdown.Take out the tool kit, jack and handlefrom the vehicle which is kept belowdriver seat

Removal of Spare wheel

Spare wheel is mounted below cabat rear side of vehicle.Open the tail doorLift the carpet cutout covering thespare wheel winch screw hole.Rotate the wheel winch screw inanti-clockwise direction using the

wheel spanner to lower the sparewheel.Let the wheel touch the ground.Loosen it further to take outretaining plate from spare wheel.Remove spare wheel.

JACKING POINTS, FLAT TYRES REPLACEMENT

74

Incase Of EmergencySPARE WHEELFitting the spare wheel back

Place the spare wheel on theground below its location with outerside of the wheel rim facingupwards.Locate the retaining plate in thecentral hole of the spare wheel.Using the wheel spanner, the sparewheel can be raised by rotating thewheel winch screw in clockwisedirection.Align one of the wheel mountingscrew holes with the locating pinon the frame while raising the sparewheel.Continue to rotate the wheel winchscrew in anticlockwise directionuntil spare wheel is raisedcompletely.

Changing the flat tyre

Block the wheel which is diagonallyopposite to the flat tyreTake out wheel cover (If fitted) andloosen the wheel mounting nuts offlat tyre. (Do not remove the flattyre at this stage).

Set the jack properly at correct jackpoint as shown for front or rearwheel and slowly lift the vehiclewith the help of jack handle.

Jacking point - Rear

Jacking point - Front

7575

Incase Of EmergencySPARE WHEEL & LIMP HOME MODE

NOTICE

Limp Home Mode :

When water gets accumulated inwater sedimenter “water in fuelindicator lamp” on instrumentcluster remains ON continuously.

This causes the vehicle to run on“Limp Home Mode”; there is adrastic reduction in performance ofthe vehicle in Limp Home Mode.

At initial “Key-ON” the water infuel lamp indication on thedashboard glows for 2 secondsand goes ‘OFF’ automatically.If this lamp does not glow,vehicle has to be taken to theservice station for verificationand necessary attention.

CAUTIONDo not lift the vehicle with someone inside.Raise the vehicle only highenough to remove and changethe flat tyre.Do not carry any other workunder the vehicle supported byjack otherwise personnel injurymay occur.Do not start or run the vehiclewhile supported by jack.

Remove wheel-mounting nuts andtake out flat tyre.Roll the spare wheel into positionand align the holes in the wheel withstuds. Then reinstall the wheel nuts(taper end inward) and tighten themas much as you can by hand.

Lower the jack completely thentighten the wheel nuts one by oneusing wheel spanner. Fit the wheelcover back (if fitted).

Restore all the tools and jack at theirrespective location.

Place the flat tyre at spare wheellocation as described and tightenproperly.

CAUTIONCheck and correct the tyrepressure and nut tightness of thechanged wheel as perrecommendation at nearestService station. Also get thepunctured tyre repaired.

76

Incase Of Emergency

CAUTION

Connect leads in the order asshown in the sketch

STARTING THE ENGINE WITH JUMP LEADSStarting the Engine with JumpLeads :The engine with a dischargedbattery may be started bytransferring electrical power from abattery in another vehicle.This may be dangerous as anydeviation from the followinginstructions could lead to personalinjury resulting from any batteryexplosion, as well as damage tothe electrical systems in bothvehicle.

providing the jump start has thesame voltage as the battery inyour vehicle (12 V). Its capacitymust be approximately thesame as the original batterycapacity. The voltage andcapacity are given on thebatteries.

• Do not disconnect thedischarged battery from thevehicle.

• Switch off all unnecessaryelectrical loads.

• Do not lean over the batteryduring jump starting.

• Do not allow the terminals ofone lead to touch those of theother lead.

• Apply the hand brake. Keep thegearshift lever in neutral.

• Do not connect the lead to thenegative terminal of thedischarged battery.

• The connection of the -ve leadpoint should be as far awayfrom the discharged battery aspossible and close to the starter

motor on engine/transaxle.• Route the leads so that they

cannot get caught by therotating parts in the enginecompartment.

• The engine of the vehicleproviding the jump start can beallowed to run during starting.

Attempts to start the engine of thevehicle with the discharged batteryshould be made at intervals of oneminute and should not last morethan 15 seconds. After starting,allow both engines to idle forapproximately 3 minutes with theleads still connected.

Do not allow battery electrolyteto come in contact with eyes,skin, fabrics or painted surfaces.The fluid contains sulphuric acidwhich can cause injury andsevere damage. Wear rubbergloves, to avoid risk of contact.

Jump start bettry ofanother car

Discharged bettry

To lessen the risk of injury, weareye protection when working nearany battery.• Make sure that the battery

7777

Incase Of EmergencyTOWING THE VEHICLE

Tow Hook Location at Front

Tow Hook Location at Rear

Towing the Vehicle :• For towing a vehicle, the best

way is to use a wrecker.• Alternatively use a rigid tow

bar.• Avoid using a flexible cable

or rope as your vehicle maycrash into the vehicle towingyour car when it stopssuddenly.

• Switch ‘ON’ the hazardwarning signals of both thevehicle to warn other roadusers.

• Where possible, keep theengine idling so that powersteering assistance andbrake vacuum are available.

• Limit the speed to 20-30kmph.

• In case of brake failure, usethe parking brake to controlthe vehicle.

Front and Rear Tow HookLocation :

78

Incase Of EmergencyROUTINE SERVICEThis manual will help you tounderstand your vehicle.Inspection, maintenance of thevehicle should be handled byprofessionals only.

Please be careful while personallyinspecting / maintaining the vehicleas it may cause damage to thevehicle and may be unsafe.

The ignition and fuel systems arehighly important in view of emissioncontrol and for efficient engineoperation. Similarly the brakesystem for safety. Do not tamperwith them.

All inspections and adjustmentsmust be made by a qualifiedtechnician. We stronglyrecommend that all servicingrelated to these systems be doneby an Authorised dealer/TASC.

OWNER MAINTENANCE

Routine Service

We highly recommend that theseitems be inspected at least everyweek.Engine Oil Level, Engine coolantLevel, Brake Fluid Level, WasherFluid Level, Battery, Tyre inflationpressure

Do it Yourself Service

Improper or incomplete servicemay result in problems.Several mantenance procedurescan be done only by a qualifiedservice technician with specialtools. Improper do it ourselfmaintenance during the warrantyperiod may affect warrantycoverage. If you’re unsure aboutany servicing or maintenanceprocedure, have it done by anAuthorized Dealer / TASC.

WARNINGMaintenance procedures:Performing maintenance workon a vehicle can be dangerous.You can be seriously injuredwhile performing somemaintenance procedures. If youlack sufficient knowledge andexperience or the proper toolsand equipment to do the work,have it done by qualifiedtechnician.

7979

ENGINE

Preliminary Trouble shooting

(These tips are given for your guidance and preliminary jobs to be done in an emergency situation. In normal case,the problems should be attended in an Authorised Workshop by following the repair procedures given in WorkshopManual)

SR. NO.SR. NO.SR. NO.SR. NO.SR. NO. PROBLEM OBSERVEDPROBLEM OBSERVEDPROBLEM OBSERVEDPROBLEM OBSERVEDPROBLEM OBSERVED CAUSECAUSECAUSECAUSECAUSE AAAAACTION CTION CTION CTION CTION TTTTTO BE O BE O BE O BE O BE TTTTTAKENAKENAKENAKENAKEN

ENGINEENGINEENGINEENGINEENGINE

1. Engine not cranking Dead battery loose or dirty • Get battery checked&/or changedbattery connections • Clean and tighten battery

connections2. Engine cranks but does not start Air in the fuel system • Press pear pump for air removal

• Check leakagesService lamp should glow • Get defect rectifiedEMS fuse blown • Replace the fuse

3. Engine overheats Coolant level low • Top up coolant, check andcorrect leakages

Hose collapse / torn • Get the hose replacedLow engine oil level • Add oilRadiator cap not sealing properly • Fit the radiator cap correctlyA.C. condensers fans not working • Get defect rectifiedBrakes binding • Get defect rectifiedElectric fan not working • Get defect rectifiedHigh delivery pressure in A.C. • Get defect rectifiedrefrigerant circuit

4. Charging indicator continuously Battery not getting charged • Get the belt tension adjustedremains ‘ON’ due to loose belt drive Replace if broken

80

CLUTCH & GEAR BOX


5. Poor pickup Loose contact of connectors • Get defect rectified.Blocked fuel filter • Clean/replace fuel filter elementClogged air filter • Clean / replace the elementEGR malfunctioning • Get checked & corrected

• Check for loose pipes &connections.

6. Does not accelerate Accelerator pedal module defective • Get defect rectified7. Belt squeal Loose belt • Get belt tension adjusted

Belt glazed • Get belt replacedCLUTCH

1. Clutch does not get disengaged Air in the hydraulic system • Bleed the systemLess fluid in the master cylinder • Get the clutch fluid filled

2. Clutch pedal goes too low Air in the hydraulic system • Bleed the systemLess fluid in the master cylinder • Get the clutch fluid filled

3. Clutch pedal return sluggish Blocking of vent in clutch fluid • Open the cap from the bottlebottle & clean the breather hole, if

clogged

GEAR BOX

1. Hard gear shifting / Clutch does not disengage • Get the clutch hydraulic systemcrash engagement properly attended


8181

AXLE & BRAKE


REAR AXLE 1. Loss of lubricant (Oil) Breather hole clogged • Clean the breather hole on the

axle housingDifferential cover gasket torn • Get replacedPinion oil seal damaged • Get replaced

2. Differential housing overheating Insufficient oil • Get the oil filledIncorrect lubricant used • Drain, flush and get correct

lubricant filled

BRAKES

1. Poor brakes Insufficient brake fluid. • Get the brake fluid filledAir in the system • Bleed the systemMalfunction of automatic adjuster • Check & rectify auto adjuster

mechanism or replaceVacuum leakage • Rectify the leakageBrake fluid contamination • Replace the brake fluidBrake fluid, grease, oil or water • Replace the leaking line, bleedon pad /drum the system. Clean pad/lining.

replace seals if leakingWorn brake lining/pad • Get the liners/pad replacedExcessive worn drums at rear • Replace rear drumssoft or weak hose • Check & replace


82

BRAKES


2. Spongy pedal Air in the system • Bleed the system

3. Brake pulling to one side Oil on the lining/pad • Clean the pad liningOne side shoe (pad) worn • Get the shoe pad replacedLoose brake anchor plate • Tighten the boltsWheel adjustment disturbed • AdjustUnequal tyre pressure • AdjustOne side brake pipe clogged • Get the brake line cleaned &

bleed the system

4. Brake grab Improperly adjusted parking brake • Get correctly adjustedBrake fluid container breather hole • Clean the hole on the containercloggedNo brake pedal free play/brake • Adjust brake pedalpedal not returning fullyDefective tandem master cylinder • Replace/rectify tandem master

cylinder

5. Brake Squeal Defective brake lining/pad • ReplaceGlazed lining/pad • Clean or replace lining/padLoose rivets • Install rivets properlyWrong lining/pad • Install correct lining/padShoe return spring broken • ReplaceFront pads /Antisqueal shims • Get corrected rubbing on the disc


8383

ANTI-LOCK BRAKING SYSTEM & STEERING


ANTI-LOCK BRAKING SYSTEM (IF FITTED)

1. ABS warning lamp stays ‘ON’ ABS unit faulty • Check wiring connections &No supply to ABS unit battery condition.Electrical circuit problem : • Check wiring harnessIntermittent contact, Wiring connectionsconnections / connections loose/faultyComponent and sensor failure : • Check gap between sensor &RPM sensors/toner rings fitting toner ringloose, gap disturbances, Sensorsignal that deviates from thespecified levelsCircuit / bulb failure • Replace bulbLeakage from hydraulic unit ports • Eliminate leakage by tighteningHydraulic unit fluid level low • Check reservoir fluid level and

bleed properly.Unusual response and malfunction • Check sensor condition &in the actuators replace if necessary.

STEERING SYSTEM

1. Hard steering Less fluid in the power steering • Get the fluid topped up totank correct level


84

Air in the system • Get the air removed by bleedingthe system

Loose pump belt • Get the belt correctly adjustedELECTRICAL1. No lights on the dash board after Battery terminal got disconnected • Get the battery properly

turning on the ignition key Battery completely dead connected• Get the battery charged• Get the alternator & charging

circuit checked• Check for parking lamp fuse

2. Non functioning electrical Blown fuse in the circuit • Replace the fuse if blownaccessories such as power Loose connectors • Get the connection properlywindows, head lamps, fuel tightenedtank flap, wiper and washer etc. Circuit relay loose • Tighten the relay correctly

in the mountingDefective components • Get the defective component

replaced from AuthorisedWorkshop

AIR CONDITIONING1. Fan motor does not operate Blown fuse • Replace fuse and correct any

wiring shortFaulty connection • Properly connect poor

connectionsFaulty motor • Replace motor if no conductance


ELECTRICAL & AIR CONDITIONING


8585

Faulty or poor • Replace resistor block if defectiveconnection at resistorFaulty fan switch • Replace switch

2. Motor operates but air flow Obstruction at evaporator inlet • Clean evaporatoris minimum Air leak • Correctly seal

Faulty thermostat • Adjust or replace thermostat3. Insufficient cooling, Air flow Incorrect refrigerant quantity or • Get the defect rectified at

normal and compressor defect in system aggregates nearest authorised serviceoperating centre

WIPERS

1. Narrow streaks are left on the Foreign matter has • Clean the edgeof the blade. Ifwind shield making it hard to see attached to the blade or streaks still appear, replace the

blade edge of the blade is worn out.2. The wiper blade jumps across No proper contact of wiper blade • Clean the wind shield. If jumping

the windshield and makes a lot with wind shield glass and wiper persists replace the blade.of noise (Un-smooth operation) blade does not move smoothly

across the surface but vibrates,noisily and bounces.

3. The wipe leaves large un-wiped Rubber deformed • Replace the bladespots.

4. The blade does not contact with Deformed wiper blade • Replace wiper blade / armthe wind shield surface evenly, / armleaving a large un-wiped surface.


WIPERS


86

FUSES & RELAYS

Electrical Maintenance

8787

FUSES & RELAYS


88

BULB SPECIFICATION


BULB SPECIFICATIONDESCRIPTION CAP TYPE COLOUR SPECIFICATION QTYHead lamp - Halogen H4 P43t White H4 12V,55/60 W 2Parking lamp - Front Wedge base (w 2.1 x 9.5d) White 12V, 5W 2Front fog lamp H11 PGJ 19-2 White H11 12V, 55W 2Direction Indicator lamp - Front BAU15S Amber 12V, 21W 2Direction Indicator lamp - Side Wedge base (w 2.1 x 9.5d) Amber 12V, 5W 2Direction Indicator lamp - Rear BAU15S Amber 12V, 21W 2Stop lamp + parking lamp - Rear BA15S White 12V, 21/5W 2Reverse lamp BA15S White 12V, 21W 2Rear fog lamp BA15S White 12V, 21W 2Cabin lamp - Ist Row Festoon White 12V, 10W 1Spot lamp - Ist Row Wedge base (w 2.1 x 9.5d) White 12V, 5W 2Cabin lamp - IIst Row Wedge base (w 2.1 x 9.5d) White 12V, 5W 1Cabin lamp - IIIrd Row Wedge base (w 2.1 x 9.5d) White 12V, 5W 1Engine lamp BA15S White 12V, 10W 1Puddle lamp - All doors Wedge base (w 2.1 x 9.5d) White 12 V, 5W 5LED DETAILSDoor Ajar lamp - Front & Rear Doors Not applicable Red LED NAHigh Mounted stop lamp - Rear Red LEDInstrument cluster illumination White LEDKey hole illumination White LEDFacia switches, Window winding switches White LED

8989

Electrical MaintenanceBULB REPLACEMENT

Procedure :

1. Make sure light stalk is in’ OFF’position & bulb is not hot.

2. Lift the engine bonnet to accessthe headlight bulb.

Bulb Replacement :Replacing the Headlight Bulb :Your vehicle’s headlights havereplaceable halogen bulbs.Headlight bulb can be replacedwithout even disturbing or removingthe entire headlight unit.

WARNINGHandling Halogen Bulbs:It is dangerous if a halogen bulbbreaks,. These bulbs containpressurized gas and if broken, willexplode and serious injuries couldbe caused by the flying glass.Halogen bulbs can break if the glassportion is touched with bare hands,body oil could cause the bulb tooverheat and explode when lit.Never touch the glass portion of thebulb with your bare hands andalways wear eye protection whenhandling or working around halogenbulbs. Always keep halogen bulbsout of the reach of children.

1 2

3 4

5 5

90

BULB REPLACEMENT


3. Remove the dust cover at theback of Headlamp Fig.1.4. Disconnect the electrical

connector Fig.2.5. Press and release the bulb

retaining spring Fig.3.6. Swing the retaining spring out

to free the headlight bulb fromthe socket by pulling it straightback.

7. Carefully remove the headlightbulb from the socket Fig. 4.

8. Replace the bulb.9. Install in the reverse order ofremoval.

Replacing the Parking Bulb :

1. Make sure lighting stalk is in‘OFF’ position.2. Lift the engine bonnet. Theparking bulb is locatedbelow the Headlamp bulb on theassembly.3. Pull the bulb holder from thesocket.4. Carefully remove the parkingbulb from the socketby pulling it straight back Fig. 5.5. Replace the bulb.6. Install in the reverse order ofremoval.

Replacing Tail Lamp Bulb:1. Make sure lighting stalk is in

‘OFF’ position.2. Open the tail gate.3. Remove the bolts (2 nos) holding

the tail lamp cluster using a size10 (10mm) spanner. Take outthe entire tail lamp assy. bydisconnecting the connector.Fig. 1 & 2.

4. Rotate and pull out the socketwith bulb to be replaced.Fig. 3.

5. Carefully remove the fused bulbfrom the socket by rotating andpulling it.

6. Replace the bulb.7. Install in the reverse order of

removal.

9191

BULB REPLACEMENT


Replacing Reversing light lampBulb :1. Open the tail gate.2. Remove the cover located on the

inner side of tail gate. Fig. 4.3. Rotate and pull out the socket

with bulb to be replaced.Fig. 5.4. Carefully remove the fused bulb

from the socket by rotating andpulling it.

5. Replace the bulb.6. Install in the reverse order of

removal.

1 2

3

4 5

92

NOTICE

VEHICLE CARE :The Vehicle is subjected to manyexternal influences such asclimate, road conditions, industrialpollution and proximity to the sea.These conditions demand regularcare of the Vehicle body. Dirt,insects, bird droppings, oil, grease,fuel and stone chippings should beremoved as soon as possible.Washing :Do not wash the Vehicle in directsunlight, wash in shade. Spray theVehicle thoroughly with a cold waterjet (Vehicle on a washing pit orhoist). Mix Vehicle shampoo in thewash water. No solvent (fuel,thinners) need be used.

Avoid wiping of painted surfacein dry condition as it may leavescratches on the paintedsurface.

Use a soft bristle brush, sponge orsoft cloth and rinse it frequentlywhile washing. When you havewashed the whole exterior, dry itwith a chamois or soft cloth. Afterdrying the Vehicle, inspect it forchips and scratches that couldallow corrosion to start. Apply touchup paint where necessary.

Polishes :Polishes and cleaners can restoreshine to the painted surface thathas oxidised and become dull. Theynormally contain mild abrasives andsolvents that remove the top layerof the finish coat. Polish yourVehicle, if the finish does not regainits original shine after using wax.

Cleaning of Carpets :Vacuum clean the carpet regularlyto remove dirt. Dirt will make thecarpet wear out faster. Periodicallyshampoo the carpet to keep itlooking new.

Use carpet cleaners (preferablyfoam type). Follow the instructionsthat come with the cleaner, applyingit with a sponge or soft brush. Keepthe carpeting as dry as possibleby not adding water to the foam.

Cleaning of Windows, Front &Rear Glasses :Clean the windows inside andoutside with commercially availableglass cleaners.This will remove the haze that buildsup on the inside of windows. Usea soft cloth or paper towels to cleanall glass and plastic surfaces.

Vehicle CareWASHING & CLEANING

9393

WASHING & CLEANING

Vehicle Care

Non use maintenances :Park the Vehicle in covered, dryand if possible well-ventilatedpremises. Engage a gear.Remove the battery terminal cables(first remove the cable from thenegative terminal).Make sure the hand brake is notengaged.Clean and protect the painted partsusing protective wax.Clean and protect the shiny metalparts using commercially availablespecial compounds.Sprinkle talcum powder on therubber windscreen wiper and liftthem off the glass.Slightly open the windows.Cover the Vehicle with a cloth orperforated plastic sheet. Do not usesheets of imperforated plastic asthey do not allow moisture on theVehicle body to evaporate.

Inflate the tyres to 0.5 bar abovethe normal specified pressure andcheck it at regular intervals.Check the battery charge every sixweeks.Do not drain the engine coolingsystem.

Wiper Care :

Wiper blade attack angle onwindshield glass should be 900 i.e.perpendicular.Remove wiper blade and root wiperarm on windshield glass in thecentre position. Check the gapbetween arm strip and glass.

FOLLOWING GUIDELINES WILLHELP YOU TO PROTECT YOURVEHICLE FROM CORROSIONEFFECTIVELY.

PROPER CLEANING :In order to protect your vehicle fromcorrosion it is recommended thatyou wash your vehicle thoroughlyand frequently in case :1. There is an heavy accumulation

of dirt and mud especially on theunderbody.

2. It is driven in areas having highatmosphere pollution due tosmoke, soot, dust, iron dust &other chemical pollutants.

3. It is driven in coastal areas.4. The underbody must be

thoroughly pressure washedafter every three months.

In addition to regularly washing yourvehicle, the following precautionsneed to be taken.

O KO KO KO KO K

FOR CHAFOR CHAFOR CHAFOR CHAFOR CHATTTTT TERING & NOISY PRTERING & NOISY PRTERING & NOISY PRTERING & NOISY PRTERING & NOISY PROBLEMSOBLEMSOBLEMSOBLEMSOBLEMS

NOT OKNOT OKNOT OKNOT OKNOT OK

WindshieldGlass

94

GENERAL PRECAUTIONS

Vehicle Care

PERIODIC INSPECTION :1. Regularly inspect your vehicle

for any damage in the paintfilm such as deep scratchesand immediately get themrepaired from an authorisedservice outlet, as these defectstend to accelerate corrosion.

2. Inspect mud l iners fordamages.

3. Keep all drain holes clear fromclogging.

PROPER PARKING :Always park your vehicle inshade to protect it from harshsunlight or in a well-ventilatedgarage so that there is nodampness on any part of thevehicle.

WASHING YOUR VEHICLE :Following these tips whilewashing your vehicle.HAND WASH :1. Always wash your vehicle in

shade and the surface is atroom temperature.

2. Wash with mild car wash soaplike ‘Car Shampoo’ and use asoft 100% cotton cloth toavoid scratches.

3. To avoid scratches, pleasewear soft gloves . Removefinger rings, nails, wrist watchwhile washing.

4. To remove stubborn stains andcontaminants like tar, useturpentine or cleaners like‘Stain remover’ which are safefor paint surfaces.

5. Avoid substances like petrol,diesel, kerosene, benzene or

other solvents that causedamage to paint.

6. Dry your vehicle thoroughly toprevent any damp spots.

7. Rinse all surfaces thoroughlyto prevent any traces of soapand other cleaners as this maylead to the formation of stainson the painted surface later.

9595

GENERAL PRECAUTIONS

Vehicle Care

WAXING :Waxing and pol ishing arecommended to maintain thegloss and wet-look appearanceof your paint finish.1. Use a good quality polish and

wax for your vehicle.2. Re-wax your vehicle when the

water does not slip off thesurface and collects over thesurface in patches.

Further tips for the care ofyour new vehicle finish :If your vehicle is washed in anautomatic car wash , pleaseremember that the paint can bescrathed by type of brushes,unfiltered washing water or thewashing process itself. Scrathingreduces paint durability andgloss, especial ly on darkercolours. It is suggested to washthe vehicle by hand with cool andclean water using a soft cloth orsponge. Please do not use soapbut a car shampoorecommended by your dealer.

Please take the followingprecautions :

1. Always wash your vehicle inshade, avoiding direct exposureto sunlight during washing.

2. Dry wiping your vehicle maylead to the formation of

scratches and hence alwaysuse a soft cloth and clean waterwhile wiping your vehicle.

3. Always keep your vehicle parkedin a well ventilated shade.Exposure to heat with entrappedmoisture promotes corrosion.

4. Avoid driving on gravel roads,as the possibility of paint chipoff due to the impact of stonesis high. If you are driving onfreshly tarred road, checkimmediately afterwards for anystains & clean them.

5. External contamination in theform of sap or industrial fall-out may mar or develop spotson a new finish. Hence avoidparking your vehicle neartrees, which are known to dropsap, or near factories, whichgive out heavy smoke.

96

GENERAL PRECAUTIONS

Vehicle Care

6. The acid content in birddroppings may damage thenewly painted f inish andhence any bird dropping mustbe immediately washed off.

7. The paint finish is susceptibleto damage in case petrol,brake fluid, liquid from carbattery, oi l , ant i f reeze,transmission f luid orwindshield solvent spills ontothe painted surface. In caseof such a spillage immediatelyrinse the affected area withwater. Avoid wiping the areafar as possible, however ifwiping is required, ensure thatyou wipe the area gently withsoft cotton cloth.

8. Avoid using sharp objects toscrap off tar or mud from apainted surface as it maydevelop scratches or maypeel off the paint.

Vehicle Exterior Enrichment :Why vehicles are painted?

For Corrosion protection ofthe metal surfaces.Ease of application from othercorrosion protection treatments.Cheaper than other corrosionprotection methodseg.galvanizing, anodizing.For decoration and identification.

Various Environmental Hazardsaffecting paints :

Environmental hazards : destroyyour vehicle's finish.Even as your new vehicle rollsoff the assembly line, the paintis not protected.

The enemy :Ultraviolet Rays, Pollution, TreeSap, Bird Droppings, Car WashChemicals, Road Salt, Acid Rain.

Benefits of Vehicle ExteriorEnrichment :

Removal of medium scratches,orange peel, oxidation , dust nibsetc & swirl marks from paintedsurface.Restoration of original glosslevels UV protection after glossis restored.Cleaning & dressing of tyres,Bumpers & all exterior plasticmoldings/trims.

TATA MOTORS has tied up withM/s Opulent (Waxoyl brand) andM/s 3M for this world class treat-ment at affordable prices. Thistreatment is available in all autho-rized workshops. The DealerService Marketing Executive willexplain to you the benefits andterms and conditions of this treat-ment.

9797

OPENING & CLOSING THE BONNET

Maintenance

Opening & Closing the BonnetOpening:1. Ensure that the vehicle is inneutral gear with the parking brakeapplied.2. Pull the bonnet release leverlocated under the right hand cornerof the dash board. The bonnet willpop up slightly.3. Raise the bonnet slightly andwith your finger lift the secondarylock lever located under the bonnetcentre.4. Lift the bonnet up. Pull thebonnet stay rod from its clip andinsert the free end into the slot inthe bonnet, slide stay rod outwardto secure.

Closing :1. To close the bonnet disengagethe stay rod & clamp it properly.2. Lower the bonnet and drop itfrom a short height to shut.

CAUTION

Bonnet release Lever

Location of Bonnet release lever

Ensure that the bonnet isproperly locked before driving.Do not press the bonnet ontothe bonnet lock.

Bonnet opening secondarylock lever

98

ENGINE COMPARTMENT

1. Brake fluid reservoir 2. Clutch fluid reservoir 3. Engine Oil Dipstick4. Wind shield washer container 5. Glow Plug Interface Unit 6. Battery7. ECU 8. Power steering reservoir 9. Radiator Pressure Cap

10. Auxiliary tank 11. Engine Oil Filling Cap 12. Service Indicator13. Air Filter

MaintenanceENGINE COMPARTMENT

9999

MaintenanceAIR FILTER, ENGINE OIL & COOLANT

AIR FILTER :

The air filter element should beperiodically cleaned. Replace the airfilter element with a new one, whenair cleaner service indicator showsred band, even after cleaning.

Always use a genuine air filterelement.The air filter is located on the LH sideof the engine compartment.a) When a vehicle is driven under

dusty conditions, frequentcleaning and replacement of theair-cleaner element is necessary.

b) Clogged air-cleaners lead togreater intake resistance andresult in increased fuelconsumption. Using low pressurecompressed air, blow off dust onthe air cleaner element. If the aircleaner element appears to bechoked, replace it with a new one.

ENGINE OIL LEVEL CHECKING

Warm up the engine to normaloperating temperature.Turn it off and wait 5 minutes for theoil to return to the oil panBe sure the Vehicle is on a levelsurface.

Pull out the dipstick, wipe it clean,and reinsert if fully.

Pull it out again and examine the oillevel. it should be between ‘Min’ &‘Max’ level. If not, top up withrecommended engine oil.

1. Air Filter 2. Service Indicator

1. Engine oil filling cap 2. Dip Stick

100

ENGINE COOLANT LEVEL

Manintenance

1. Auxiliary tank cap 2. RadiatorPressure Cap

ENGINE COOLANT LEVELCheck the coolant level in theradiator auxiliary tank.It should be in between maximum& minimum lines.

If the auxiliary tank is completelyempty, please check the coolantlevel in radiator as follows :

WARNINGDo not remove radiator cap whenengine is hot. It may spray hotcoolant on you causing seriousinjuries.

1. Ensure engine and radiator arecool.

2. Turn the radiator cap anticlockwise (without pressing it)until it stops. This will relieve thepressure, if any in the coolingsystem.

3. Remove the radiator cap bypushing down and turning anticlockwise.

4. The level of coolant should beupto the base of the filler neck.Coolant should be added if it islow.

5. Secure the radiator cap in itsplace.

6. Add coolant into the auxiliarytank up to the high mark.

7. Put the cap back, on theauxiliary tank.

NOTICETopping of the coolant should bedone in the auxiliary tank only.Radiator cap should not beremoved, if coolant is present inthe auxiliary tank.

101101

BRAKE & STEERING

Manintenance

BRAKE FLUID LEVEL :

The level of the brake fluid must bebetween the min. & max. marks onthe side of the brake fluidcontainer. If the level falls below themin. mark, add recommendedbrake fluid. (Refer chapter - Fuels,coolants & lubricants)In case of spongy or hard pedalor low brake efficiency, pleasecontact the nearest AuthorisedService outlet.

1. Do not allow brake fluid tomake contact with the skin oreyes.

2. Do not allow brake fluid tosplash or spill on the paintsurface as it will damage thepaint. In case of spillage,wipe it off immediately.

Power steering reservoir :The level of the power steering fluidmust be between the min. & max.marks on the side of the powersteering fluid container. If the levelfalls below the min. mark, addrecommended fluid. (Refer chapter- Fuels, coolants & lubricants)In case of leakage or hard steering,please contact the nearestAuthorised Service outlet.

1. Coolant Reservoir cap 2. Radiator Cap

CAUTION

Do not start the engine withoutoil in the power steering system.

CAUTION

Power Steering Reservoir

102

LOAD CONSCIOUS PRESSURE REDUCING VALVE (LCRV)

Manintenance

LOAD CONSCIOUS PRESSUREREDUCING VALVE (LCRV)A LCRV is required in the brakesystem during severe braking.That time, most of the car weightis transferred to the front, and thefront brakes do most of thebraking. The rear wheels are leftwith but little traction and in thiscondition, under high pressure,they have a tendency to skid.The valve is installed in the line tothe rear brake drum. During heavybraking the valves limits thepressure to the rear wheels & thisallows rear wheels to keep turninginstead of locking up and skidding.If any alteration is done in Rearsuspension the performance ofthis valve will be impaired.The valve stem gap should beadjusted whenever rear spring ischanged.

LCRV LINK mounting bracket onRear Axle

LINK “C”

103103

CLUTCH FLUID LEVEL & SEDIMENTER

Manintenance

Clutch Fluid Level :The level of the clutch fluid mustbe between the min. & max. markson the side of the clutch fluidcontainer. If the level falls below themin. mark, add recommendedclutch fluid. (Refer chapter - Fuels,coolants & lubricants)

Water draining Procedure fromSedimenter :The water sedimenter is part of thefuel filtration system, fitted to the

Water draining from SedimenterWater draining from SedimenterWater draining from SedimenterWater draining from SedimenterWater draining from Sedimenter

4 Unscrew the water sensor about2 - 3 turns

5 Wait until all the water hasdrained out of the watersedimenter.

6 As soon as the flow is free ofwater, screw the water sensor.

7 Clip the hydraulic connector andthe electric connector to thewater sensor.

8. Use hand primer/Pear pump torefill the line before restarting.

chassis frame, near fuel tank belowthe vehicle. It is used in the fuelsupplying system in order toreduce the water content in the fuelprovided to the DICOR system.A water sensor is fitted to the watersedimenter in order to indicate tothe driver that the sedimenter hasto be drained. Whenever water infuel sedimenter indicator glows ininstument cluster, the water needto be drained from the sedimenter.Water drain operation to be doneon sedimenter.Procedure1 Stop the engine, and wait until

pressure stabilizes.2 Unclip one of the hydraulic

connections (either inlet oroutlet) and the electricconnector of the water sensor.

3 Place a container underneaththe water sedimenter.

Clutch Fluid Container

104

FILTER & PRIMING PUMP

Manintenance

NOTICEDo not loosen the HP lines ofDICOR system for bleeding theair from fuel system.

Priming Pump / Pear pump :

This is used for priming the fuelmanually after overhauling of theengine or after refitment of fuellines or after changing either fuelfilter or sedimenter pump, bymeans of priming pump / pearpump until all air in the fuel lineremoved. Before cranking theengine ensure that there is no airin the fuel system.

Fuel Filter :

Fuel filter separates dust particlesfrom the fuel & allows clean fuel into the common rail system. It alsoseparates & stores water.

Fuel FilterFuel FilterFuel FilterFuel FilterFuel Filter Priming/Pear pumpPriming/Pear pumpPriming/Pear pumpPriming/Pear pumpPriming/Pear pump

105105

WINDSHIELD WASHER & TYRE

Manintenance

NOTICE

11111 22222 33333Windshield Washer :

Windshield washer fluid containeris located behind the front righthand side panel and its filler neckis provided near auxiliary tank inthe engine compartment.

Do not add detergent or anysolvent in the windshield washingwater.

Tyres : You should have your own tyrepressure gauge and use it at alltimes. This makes it easier for youto tell if pressure loss is causedby a tyre problem and not byvariation between gauges.Keeping the tyres properly inflatedgives you the best combination ofriding comfort, handling, tyre lifeand better fuel efficiency.Over inflation of tyres makes thecar ride bumpy and harsh. Tyresare more prone to uneven wear anddamage from road hazards.Under inflated tyres reduce yourcomfort in car handling and areprone to failures due to hightemperature. They also causeuneven wear and more fuelconsumption.

Check for inflation and condition ofyour car tyres periodically.Inflation :Check the pressure in the tyreswhen they are cold.

1. Underinflation - Excessive SideTread Wear

2. Correct Tyre Pressure - UniformTyre Wear

3. Overinflation - Excessive CentreTread Wear

WWWWWindshield indshield indshield indshield indshield WWWWWasher Fasher Fasher Fasher Fasher Fluid Cluid Cluid Cluid Cluid Cononononontainertainertainertainertainer11111 22222 33333

106

TYRE INSPECTION

Manintenance

Repairing a Tyre/Tube :Mark the tyre position suitably (iforiginal colour dot mark is notvisible) with respect to valve stemhole to ensure that the tyre isrefitted in the original location onthe wheel rim.Ensure that balancing weights arenot disturbed during removal oftyres.

Check the balance weight prior tothe removal of the tyre. If foundloose, mark its location on the rim& refit properly.

Balance the wheel after everydismantling and assembly of tyreon the wheel rim.

While fitting wheels on the vehicleensure that wheel pins are free fromdust, scratches, dirt, dents, etc.Ensure the tube being replaced hasthe correct valve.

CAUTIONRecommended Tyre Pressures• Bumps or bulges in the tread

or the side of the tyre.Replace the tyre if you findeither of these conditions.

• Cuts, splits or cracks in theside of the tyre. Replace thetyre if you notice this on thefabric or cord.

• Excessive tread wear or nonuniform tyre wear.

PSI Bar

Laden

Unladen28

28

2.0

2.0

WheelsVeh.condition

FAW

RAW

Tyre 235/70 R16*

2832

2.02.3

FAWRAW

NOTICEDo not apply any oil on the wheelpins. Wipe off the oil if present.

CAUTIONEvery time you check inflationpressure, you should alsoexamine tyres for damage,foreign objects & wear.

* Tubeless tyre

107107

CARE FOR TUBELESS TYRES & TYRE ROTATION

Manintenance

Special care for tubeless tyres

1. While removing tyre from wheel rim and mountingit back on wheel rim, take precautions not to damagetyre bead. Use tyre removal and assemblymachines. Damage or cut on tyre bead may causegradual loss of air and deflation of tyre.

2. Do not scratch inside of tubeless tyre with metallicor sharp object. Tubeless tyres are coated withimpermeable layer of rubber from inside which holdsthe air inside the tyre. Removal of this layer due toscratching may cause gradual loss of air anddeflation.

3. If wheel rim gets damaged in service, get the wheelrim repaired/replaced immediately. Running thevehicle with damaged rim may cause deflation oftyre and subsequent dislodging of tyre from rim.

4. Maintain recommended inflation pressure. Over-inflation, in particular, may cause puncture orbursting of tyre.

NOTELife and wear pattern of tyres depends on variousparameters like tyre pressure, wheel alignment,wheel balancing, tyre rotation, etc. It also largelydepends on vehicle speed, load carried, usage,driving habits, road conditions, tyre quality, etc. Incase fault is suspected to be due to poor quality oftyres, the same may be taken up with concernedtyre manufacturer.

Tyre RotationTo help increase tyre life and distribute wear moreevenly you should have tyres rotated at specifiedintervals or earlier depending on the operation of vehicle.The illustrations shows how to rotate tyres when normalspare wheel is included in tyre rotation.

108

WHELL ALIGNMENT, BALANCING, CATALYTIC CONVERTER MAINTENANCE

Manintenance

Wheel alignment :

Incorrect wheel alignment causesexcessive and uneven tyre wear.Check wheel alignment atspecified intervals. Wheelalignment values are given below :

Caster : 30 ± 30 ’

Camber : 00 ± 10 ’

Toe in : ± 1 or -9’ +9’

On vehicles with torsion barsuspension, wheel alignmentneeds to be checked only afteradjusting chassis height as perprocedure. Chassis height for 16inch tyre is 510 ± 3 mm Checkand maintain tyre pressureperiodically to obtain longer tyrelife.

Wheel Balancing :

Wheels of your vehicle arebalanced for better ride comfortand longer tyre life. Balancingneeds to be done whenever tyreis removed from rim.

1. Permissible imbalance for tyrewith rim = 250 gm-cm max.

2. Total balance weight should bewithin 140 gms on each side.

3. Relocate the tyre if the weightrequired to balance is morethan 140 gm.

4. Balance weights are availablefrom 10 gms to 140 gms insteps of every 10 gms and from15 gms to 135 gms in steps ofevery 10 gms.

5. Do not use more than onebalance weight on one side.

Care for the Catalytic Converter:

The catalytic Converter does notrequire any special maintenancehowever, following precautionshould be taken for the effectivefunctioning of the converter and toavoid damage to the Converter.

It is mandatory to use Dieselfuel with sulphur content lessthan 350mg/kg. Use of anyother diesel fuel can increasethe pollutants.

CAUTIONAvoid parking the vehicle overinflammable materials, such asdry leaves, grass etc., as theexhust system is hot enough toinitiate ‘FIRE’

109109

Check the battery for properelectrolyte level and corrosion onthe terminals.

1. Check the battery forelectrolyte level against themarking on the battery outercase.

2. Check the battery terminals forcorrosion (a white or yellowishpowder). To remove it, cover theterminals with a solution ofbaking soda. It will bubble upand turn brown.

BATTERY

NOTICE3. When this stops wash it off withplain water. Dry off the batterywith a cloth or paper towel.

4. Coat the terminal with petroleumjelly to prevent future corrosion.

Use a proper wrench to loosen andremove cables from the terminals.

Always disconnect the negative(-ve) cable first and reconnect itlast.

Clean the battery terminals with aterminal cleaning tool or wire brush.Reconnect and tighten the cables,coat the terminals with petroleumjelly.Ensure that battery securelymounted.If you need to connect the batteryto a charger, disconnect bothcables to prevent damage to thevehicle’s electrical system.

BATTERY :

During normal operation, thebattery generates gas which isexplosive in nature, a spark oropen flame can cause thebattery to explode causing veryserious injuries.Keep all sparks & open flamesand smoking materials awayfrom the battery.Getting electrolyte in your eyesor on the skin can cause severeburns. Wear protective clothingand a face shield or have askilled technician to do thebattery maintenance.The battery contains sulphuricacid (electrolyte) which ispoisonous and highly corrosivein nature.

110

BELT TENSION

Important Technical Information

Belt Tension :Check the conditions of belts onthe engine. Examine the edge ofthe belt for cracks or fraying.Check the tension of the belt bypushing on it with your thumb forAlternator belt and A.C.compressor belt and PowerSteering belt as shown inschematic diagram.The belts should have deflection of4 to 6 mm.If the belt tension is not proper, getit attended at the nearest authorisedservice outlet.Correct tension of the belt is verycritical from belt life and belt noisepoint of view. It is recommendedthat belt tension should bemeasured with clavis gauge toensure recommended values asgiven below Alternator / Power Steering BeltAlternator / Power Steering BeltAlternator / Power Steering BeltAlternator / Power Steering BeltAlternator / Power Steering Belt

ArrangementArrangementArrangementArrangementArrangement

A.C. Compressor Belt ArrangementA.C. Compressor Belt ArrangementA.C. Compressor Belt ArrangementA.C. Compressor Belt ArrangementA.C. Compressor Belt Arrangement

Alternator / power steering belt· Frequency should be 250 + / -10HZ for new belt measuredbetween alternator & powersteering pump span.· New belt to be retensioned to 220+ /- 10 HZ on vehicle after runningfor 15 min.For compressor beltSpan AC to dampers· Frequency should be 200 +/- 10HZ· Belt to be retension to 180 +/-10HZ on vehicle after running for15 min.

111111

FUEL, LUBRICANTS & COOLANTS


PLEASE USE ONLPLEASE USE ONLPLEASE USE ONLPLEASE USE ONLPLEASE USE ONLY FOLLY FOLLY FOLLY FOLLY FOLLOOOOOWING GENUINE OILS,WING GENUINE OILS,WING GENUINE OILS,WING GENUINE OILS,WING GENUINE OILS, CCCCCOOLOOLOOLOOLOOLANTANTANTANTANTS ,S ,S ,S ,S , L L L L LUBRICUBRICUBRICUBRICUBRICANTANTANTANTANTS ,S ,S ,S ,S , ANTI R ANTI R ANTI R ANTI R ANTI RUST & SOUNDUST & SOUNDUST & SOUNDUST & SOUNDUST & SOUNDDEADENING CDEADENING CDEADENING CDEADENING CDEADENING COOOOOAAAAATTTTTS,S,S,S,S, WINDSCREEN SEALWINDSCREEN SEALWINDSCREEN SEALWINDSCREEN SEALWINDSCREEN SEALANTANTANTANTANT,,,,, ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BR ADHESIVES & FUEL ADDITIVES BRANDED BY ANDED BY ANDED BY ANDED BY ANDED BY TTTTTAAAAATTTTTAAAAA

MOMOMOMOMOTTTTTORS FORS FORS FORS FORS FOR OPTIMUM PERFORMANCE OF OR OPTIMUM PERFORMANCE OF OR OPTIMUM PERFORMANCE OF OR OPTIMUM PERFORMANCE OF OR OPTIMUM PERFORMANCE OF YYYYYOUR OUR OUR OUR OUR TTTTTAAAAATTTTTA SUMO GRANDEA SUMO GRANDEA SUMO GRANDEA SUMO GRANDEA SUMO GRANDE ...............

ITEM SPECIFICATION COMPANY & BRAND QTYENGINE OILENGINE OILENGINE OILENGINE OILENGINE OIL API-CH4+MB228.3API-CH4+MB228.3API-CH4+MB228.3API-CH4+MB228.3API-CH4+MB228.3 CASTROL - Castrol GTX (Diesel)CASTROL - Castrol GTX (Diesel)CASTROL - Castrol GTX (Diesel)CASTROL - Castrol GTX (Diesel)CASTROL - Castrol GTX (Diesel)

OR Higher gradeOR Higher gradeOR Higher gradeOR Higher gradeOR Higher grade HPCL - HP MILHPCL - HP MILHPCL - HP MILHPCL - HP MILHPCL - HP MILCY CY CY CY CY TURBO PLTURBO PLTURBO PLTURBO PLTURBO PLUSUSUSUSUS 7.5 Litres7.5 Litres7.5 Litres7.5 Litres7.5 Litres

COOLANTCOOLANTCOOLANTCOOLANTCOOLANT Class II / JIS K2234Class II / JIS K2234Class II / JIS K2234Class II / JIS K2234Class II / JIS K2234 SUNSTSUNSTSUNSTSUNSTSUNSTAR - GAR - GAR - GAR - GAR - Golden Colden Colden Colden Colden Crrrrruiser Puiser Puiser Puiser Puiser Prrrrremium 1400 Memium 1400 Memium 1400 Memium 1400 Memium 1400 M(Antifreeze agent + Soft HPCL - HP HPCL - HP HPCL - HP HPCL - HP HPCL - HP TTTTThanda Rhanda Rhanda Rhanda Rhanda Raja Paja Paja Paja Paja P Approx 13 LitresApprox 13 LitresApprox 13 LitresApprox 13 LitresApprox 13 Litreswater) CASTROL - RadicoolCASTROL - RadicoolCASTROL - RadicoolCASTROL - RadicoolCASTROL - Radicool

GEAR BOX (G-76)GEAR BOX (G-76)GEAR BOX (G-76)GEAR BOX (G-76)GEAR BOX (G-76) SAE 75W90 - GL4SAE 75W90 - GL4SAE 75W90 - GL4SAE 75W90 - GL4SAE 75W90 - GL4 HPCL - HP Gear Oil XP 75W90HPCL - HP Gear Oil XP 75W90HPCL - HP Gear Oil XP 75W90HPCL - HP Gear Oil XP 75W90HPCL - HP Gear Oil XP 75W90CASTROL - Castrol Syntro 75W90 GL4CASTROL - Castrol Syntro 75W90 GL4CASTROL - Castrol Syntro 75W90 GL4CASTROL - Castrol Syntro 75W90 GL4CASTROL - Castrol Syntro 75W90 GL4 1.6 Litres1.6 Litres1.6 Litres1.6 Litres1.6 Litres

POWER STEERING OILPOWER STEERING OILPOWER STEERING OILPOWER STEERING OILPOWER STEERING OIL AAAAATF TF TF TF TF TTTTTypypypypype A,e A,e A,e A,e A, HPCL - HP-AHPCL - HP-AHPCL - HP-AHPCL - HP-AHPCL - HP-ATF DTF DTF DTF DTF Deeeeex IIx IIx IIx IIx II 1.4 Litres1.4 Litres1.4 Litres1.4 Litres1.4 LitresSuffix ASuffix ASuffix ASuffix ASuffix A CCCCCASTRASTRASTRASTRASTROL - COL - COL - COL - COL - Castrastrastrastrastrol ol ol ol ol TTTTTQDQDQDQDQD

REAR AXLE,REAR AXLE,REAR AXLE,REAR AXLE,REAR AXLE, SAE 85W140 GL5SAE 85W140 GL5SAE 85W140 GL5SAE 85W140 GL5SAE 85W140 GL5 HPCL - HP AXLE OIL 85W140HPCL - HP AXLE OIL 85W140HPCL - HP AXLE OIL 85W140HPCL - HP AXLE OIL 85W140HPCL - HP AXLE OIL 85W140 2.2 (Rear)2.2 (Rear)2.2 (Rear)2.2 (Rear)2.2 (Rear)LIVE FRONT AXLE,LIVE FRONT AXLE,LIVE FRONT AXLE,LIVE FRONT AXLE,LIVE FRONT AXLE, Angolmol AG043Angolmol AG043Angolmol AG043Angolmol AG043Angolmol AG043 CASTROL - Castrol Long Drain 85W140CASTROL - Castrol Long Drain 85W140CASTROL - Castrol Long Drain 85W140CASTROL - Castrol Long Drain 85W140CASTROL - Castrol Long Drain 85W140 1.2(Front)1.2(Front)1.2(Front)1.2(Front)1.2(Front)

BRAKE / CLUTCH FLUIDBRAKE / CLUTCH FLUIDBRAKE / CLUTCH FLUIDBRAKE / CLUTCH FLUIDBRAKE / CLUTCH FLUID SAE J 1703, DOT 4SAE J 1703, DOT 4SAE J 1703, DOT 4SAE J 1703, DOT 4SAE J 1703, DOT 4 HPCL - Super Duty Brake Fluid DOT - 3HPCL - Super Duty Brake Fluid DOT - 3HPCL - Super Duty Brake Fluid DOT - 3HPCL - Super Duty Brake Fluid DOT - 3HPCL - Super Duty Brake Fluid DOT - 3 As requiredAs requiredAs requiredAs requiredAs requiredCASTROL - Universal Brake Fluid DOT 3CASTROL - Universal Brake Fluid DOT 3CASTROL - Universal Brake Fluid DOT 3CASTROL - Universal Brake Fluid DOT 3CASTROL - Universal Brake Fluid DOT 3

WHEEL BEARING &WHEEL BEARING &WHEEL BEARING &WHEEL BEARING &WHEEL BEARING & SS6805SS6805SS6805SS6805SS6805 HPCL - HP Multipurpose Grease-2HPCL - HP Multipurpose Grease-2HPCL - HP Multipurpose Grease-2HPCL - HP Multipurpose Grease-2HPCL - HP Multipurpose Grease-2 As requiredAs requiredAs requiredAs requiredAs requiredCHASSISCHASSISCHASSISCHASSISCHASSIS CASTROL - Castrol AP2CASTROL - Castrol AP2CASTROL - Castrol AP2CASTROL - Castrol AP2CASTROL - Castrol AP2

ANTI RANTI RANTI RANTI RANTI RUST UST UST UST UST TREATREATREATREATREATTTTTMENTMENTMENTMENTMENT DINITROL - DinitrolDINITROL - DinitrolDINITROL - DinitrolDINITROL - DinitrolDINITROL - Dinitrol —————& SOUND DEADENING& SOUND DEADENING& SOUND DEADENING& SOUND DEADENING& SOUND DEADENING WUERTH - WuerthWUERTH - WuerthWUERTH - WuerthWUERTH - WuerthWUERTH - Wuerth

3M - 3M3M - 3M3M - 3M3M - 3M3M - 3M —————

WIND SCREEN SEALANTWIND SCREEN SEALANTWIND SCREEN SEALANTWIND SCREEN SEALANTWIND SCREEN SEALANT WUERTH - WuerthWUERTH - WuerthWUERTH - WuerthWUERTH - WuerthWUERTH - Wuerth —————3M - 3M3M - 3M3M - 3M3M - 3M3M - 3M —————Car System - Car SystemCar System - Car SystemCar System - Car SystemCar System - Car SystemCar System - Car System

112

Lubricants and Oils :Recommended lubricants conform tothe following specifications :1. Engine oil -API-CH4 + MB 228.3

or higher grade engine oil2. Gear Box oil - 75W90 GL-43. Power Steering - ATF Type A,

Suffix A4. Rear axle - M/Grade oil SAE 85W

140 GL5 Angolmol AG043 oil* Friction modifier 40819 (2- 5%) tobe added to oil for Limited SlipDifferential

5. Chassis and wheel bearing-SS6805 bearing grease

NOTICE

WARNING

Fuel : High Speed dieselconforming to IS1460 or EN 590or equivalent is recommended tobe used as fuel.At very low temperature fluidity ofdiesel may become insufficient dueto paraffin separation. It is thereforenecessary to mix supplementaryfuel with summer or winter gradediesel. The supplementary fuel tobe used is kerosene or aviationturbine fuel.Ratio for mixing of supplementaryfuel and diesel are shown in thetable.

Do not mix gasoline or alcoholwith diesel. This mixture cancause explosion.

Recommended Fuel Specificationfor engines to be added.

Parameter Unit BS III

1 Cetane Number (min) CN 512 Sulphur content mg/kg 350

3 Lubricity (HFRR) micon 460

Important Technical InformationFUEL, LUBRICANTS & COOLANTS

Ambienttemperatureupto Deg. C

PercentageSummer

grade dieselSupplementary

fuel

Upto 00 to -10

-10 to -15

1007050

03050

Ambienttemperatureupto Deg. C

PercentageWinter

grade dieselSupplementary

fuelUpto -15-15 to -20

-20 & below

1007050

03050

Care should be taken that dieseland supplementary fuel arethoroughly mixed before filling.

Where oxidation catalyticconverter is fitted, it ismandatory to use Diesel fuelwith sulphur contents as under.Use of any other diesel fuel canincrease the pollutants.

113113

Important Technical InformationENGINE OIL

Gear Box oil :Gear Box oil :Gear Box oil :Gear Box oil :Gear Box oil : Qty : 1.6 Litres Qty : 1.6 Litres Qty : 1.6 Litres Qty : 1.6 Litres Qty : 1.6 Litres

75W90, (Synthetic oil GL4)

Hub bearing grease :Use lithium base multipurpose grease-Quantity : 92 gms per hub.

(Front axles 4X4)47 gms per hub.(Front axles 4X2)25 gms per hub.(Rear)

Brake and Clutch Fluid :Brake fluid confirming to SAE J 1703,DOT 3 is recommended.

Spicer propeller shaft :

Lubricant slip joint with NLGI-2 gradegrease.

Please use only recommendedgrades for good performance.DO NOT mix grease of different brandsand optional grades. Replace old greasecompletely.

The oil change periods recommendedin maintenance schedule should beadhered to.

EngineEngineEngineEngineEngine Qty : 7.5 Litres Qty : 7.5 Litres Qty : 7.5 Litres Qty : 7.5 Litres Qty : 7.5 Litres

Recommended grades of engine oil forrange of ambient temperature :

AmbientAmbientAmbientAmbientAmbient Engine OilEngine OilEngine OilEngine OilEngine OilTTTTTemp emp emp emp emp 00000CCCCC GradeGradeGradeGradeGrade

- 5 and above SAE 15W/40- 10 to 0 SAE 5W30

- 20 and -10 SAE 0W30

Front live axle and rear axle oilFront live axle and rear axle oilFront live axle and rear axle oilFront live axle and rear axle oilFront live axle and rear axle oil(Spicer axles)(Spicer axles)(Spicer axles)(Spicer axles)(Spicer axles)

Use Multigrade oil SAE 85W 140Angolmol A6043 oil

Capacity :Capacity :Capacity :Capacity :Capacity :

For Rear axleFor Rear axleFor Rear axleFor Rear axleFor Rear axle - 2.2 litres- 2.2 litres- 2.2 litres- 2.2 litres- 2.2 litres

CoolantsQty : Approx. 9-10 LitresPresence of dirt in coolant chokes uppassages in radiator, cylinder head andcrankcase, thereby causingoverheating of engine.To prevent rust formation and freezingof coolant inside the passages ofradiator, crankcase and cylinder headuse premixed coolant asrecommended.It is recommended that the entirecooling system should be drained andfilled with fresh premixed coolant.Engine coolant antifreeze coolant asper class II, JIS K2234Windscreen Washer AntifrostMake - Antifrost- KConcentration - 1 : 5 For 00C

1 : 1 For 100C2 : 5 For 160C1 : 0 For 370C

114

Important Technical InformationOIL FILLING & DRAIN POINTS

GEARBOX (G-76)A. OIL LEVEL PLUG B. DRAIN PLUG

ENGINE OIL DRAIN PLUGREAR AXLE (SPICER)A. OIL LEVEL PLUG B. DRAIN PLUG

ENGINE OIL FILLING CAP

115115

TECHNICAL SPECIFICATION


1. ENGINE

Model : TATA 2.2L DICOR

Type : Direct Injection Common RailTurbo Charged IntercooledDiesel Engine

No. Of Cylinders : 4 Inline

Bore / Stroke : 85 mm x 96 mm

Capacity : 2179 cc

Max. Engine Output : 88.3 kW (120 ps) at 4000 rpm asper CMVR/TAP-115/116

Max. Torque : 250 Nm @1500-2500 rpm as perCMVR/TAP-115/116

Firing Order : 1 - 3 - 4 - 2

Engine Oil Capacity : 5.5 Litre Min. & 7.5 Litre Max.

2. CLUTCH

Type : Single plate dry friction diaphragmtype.

Outside diameter : 240 mmof clutch liningFriction area : 503 sq. cm. (Approximately)

3. GEAR BOX

Model : GBS-76-5/4.1 with overdrive

Type : Double Synchromesh on all gears.

No. of gears : 5 forward, 1 reverse.Gear Ratios : 1st - 4.10

2nd - 2.223rd - 1.374th - 1.005th - 0.77Rev. - 3.75

4. REAR AXLE : Single Reduction, Salisbury TypeRear Axle with Hypoid Gears andSemi-Floating Axle Shafts & Withoutlimited slip differential.

Ratio : 3.73

5. FRONT AXLE

Type : Independently suspended

116



6. STEERINGType : Power SteeringRatio : 18.2:1Steering Wheel : 400 mm dia.Steering column : Collapsible with tilt. Standard fitment

7. BRAKES

Service brakes : Vacuum Assisted IndependentHydraulic Brakes on Front and Rearwheels through Tandem MasterCylinder & Tandem Booster.

Front brake : 281 dia. Ventilated Disc Brakes withTwin Pot Calliper.

Rear brake : 282 dia. Drum Brake With AutoAdjuster with 25.4 mm wheel cylinder

Load conscious : Provided for rear brakespressure reducingvalveParking brake : Lever type Floor console mounted

handle, Cable Operated MechanicalLinkages Acting on Rear Wheels.

8. FRAME

Type : Ladder Type Cranked Frame withBoxed Section Long Members &bolted / Welded Cross Members.

9. SUSPENSIONFront : Double Wishbone Type coil springRear : Parabolic Leaf Springs.Shock Absorber : Hydraulic Double Acting Telescopic

Type at Both Front & Rear.Antiroll Bar : At both Front and Rear.

10. WHEELS & TYRES

Tyres : 235/70 R 16 Tubeless tyreTyre Pressure : Unladen:- Front-28 psi, Rear- 28 psi

Laden :- Front-28 psi, Rear- 32 psiWheel rims : 6.5 J x 16No. of wheels : Front - 2, rear - 2, spare - 1.

11. FUEL TANK

Capacity : 65 liters

12. CAB

Type : Normal Control All Steel Shell.Ventilation : HVAC

13. ELECTRICAL SYSTEMS

System Voltage : 12 volts (-ve earth)Alternator Capacity : 125 Amperes.Battery : 12 V, 80 Ah

117117



14.PERFORMANCE

Max. speed : 140 kmph

Max. gradeabilityat rated GVW : 34%

15.MAIN CHASSIS DIMENSIONS AS PER ISO:612 inmm(Nominal) (TOLERANCES AS PER INTERE UROPESTVZO)

Wheel Base : 2550Track Front : 1496Track Rear : 1490Overall Length : 4430

Max. Width : 1800Front Overhang : 834Rear Overhang : 1036 over bumperOverall Height(Unladen/laden) : 1910 / 1890Minimum TurningCircle Dia. : 10.5 mMinimum TurningClearance Circle Dia. : 11.5 mGround Clearance : 180 mm

16. WEIGHTS (kg) (TOLERANCE AS PER INTEREUROPE STVZO)

Complete vehicle kerbweight asper ISO:1176(with sparewheel andtools) : 1950 (FAW-1000) (RAW-950)Gross Vehicle Weight : 2625 (FAW-1100) (RAW-1525)Max. Permissible FAW : 1150Max. Permissible RAW : 1600

17.PASSENGER CAPACITY : Option I - Driver +6 Option II - Driver + 7

118

INFORMATION AT A GLANCE - Dimensions


119119

LOCATATION OF AGGREGATE NUMBER


REAR AXLE NUMBER (SPICER)GEARBOX NUMBER

CHASSIS NUMBER PLATE ON LHFRONT DOOR ‘B’ PILLER

ENGINE NUMBER ENGINE NUMBER

CHASSIS NUMBER ON FRAME

120

LOCATATION OF AGGREGATE NUMBER


121121

PDI ServiceSERVICE RECOMMENDATIONS

Pre- Delivery Inspection

Following jobs are to be performedat PDI.

1. Wash & Clean the vehiclethroughly.

2. Road test the vehicle. Checkfor proper functioning ofEngine, Clutch, Transmission,Steering, Brakes etc.

3. Check vehicle behavior :Pulling to LH/RH, Wobbling,Self centering, Accelerationetc.

4. Static test : Start engine &check for idling rpm &Maximum rpm (look for anyabnormal noise), Watertemperature etc.

5. Check Engine oil level. Levelis acceptable if found betweenmid and max mark.

6. Check for any leakages ofengine oil.

7. Check for any leakages in thefuel system.

8. Check Coolant level intransparent auxiliary tank.Acceptable if level foundbetween mid and max.

9. Check for any Leakages ofcoolant.

10.Drain water from fuel waterseparator.

11.Check hose, clamps & pipes atall locations in cooling system.

12.Check hose, clamps & pipes atall locations in air intake system.

13.Check for leakages of gear boxoil.

14.Check for Proper fitment ofgear shift level rubber boot.

15.Check level of Clutch and brakefluid. Acceptable if foundbetween mid and max.

16.Check for oil leakages inclutch/brake circuit.

17.Check clutch/brake pedal freeplay.

18.Check for fitment of split pinsat Tie rod ball joints, Stub axles.

19.Check for fitment of greasenipples at all locations.

20.Check for leakages of front liveaxle oil (if applicable).

21.Check for leakages of rear axleoil.

22.Check tightness of propellershaft Centre bearing bracketmounting nut & bolt.

23.Check Power steering oil levelin reservior. Acceptable if foundbetween min & max marks.

122

24.Check for oil leakages in powersteering circuit.

25.Check for Steering wheel freeplay and adjustment.

26.Check functioning of all bulbs.

27.Check for proper functioning ofblinkers, horn, head lamp,parking light, reverse light, wipersystem, washer system etc.

28.Check headlamp alignment andadjust if necessary.

29.Check tightness of electricalconnection at battery, StarterMotor, Alternator & Starterrelay.

30.Check all fuses.

31.Check all the earth points forlooseness.

32.Check for functioning of allguages/meters/warning lamps.

33.Check connectors in allelectrical circuits.

34.Check for proper opening andclosing of doors.

35.Check functioning of doorlocks, latches and windows.

36.Check for any complaints oncab fittings, instrument paner,glove box etc.

37.Check and tighten hand loosefasteners.

38.Check for any breakages,bends, failure of anycomponent/assembly/unit.

39.Check for any fouling betweentwo components which maylead to leakages or othercomplaints. Check for foulingof fuel lines, brake pipes, clutchpipes, air intake pipe, powersteering hydraulic pipe, clutch/

NOTEWhile delivering a long storagevehicle (more than 6 monthsfrom production month),service/maintenance operationsas prescribed by us for longstorage, also needs, to becarried out before delivery.

brake linkages, accelerator rodetc.

40.Grease with grease gun : Alllocations appearing inlubrication chart.

PDI ServiceSERVICE RECOMMENDATIONS

NOTEDo not wash DICOR systemcomponents wth forced water.

123123

Service ScheduleSERVICE OPERATIONS TO BE PERFORMED

SRSRSRSRSR x 1000 kmx 1000 kmx 1000 kmx 1000 kmx 1000 km

N ON ON ON ON O OPEROPEROPEROPEROPERAAAAATIONSTIONSTIONSTIONSTIONS FREQUENCYFREQUENCYFREQUENCYFREQUENCYFREQUENCY 1 - 1 . 51 - 1 . 51 - 1 . 51 - 1 . 51 - 1 . 5 1 51 51 51 51 5 3 03 03 03 03 0 4 54 54 54 54 5 6 06 06 06 06 0 7 57 57 57 57 5 9 09 09 09 09 0 1 0 51 0 51 0 51 0 51 0 5

GENERALGENERALGENERALGENERALGENERAL

1 Wash the vehicle & Clean the condenser with compressed air Every Service x x x x x x x x

2 Check & Top up Fluids if required: Coolant, Brake / Clutch Fluid, Battery Electrolyte, Power Every Service x x x x x x x xSteering Oil, Gear Box Oil, Transfer Case & Front Axle (4X4) / Rear Axle Oil

3 Drain water accumulated in Sedimenter (OR Whenever warning lamp glows) Every Service x x x x x x x x4 Check Engine Compartment for loose Fasteners, Low pressure fuel lines, Coolant hoses, air Every Service x x x x x x x x

hoses, Vacuum hoses, hydraulic line connections for leakages if any, Attend if necessary

5 Check Underbody for loose Fasteners, hydraulic line connections, Exhaust system / Fuel Pipes Every Service x x x x x x x x for Damages / Leakages if any. Attend if necessary

6 Apply grease on door latches, door lock, door check stop, striker, bonnet opening lever & lock Every Service x x x x x x xplate, tailgate hinges & door lock inner ratchet.

7 Check & ensure normal working of engine using Diagnostic Equipment. Every Service x x x x x x x x

2.2L DICOR ENGINE2.2L DICOR ENGINE2.2L DICOR ENGINE2.2L DICOR ENGINE2.2L DICOR ENGINE

1 *Clean air cleaner filter element, Change if red band appears on service indicator even after Every Service x x x x x x xcleaning

2 *Change engine Oil and Oil filter. Use APICH4+MB228.3 or Higher grade Engine Oil. Every Service x x x x x x x

OR 1 Year whichever is earlier3 Check All accessory Drive belts, adjust tension if required, change if damaged Every Service x x x x x x x

OR 1 Year whichever is earlier

4 Change fuel filter Every Service x x x x x x x OR 2 Years whichever is earlier

5 *Replace air filter element (OR if RED band appears on Service Indicator) 45,000 km x x

6 Change coolant in the cooling system 60,000 km x OR 2 Years whichever is earlier

7 Change Sedimenter / Water seperator 1,05,000 km x

8 Change Timing Belt & Timing Belt Idler 1,05,000 km x

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9 Change vacuum hoses fotr Vacuum Modulator, Turbocharger, EGR valve & throttle valve 60,000 km x OR 4 Years whichever is earlier

GEAR BOXGEAR BOXGEAR BOXGEAR BOXGEAR BOX

1 *Change oil in gear box (First at 45,000 KM, there after every 90,000 KM) x x

2 Change oil in transfer case (If fitted) 45,000 KM x x

3 Clean breather in gear box (also Transfer case in case of 4X4) Every Oil Change x xPROPELLER SHAFTPROPELLER SHAFTPROPELLER SHAFTPROPELLER SHAFTPROPELLER SHAFT

1 Grease propeller shaft with grease gun (at slip joint - splines end) & Check Centre bracket 15,000 km x x x x x x xmounting bolts for looseness. Tighten if necessary

REAR AXLEREAR AXLEREAR AXLEREAR AXLEREAR AXLE

1 Change oil in axle (First at 15,000 KM, there after every 75,000 KM) x x

2 Clean breather in Axle Every Service x x x x x x x

SUSPENSION & STEERINGSUSPENSION & STEERINGSUSPENSION & STEERINGSUSPENSION & STEERINGSUSPENSION & STEERING

1 Grease idler arm (seal type idler arm) 15,000 km x x x x x x x

2 Check wheel alignment & balancing, chassis height & adjust if necessary 15,000 km x x x x x x x

3 Check condition of rubber bushes in the following & replace if necessary. 1)Top wishbone 30,000 km x x x2)Lower wishbone 3)Anti roll bars 4)Rear links 5)Panhard rod 6) Vibration damper

4 Check shock absorber, its bushes & steering damper bushes, replace if necessary 30,000 km x x x

5 Grease steering spindle and sleeve 30,000 km x x x

6 Check & adjust front wheel bearing play & Change grease in front hubs 45,000 km x x

7 Change oil in power steering system & change filter element 75,000 km x

CLUTCH & BRAKESCLUTCH & BRAKESCLUTCH & BRAKESCLUTCH & BRAKESCLUTCH & BRAKES

1 Check parking brakes, adjust if necessary 15,000 km x x x x x x x

2 Check front brake pads & rear brake linings. Replace if necessary 15,000 km x x x x x x x3 Change Clutch & Brake Fluid (Or 2 years whichever is earlier) 30,000 km x x x


N ON ON ON ON O OPEROPEROPEROPEROPERAAAAATIONSTIONSTIONSTIONSTIONS FREQUENCYFREQUENCYFREQUENCYFREQUENCYFREQUENCY 1-1.51-1.51-1.51-1.51-1.5 15 30 45 60 75 90 105 15 30 45 60 75 90 105 15 30 45 60 75 90 105 15 30 45 60 75 90 105 15 30 45 60 75 90 105

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Service Maintenance ScheduleSERVICE OPERATIONS TO BE PERFORMED

ELECTRICALSELECTRICALSELECTRICALSELECTRICALSELECTRICALS

1. Check headlamp focussing & functioning of other electrical equipment 15,000 km x x x x x x x

2 Check specific gravity of battery electrolyte 30,000 km x x x

HVHVHVHVHVAAAAACCCCC

1 Check the HVAC System for Satisfactory Performance & attend if required Every Service x x x x x x x x

WHEELS & WHEELS & WHEELS & WHEELS & WHEELS & TTTTTYRESYRESYRESYRESYRES

1 Tyre rotation 15,000 km x x x x x x x

* Under severe driving conditions, additional maintenance is required. Please Refer to “Additional Maintenance Schedule under severe driving condi-tions”:PPPPPrrrrrecececececautions tautions tautions tautions tautions to bo bo bo bo be take take take take taken while cleaning engine cen while cleaning engine cen while cleaning engine cen while cleaning engine cen while cleaning engine comparomparomparomparompartmentmentmentmentment :t :t :t :t : I I I I It is rt is rt is rt is rt is recececececommended tommended tommended tommended tommended to use dro use dro use dro use dro use dry loy loy loy loy low prw prw prw prw pressuressuressuressuressure aire aire aire aire air..... D D D D Do not useo not useo not useo not useo not useprprprprpressuressuressuressuressurised wised wised wised wised waaaaatttttererererer.....


N ON ON ON ON O OPEROPEROPEROPEROPERAAAAATIONSTIONSTIONSTIONSTIONS FREQUENCYFREQUENCYFREQUENCYFREQUENCYFREQUENCY 1-1.5 1-1.5 1-1.5 1-1.5 1-1.5 15 30 45 60 75 90 105 15 30 45 60 75 90 105 15 30 45 60 75 90 105 15 30 45 60 75 90 105 15 30 45 60 75 90 105

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ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS :A.. Driving in conditions such as Patrolling, Taxi, Pickup Van, Vehicle Towing, with Trailer TowingB. Driving on Dusty / Sandy roadsC. More than 50% (in terms of kms) driving in heavy city trafficD. Frequently operating in mountainous area

ITEM INTERVAL CONDITIONA B C D

1. Engine Oil & Oil Filter Change every 7500 kms.2. Air Filter Element Clean at every 7500 kms. &

replace at 30,000 kms.3. Rear Axle Oil Change Change First at 15000 kms

& thereafter at 45,000 kms.


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PDI

15,000

30,000

45,000

60,000

75,000

90,000

1,05,000

1,20,000

1,35,000

1,50,000

RecommendedService

At km

Date

OdometerreadingKms.

RepairOrderNo.

ServicingDealer's

Signature& Stamp

RecommendedService

At km

Date

OdometerreadingKms.

RepairOrderNo.

ServicingDealer's

Signature& Stamp

1,65,000

1,80,000

1,95,000

2,10,000

2,25,000

2,40,000

2,55,000

2,70,000

2,85,000

3,00,000

3,15,000

Record Of Service Performed

128

Record Of Service Performed

RecommendedService

At kmDate

OdometerreadingKms.

RepairOrderNo.

ServicingDealer's

Signature& Stamp

3,30,000

3,45,000

3,60,000

3,75,000

3,90,000

4,05,000

4,20,000

4,35,000

4,50,000

4,65,000

4,80,000

RecommendedService

At km

Date

OdometerreadingKms.

RepairOrderNo.

ServicingDealer's

Signature& Stamp

4,95,000

5,10,000

5,25,000

5,40,000

5,55,000

5,70,000

5,85,000

6,00,000

6,15,000

6,30,000

6,45,000

129129

Odometer Repair Servicing Dealer’sDate reading km Order No. Particulars of Repair Signature & Stamp

Chassis No. -

Record Of Repairs Carried Out

130

Record Of Repairs Carried Out

Odometer Repair Servicing Dealer’sDate reading km Order No. Particulars of Repair Signature & Stamp

Chassis No. -