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TATA Sumo Victa Di Turbo Owners Manual and Service Book - Team-BHP

1. Once dirt has been completely removed wash off with running hose water After rinsing wipe the body lightly with wet chamois or cloth and allow the body to dry it in the shade Warning After washing check that the brakes are dry If brakes are not dry dry them by gently repeatedly applying while driving at low speeds Washing the vehicle exterior After washing the vehicle waxing and polishing are rec ommended to protect and beautify the paint Use only good quality waxes and polishes When using waxes and polishes the precautions speci fied by the manufacturers should be observed 90 Chrome plated parts should also be waxed Protection against corrosion The following cause corrosion e Moisture trapped in body cavities Dirt and salts collected in hollows on the underside of the vehicle Removal of paint and protective coatings from the exterior and underside of the vehicle Corrosion preventive measures have been incorporated in your vehicle You can avoid corrosion of your vehicle by performing some simple periodic maintenance Repair chips and scratches in the paint as soon as you discover them e Inspect and clean the drain holes in the bottom of the doors and body Check the floor coverings for dampness Carpets and floor mats remain damp for a long time especially in winter This can eventually cause the floor panels to corrode Use a high pressure spray to clean the un
2. The gauge indicates the temperature of the engine coolant The red zone at H indicates temperature higher than the normal Avoid driving when the pointer is in the red zone It indicates engine overheating which may be due to insufficient coolant in the radiator or due to any other defect At this stage take the car to the nearest Authorised Service outlet for necessary attention Caution Never remove the radiator pressure cap from the radiator when the engine is hot Do not restart the engine until the problem has been duly attended The speedometer The speedometer indicates the vehicle speed in km hr Speedometer High Temperature Warning Temperature Guage 36 HANDLING RPM meter if provided The meter indicates engine speed in revolutions per minute rpm Change gears at appropriate engine rpm and vehicle speed to get optimum fuel economy The permitted engine rpm upper limit is the start of Red Zone on the dial Fuel Gauge The fuel gauge indicates the approximate fuel level in the tank Refill the fuel tank at the earliest before the needle touches the red band on the gauge At this point fuel level in tank is low and it is advised to get fuel filled immediately RPM meter GX High Temperature Warning Temp Guage Low Fuel Warning Low Fuel Warning Fuel Guage Fuel Guage HANDLING Steering lock cum ignition switch Steering is provided with steering lock cum igniti
3. 5 Continue to rotate the wheel winch screw in anticlockwise direction until spare wheel is raised completely Spare wheel winch grommet Loosening Tightening of wheel winch screw Lifting the spare wheel 51 JACK amp TOOLS AND PARKING BRAKE Vehicle Jack amp Tools Vehicle tool bag is kept below co driver s seat J ack and handle are kept either below the rear right jump seat or driver s seat Jack is mounted on floor over studs by wing nuts screwed on them Lift the rear right seat squab to have access jack and handle Parking brake The parking brake is mounted on floor between RH door and driver s seat To apply the parking brake pull lever UP To release it pull the lever up slightly press the release button and push the lever DOWN Ensure parking brake is released before driving the vehicle Indication is given on instrument cluster 52 HANDLING 1 Parking Brake 2 Operating Knob HANDLING CATALYTIC CONVERTER AND EGR SYSTEM IF FITTED CATALYTIC CONVERTER if fitted Your vehicle is fitted with Diesel Oxidation Catalytic Converter to reduce exhaust pollution The two way Catalytic Converter has coating of precious metals which enables conversion of pollutants Care of the Catalytic Converter The Catalytic Converter does not require any special maintenance however following precaution should be taken for the effective functioning of the converter and to avoid damage to the Converter Itis mandatory
4. Engine oil Recommended grades of engine oil conforming to SAE API CF4 specifications and range of ambient temperature at which these can be used are given below Ambient temperature C Engine oil grade 10 and above SAE 15W 40 20 TO above SAE 10W 30 or SAE 5W 20 Gear box oil Use recommended gear oil conforming to General Motors Type A Suffix A specifications Rear axle live front axle and mechanical steering gear box oil Not applicable for power steering Use oils conforming to APIGL 5 specification SAE 90 oil should be used upto 9 C and SAE 75 between 9 C and 40 C 92 Hub bearing grease Tata Motors axles amp front hub Use Lithium base multipurpose grease Quantity 25 gms per hub Rear Brake and clutch fluid Brake fluid conforming to IS 8654 DOT 3 is recommended Spicer propeller shaft where applicable Lubricate slip joint with Multipurpose grease 2 grade grease Lubrication of steering spindle ball joint Lubricate steering spindle ball joint with Moly Kote BR2 grease at every 10 000 km of operation Sliding spindle on steering column not be pulled beyond the stopper as it may damage the splines Coolants Presence of dirt in coolant chokes up passages in radiator cylinder head and crankcase thereby causing overheating of engine To prevent rust formation and freezing of coolant inside the passages of radiator crankcase and cylinder head use only branded premixed
5. TATA TATA MOTORS Tata Sumo Victa DI Turbo Owner s Manual amp Service Book TATA MOTORS TATA Motors Limited Mumbai Pune The contents given in this book are not binding subject to change without notice and are for illustration purpose only DOYOUKNOW While taking delivery of your New TATA Sumo Victa DI TC you are privileged to have the following 1 Owner s Manual amp Service Book 2 Battery warranty Card 3 First Aid Kit 4 Advance Warning Triangle 5 Jack and Handle 6 Spare Headlamps Bulbs 2 Nos 7 Spare Fuses Provided in fuse box 8 Pre delivery inspection and service 9 Complimentary diesel in the fuel tank 10 Music System Manual 10 Immobiliser Manual 12 Toolkit a Wheel Spanner b Screw Driver c Ring Spanner 8 9 d Socket Handle You are also entitled for 1 Free Services as per details given in your Owner s manual and service book at any Tata Motors Dealership or Tata Motors Authorised Service Centre TASC or Tata Motors Authorised Service Point TASP 1 On the spot settlement of warranty as per terms and conditions given in this book We welcome your suggestions for better service Should you require any assistance please contact Works Manager of Tata Motors Dealership or TASC EXCELLENT CUSTOMER SUPPORT FOR TOTAL SATISFACTION Dear Customer Thank you for choosing the Tata Sumo Victa DI Turbo another quality offering from the company s growing range of passenger vehicles We woul
6. Wheneverany repair overhaul or disconnecting of any brake pipe is done or level of brake fluid has fallen so low that air has been drawn into master cylinder it is necessary to bleed the system to remove the trapped air Proceed as follows for bleeding the brake system a Clean all dirt from around the fluid container Remove cap and top up fluid upto the maximum level b Remove dust cap at each bleed screw and clean the area around it C Attach the bleed tubeto the front left calliper bleed screw and place the other end in a clean jar containing sufficient fluid to submerge the end of the tube holding the jar just above the bleed screw level d Pump the brake pedal 3 4 times slowly throughout its stroke and by holding the pedal depressed loosen the bleed screw and watch for air bubbles in the glass jar 79 Brakes VEHICLEMAINTENANCE _ f Re tighten the bleed screw and release the brake pedal Repeat theprocessuntil airbubbles ceaseto appear atthe end of bleed tube allowing only fluid to flow Replace the dust cap on bleed screw Repeat the same procedure steps a to f on the front right calliper rear left wheel cylinder followed by rear right wheel cylinder After completion of bleeding apply the brake several times and check for any leakages at joints and bleed screws During the bleeding process keep the following points in mind 1 Ensure that the fluid level in the fluid container does n
7. hydraulic brakes on front and rear Vacuum pump mounted on alternator 262 dia disc brake 282 dia auto adjusted drum Brake Cable operated Mechanical linkages acting on rear wheels Ladder type cranked frame with boxed section long members and welded cross members 110 mm maximum 60 mm Suspension Front Rear Shock Absorber Antiroll bar Wheels and tyres Tyre Wheel rims No of wheels Fuel Tank Capacity Electrical System System voltage Alternator Capacity Battery 95 Double wishbone type with coil springs Semi elliptical leaf springs Hydraulic double acting telescopic type at front and rear At both front and rear 185 85 R 16 55 x16 Front 2 Rear 2 Spare 1 65 litres 12 volts ve earth 75 Amps for HVAC version 40 Amps for Non AC version 12V MF 70 Z IECHNICAL SPECIFICATIONS Performance Weight kg Tolerances as per INTEREUROPE STVZO Max speed at rated GVW 120 km hr Complete vehicle kerb Max gradeability at rated GVW 32 96 weight as per ISO 1176 1875 FAW 1030 RAW 845 LX With spare wheel amp tool 1855 FAW 1010 RAW 845 CX Grade Restartability 26 96 Main Chassis Dimensions As per ISO 612 in mm Gross Vehicle weight 2600 FAW 1080 RAW 1520 Nominal Tolerances as par INTEREUROPE STVZO Max Permissible FAW 1100 Wheel base 2425 Max Permissible RAW 1560 Track front 1496 Passenger Capacity Option Driver 6 T
8. 250 gm cm max 2 Permissible balance weight for tyre with rim 140 gm max 3 Relocate the tyre if the weight required to balance is more than 140 gm 4 Balance weights are available from 10 gm to 90 gm in steps of 10 gm and from 80 to 140 gm in steps of 20 gm 5 Do not use more than one balance weight on side 83 SCHEMATIC DIAGRAM TYRE ROTATION RADIAL PLY TYRES N in FRONT SPARE WHEEL Tyre rotation Tyre rotation is recommended for achieving identical wear on each tyre It is also advisable to change rotating direction to relieve tyres of continual one way rotation Regular rotation of tyres also will prevent abnormal wear The sketch indicates a suggested sequence of tyre rotation Rotate tyres first at 12 000 km then at every 8 000 km or earlier depending on operation 84 Headlamps The head lamp provides two types of light beams a high beam to give maximum light well ahead of vehicle and a low beam which is shorter and lower so that it will not dazzlethe oncoming drivers and can be use in low visibility area The head lamp also incorporates a parking lights The head lamps must be properly aligned in order to obtain maximum road safety proper road illumination and reduced glare to oncoming traffic It is recommended to check alignment of headlamp beams periodically and whenever headlamp bulbs are replaced by means of a headlamp aligner or with the help of a screen as
9. A and B of intersection of vehicle lines and horizontal lines It is possible that high beams may not be exactly symmetrical but for this reason headlamps should not be realigned Preferably the alignment should be done in the dark No masking of headlamps with black paint is required If done this will reduce the intensity of light Head lamp focusing should be carried out in the level O position where head lamp leveling switch provided of the switch only 85 system VEHICLE MAINTENANCE _ Head lamp bulb replacement Raise the bonnet of the vehicle Remove the rear protective cover Pull out cable socket from bulb Remove lock ring holding the bulb and remove the bulb Install new bulb properly locating it in the housing Fit back locking ring cable socket and protective cover Realign headlamp beam after replacing bulb Do not clean the reflector as it will cause damage to mirror finished surface Do not replace bulb with dirty or oily hands since oil will evaporate due to bulb heat and stain the reflector 86 ocation type ___ pecifications Headlights Headlamp Halogen P43t 2 Turn indicator light Front BAU15 S 2 Tail lamp BAU15 S 2 Stop lights Tail lights Tail lamp BAY 15S 2 Parking lights Head lamp 5W 2 Registration number plate lights Near number light 5W 2 Reverse indicator lights Tail lamp 15 5 2 Side Re
10. Resettable Counts up to 1999 9 kms Trip meter B Resettable Counts up to 1999 9 kms Intensity level of instrument panel illumination selection among preset levels LCD has two line display The first line displays the Odometer count The second line displays either of Trip meter A Trip meter B Intensity level of panel illumination The selection and control of functions are done through MODE and SET push buttons knobs provided on either side of the LCD The MODE knob is used to select one of the Trip meter A Trip meter B OR Intensity level of panel illumination Switching among the above three functions can be done by pressing the knob 34 HANDLING ie 3 5 6 Odometer 9999 roro Intensity level of tor panel illumination 123456 999 Display for Trip B SET MODE knob selector knob HANDLING The SET knob is used to control the chosen function Pressing the knob for a few seconds resets the chosen trip meter and varies the intensity level of instrument panel illumination The panel illumination intensity varies among preset levels as follows This display returns to Trip meter A after a few seconds of intensity level selection if left in this mode NOTICE Main odometer and trip meter A indication will remain on display even if the ignition key is removed 35 INDICATORS Intensity Level Indicator GAUGES Temperature gauge
11. The driver co driver and middle seat of your vehicle are fitted with adjustable headrestraint Headrestraint can help to protect you from whiplash and other injuries For best protection adjust the top of the headrestraint as shown in the figure The headrestraint can be adjusted by using release button as shown in figure Release Button for Head rest height adjustment Pd AW PoorAdjustment Good Adjustment 27 DRIVING CONTROLS HANDLING Steering Wheel Instrument Cluster Combi Switch Head Lamp Leveling Switch Ignition Switch Cum Steering Lock Bonnet Opening Lever Clutch Pedal Brake Pedal Accelerator Pedal pan ove BW Non 10 Fuel Flap Opening Lever 11 Parking Brake 12 Gear Shifting Lever Driving Controls Sumo Victa DI Turbo 28 HANDLING INSTRUMENT PANEL INSTRUMENT PANEL All indicators may not be provided on some instrument cluster and may not be applicable to all models 29 INSTRUMENT PANEL HANDLING INSTRUMENT PANEL All indicators may not be provided on some instrument cluster and may not be applicable to all models 30 HANDLING Do Oy Mr new ee ee 10 SERVICE Indicator Amber Immobilizer Warning If fitted Red Direction Indicator Green Head Lamp Main Beam Indicator Blue Low Engine Oil Pressure Indicator Red Battery Charging Indicator Red Brake Fluid Level Check Parking Brake Indicator Red Seat Belt Indicator Red Glow
12. 1 i nu eth ree li 1 7 E 41 Etung f E Um UU g 12 y Seat belt Arrangement on Driver amp Co drivers Seat SEAT BELTS Lap belt for middle passengers of front bench seat Middle passenger is provide with lap belt Adjust length of belt to suit convenience Insert belt tongue in buckle A positive click indicate correct assembly To release press the release button The tongue will be ejected from the button CAUTION The belt is designed for use of only one person It is not intended for children under 10 years The belt should at all time be adjusted and used in accordance with the instructions and no excessive slackness in the belt should be evident Avoid twisting the straps during use Webbing must not be allowed to chafe against sharp edges on seat or bodywork Do not make any alterations or additions to the belt If in doubt consult the authorised service outlet The belt that have been cut frayed damaged or have been stressed through impact should be replaced To clean and occasional wipe with warm soapy water will maintain the webbing in a clean condition Do not use bleach or dye under any circumstances 1 Periodic inspection of the installation will ensure safe and reliable service of the seat belt H H H H H 26 HANDLING i 4 Seat beltArrangementon Middle Seat HANDLING ADJUSTABLE HEADRESTRAINT Adjustable Headrestraint
13. 9 considered characteristic of the vehicle This warranty shall be null and void if the vehicle is subjected to abnormal use such as rallying racing or participation in any other competitive sports This warranty shall not apply to any repairs or replacement as a result of accident or collision This warranty is expressly in lieu of all warranties whether by law or otherwise expressed or implied and all other obligations or liabilities on our part and we neither assume nor authorise any person to assume on our behalf any other liability arising from the sale of the vehicle or any agreement in relation thereto The buyer shall have no other rights except those set out above and have particular no right to repudiate the sale orany agreement orto claim any reduction in the purchase price of the vehicle or to demand any damagesor compensation for losses 10 1 m 12 TERMS AND CONDITIONS incidental or indirect or inconvenience or consequential damages loss of vehicle or loss of time otherwise incurred or accrued Any claim arising from this warranty shall be recognised only if it is notified in writing to us or to our concerned dealer without any delay soon after such defect as covered and ascertained under this warranty This warranty shall stand terminated if the vehicle is transferred or otherwise alienated by the buyer without our prior written consent We reserve our rights to make an
14. Plug Indicator Speedometer 11 12 13 14 15 16 17 18 19 3l INSTRUMENT PANEL RPM Meter if fitted Fuel Gauge Low Fuel warning Indicator Temperature Gauge High Temperature Warning Indicator Mode Selector Knob Odometer Set Knob Odometer Cumulative Odometer Trip Odometer INDICATORS SERVICE Indicator This lamp indicates your vehicle s engine condition when a malfunctioning occurs in the engine 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 engine is running if malfunc tioning occurs A CAUTION When Service lamp is ON while the engine is running the engine s performance deteriorates marginally and sometimes drastically Please get the malfunctioning rectified at a nearest authorized service outlet Immobiliser Warning This system disables engine starting if original key is not used The user has to use original key for authentification and unlocking the car Refer to Immobiliser section for details Lamp Blink Car is in immobilised condition when key is not inserted Lamp OFF Normal condition Authenticated user and engine will start 32 HANDLING Lamp On Problem with key system Show your car to TATA Authorised service centre Turn signal lamps can be operated only when the ignition supply is ON and by using the turn in
15. Vehicle Weight RPM Ignition Sec Kilogram Sq cm Kilometer TASC Kilometer per hour TASP Left Hand V Maximum W Main Dealer Wt Minimum 106 Meter per Kilogram Millimeter Mounting Number Newtonmeter Passenger Car Business Unit Pre delivery Inspection Pounds per Square Inch Pollution Under Control Rear Axle Weight Regional Customer Support Manager Right Hand Regional Manager Revolution Per Minute Seconds Square Centimeter Tata Motors Authorised Service Centre Tata Motors Authorised Service Point Volts Watts Weight A D F Aggregate Numbering 14 Do s 10 Fan Belt Tension Adjustment 76 Accessory Switches 45 Don ts 13 Fuel Economy 64 Air Conditioning 57 Door Locking 17 Fuel Flap Opening 49 Anti theft Device 16 Driver s Seat 21 Fuel 91 Ash Tray 48 Driving Climbing Sharp Gradients 67 Fuses 88 B Driving Descending Sharp Bonnet Opening amp Closing 49 Gradients 58 Brake Adjustment 81 Driving at Night e Gauges 36 Brake Clutch System Bleeding 79 Driving Controls Gear Shift lever 50 Brake System 79 Driving Instruction 63 77 PP Specingatign uh Driving on Snowy or Icy Roads 65 Head Lamp Adjustment 84 C Driving Safety 70 Head Lamp Bulb Replacement 86 Catalytic Converter 53 Driving Through Water 66 Head restraint 27 Changing Engine Oil 73 Headlamp Leveling Switch 44 Changing Fuel Filter Element 75 Headlamps 84 Changing Oil Filter 73 FGR System High Mounted Stop Lamp 42 Combi Switch 39 Engin
16. coolant Coolant should be drained and fresh premixed coolant filled every two years or 50 000 km whichever is earlier RECOMMENDED OILS LUBRICANTS AND FILLING CAPACITIES PLEASE USE ONLY FOLLOWING GENUINE OILS COOLANTS LUBRICANTS ANTI RUST amp SOUND DEADENING COATS WINDSCREEN SEALANT ADHESIVES amp FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM PERFORMANCE ITEM COMPANY BRAND QTY ENGINE OIL CASTROL Castrol GTD 15W 40 5 5 Litres HPCL HP Milcy Power 15 W 40 COOLANT Premixed SUNSTAR Golden Cruiser Premium 1400 M 12 Litres Approx HPCL HP Thanda Raja P GEAR BOX G 76 HPCL HP Gear EP 75W90 T 1 6 Litres CASTROL CASTROL Syntro 75W90 GL4 Exxon Mobil MobiLube 1 SHC 75W90 POWER STEERING OIL HPCL HP ATF 2 0 Litres TML CASTROL CASTROL Transpower TQ 2 2 Litres DANA REAR AXLE HPCL HP Gear Oil XP 85W140 GL5 1 9 Litres CASTROL CASTROL Extreme Pressure 85W140 BRAKE CLUTCH FLUID HP CL HP Super Duty Brake Fluid DOT 3 As required CASTROL CASTROL Universal Brake Fluid DOT 3 WHEEL BEARING amp CHASSIS HPCL HP Multipurpose Grease 2 As required Propeller shaft joints Sliding Yokes Vacuum Booster ANTI RUST TREATMENT DINITROL Dinitrol amp SOUND DEADENING WUERTH Wuerth DIESEL ADDITIVE IFTEX Iftex Clean System D 250 ml pack Add to Diesel as per the dosage recommended by M s IFTEX 93 Engine Model Type No of cylinders Bore Stroke Capacity Max en
17. function A CAUTION Ensure that all turn signal indicators are working properly Get it rectified in case of problem ACCESSORY SWITCHES POWER SOCKET AND ASH TRAY Power Socket A power socket is provided on the central console below A C control knobs This can be used connecting loads upto 10A maximum To use this socket remove the cap first Z CAUTION Always keep this socket covered with the cap when not in use Ash Tray Ash tray is proveded on the dash board central console To open ash tray pull it out by sliding 48 HANDLING Ash tray HANDLING Bonnet opening and closing To open pull lever 1 This will release the bonnet lock To open fully lift the additional lock lever located on the bonnet centre with the help of finger Use the bonnet stay rod to keep the bonnet open For closing the bonnet disengage the stay rod clamp it properly and press down the bonnet till it is fully shut Ensure that the bonnet is fully locked before driving off In case of failure of cable attached to lever 1 bonnet lock can be opened by inserting a screw driver from the top centre position of grill through a slot provided behind it on the sheet metal and by pressing the lock plate towards your left Push upward the additional lock lever at your right and lift the bonnet while the lock plate is kept pressed with the help of screw driver Fuel filling Cap The fuel filling cap is located at t
18. loss of traction e Undernoconditionsshould the vehicle be moved diagonally across a hill The danger is in loss of traction and sideways slippage possibly resulting in tipping over If unavoidable choose as mild an angle as possible and keep the vehicle moving If the wheels start to slip within few feet of the end of the climb motion can be maintained by swinging the steered wheels left and right thereby providing increased grip If the vehicle stalls or losses headway while climbing a steep hill make a quick shift to reverse and allow the vehicle to move back with the control of engine compression Descending Sharp Gradients Select the lower gear and depending on the severity of the gradient shift into appropriate gear Use engine braking judiciously without over revving the engine Brake application under such situations should be done very smoothly to avoid loss of control Select appropriate gear so that gear changing or clutch disengagementis not involved while descending the gradient Towing the Vehicle For towing the vehicle the best way is to use a recovery van Alternatively use a rigid tow bar Avoid using flexible cable or rope as your vehicle may crash into towing vehicle when it stops suddenly Switch ON Hazard warning switch to warn the other road users Keep the engine in idling so that power steering assistance Front Towing Hook iS available This will also built the
19. on the ambient temperature the indicator light only goes off indicating that the engine can be started Glow plugs remain ON for few seconds and switches OFF automatically As a Safety feature glow plugs are automatically switched OFF after a lapse of certain time if the engine is not started to conserve battery In this case to start the engine repeat the operation by first going to ACC or LOCK position START Turn the key further clockwise to start position spring loaded to operate starter motor As soon as the engine starts release the ignition key so that key can come back to ON position and starter motor disengages and glow plug is switched OFF Vehicle is driven in this position By turning the ignition key from ON position to ACC or LOCK position engine can be stopped 38 HANDLING HANDLING COMBINATION SWITCH amp LIGHTS Combi switch WIPER STALK LIGHT STALK FLASH HIGH BEAM FLICK WIPE SPRING RETURN SPRING RETURN A DIP BEAM OFF NORMAL POSITION HIGH BEAM 7 FAST WIPE LEFT TURN SLOW WIPE SIGNAL SELF CANCELLING PUSH SWITCH TS LANE CHANGE LEFT SPRING FORWASH amp WIPE _ 7 GE 1 LANE CHANGE RIGHT SPRING RETURN RIGHT TURN SIGNAL SELF CANCELLING LIGHTS CONTROL SWITCH INTWIPE DELAY TIMING FOR I INTERMITTENT WIPE y MIN eee 39 LIGHT
20. ASC S TASP s Workshops in India irrespective of the dealer who sold the vehicle provided the vehicle is sent to them at the kilometerages specified and that this service book is produced before them The vehicle is entitled to pre delivery service with free labour After the delivery of the vehicle in the subsequent 4 free services labour would be free but materials if any would be charged for All services other than the above must be paid for both for materials and labours material at prevailing rates for the quantity consumed and labour at our scheduled rates available with our Authorised Dealers TASCs TASPs In the event of a schedule Service not performed within specified kilometers the respective coupons will be detached by the Authorised Dealer s Workshop when the vehicle is sent to them next Should a major service have been missed all the works listed for such service must be performed when the vehicle is taken next to one of our Authorised Dealer s TASC s TASP s Workshop It is an important condition of our sales policy that no warranty claims shall be entertained by us unless all services upto time of the claim arising have been performed on the vehicle by one of our Authorised Dealer s TASC s TASP s Workshops Failure to carry out the services listed in this book can cause considerable damage to the vehicle and inconvenience to you It is therefore in your own interest to take your vehicle to one of our Auth
21. HES Rear Windshield Wash and Wipe unlatched switch Push and hold the switch knob for the operation of the wash function for the desired duration for rear visibility through glass The function indicator lights up when wash function is ON Along with wash fluid getting sprayed the wiper also operates with a delay to wipe the glass surface through a timer control unit On release of this switch this function stops Rear Windshield Wiper latched switch To operate this function push to switch ON and again push to switch OFF The function indicator lights up when the wiper function is ON 46 HANDLING HANDLING Front Fog lamp unlatched switch The fog lamps are provided on front bumper to improve the visibility in foggy weather or during heavy rains The front fog lamps can be switched ON with parking lamp ON and can be remain on till the parking lamp is switched OFF NOTICE Use only during foggy conditions or heavy rains if required Hazard Warning Hazard warning is used in case of breakdown especially during night and vehicle has to be parked at the side of the road or vehicle being operated in adverse condition This can be operated without Ignition ON Press hazard warning switch to switch ON All outside turn signal lights and indicators on cluster will flash simultaneously to warn the other road users about hazardous condition of the vehicle Depress the switch to switch OFF the hazard
22. Power Steering Fluid Dip Stick Check level of water in Windshield washer reser voir Top up with clean water if required Use good quality cleaning solvent available in the market in the ratio as specified by its manufacturer Check oil level in power steering hydraulic tank where applicable Check and correct tyre inflation pressure In cold condition 62 HANDLING DRIVING AND GEAR SHIFTING Start the engine and observe that BEFORE DRIVING Check Fuel level Coolant level Engine oil level Tyre pressure Brake and clutch fluid level Doors are firmly closed Adjust Driver seat Rear view mirrors Ensure Gear shift lever is in neutral position All switches and lamps are working Brake fail indicator is OFF Fuellevel indicated on fuel gauge is above reserve tank Low oil pressureindicatorlight goes OFF Battery charging indicatorlight goes OFF ENSURE THAT PARKING BRAKE IS RELEASED INDICATOR LAMP OFF VEHICLE IS NOW READY FORA DRIVE DO NOT ALLOW VEHICLE TO ROLL BACK ON GRADIENTS During running in period i e first 2 000 km of operation Do not exceed the following vehicle speeds Gear Min Max Ist 20 2nd 15 35 3rd 25 55 4th 35 75 5th 45 Max 95 Avoid rapid acceleration and prolonged high speed running of the engine Avoid sudden braking Retighten wheel nuts to 12 15 mkg torque af
23. S amp WIPER CONTROL LEVER m om Wiper Control Lever Left Selector Wiper OFF position Slow Wipe Fast Wipe Intermittent wipe Pull up for windshield wipe Flick Wipe Spring Return Press side knob for wash Rotate selector to set delay timing for inter mittent wipe 40 HANDLING Lights Control Lever Right Head lamp OFF position Position lamp ON Position lamp amp head lamp ON Push down the lever for high beam Pull up the lever spring return for high beam flash Lane change left self cancelling Side Indicator LH Lane change right self cancelling Side Indicator RH HANDLING MUSIC SYSTEM amp ENGINE COMPARTMENT LAMP Music System The music system is fitted in the centre console Two Oss speakers are provided in the dashboard as well as two speakers are in the rear The Antenna is loacated on the RH side of front windshield glass on the A piller Please refer the music system User s Manual provided in the vehicle for understanding it s function Music System Engine Compartment Lamp To operate engine compartment light pull switch 2 Engine Compartment Lamp 41 TAIL LAMP Tail Lamp The tail lamp assembly incorporates the following Rear direction indicator Parking Rear stop lamp Reverse light Reflex reflecor Fog lamp HE Registration Plate Lamp Two concealed lamps are provided
24. Switch E Fresh air mode condition Once the windscreen has become clear move the fan switch to desired speed NOTICE Electric heater coil is provided for demisting of tail gate glass for deluxe versions Normal Heating For vehicles fitted with HVAC Knob A Suitable temperature position Knob B Suitable blower speed Knob C Towards face amp feet gr OFF Air Circulation Fresh switch 59 PREPARING THE VEHICLE FOR THE DRIVE HANDLING Fuel Filling Cap 1 Engine Oil Filler Cap Engine Oil Filter 2 Dip Stick Check the following regularly particularly before 3 Coolant level starting on along journey With the engine cool check the coolant in the auxiliary 1 Fuel level in tank tank The level should be between the FULL and MIN Top up if required with correct diesel fuel secure cap mark top up with the recommended coolant Bring and lock the flap the level upto the FULL mark The level must not 2 Engine oil level exceed the FULL mark If the coolant level drops Check engine oil level before starting the engine or within a short time after replenishing there may be a at least 20 minutes after stopping the engine Top up leak in the system Rectify the leakage and top up if oil level is less than midway between upper and radiator also lower marks on the dipstick Use genuine company branded coolant The oil level should not exceed the MAX mark If no leak can be foun
25. Workshop to check entry of water in cylinders twill also be necessary to replace lubricants of engine gearbox transfer case front axle and rear axle if water has entered Get the starter and alternator checked Driving on a Rainy Day Check brakes steering and windows Check tyres for wear and tyre pressure Check wiper blades for proper functioning Avoid harsh braking and sharp turns It may cause loss of control and lead to a skid For slowing down shift to lower gears and brake gently Keep lights ON if visibility is poor DRIVING IN ADVERSE CONDITION Night Driving e Dip the head lamp for oncoming traffic during night driving e Maintain a speed such that you can stop within illuminated distance of head lamps Use head lamp main dip beam to alert other road users on turns cross roads etc Use side indicators for lane change or turning e Puton hazard warning switch in case of hazardous parking or if your vehicle is disabled to warn the passing traffic Climbing Sharp Gradients Select the lower gear and start off smoothly Apply power gently so there is no loss of traction by over revving of the engine Choose as smooth a slope as possible and select the appropriate gear so that gear changing in the middle of the climb is not required Changing gears in the middle of the climb can cause loss of momentum and engine stalling Shifting to lower gear has to be done cautiously to avoid
26. arm of combi switch If flasher is shutting off or fuse is blowing off repeatedly the flasher circuit should be checked for short circuit Check the flasher separately for its functioning 88 Fuse box below dash board Relays Relays Engine Compartment RH Engine Compartment LH Care and cleaning of the vehicle When cleaning the interior exterior of the vehicle NEVER USE volatile solvents such asthinner petrol or any other cleaning materials such as bleaches or strong household detergents These materials may be poisonous or flammable and their improper use may cause personal injury or damage to the vehicle Cleaning of vehicle interior Floor mat Dirt can be removed from the mat with water and mild soap Use a brush to help loosen dirt After dirt is loosened wash the mat thoroughly with water and dry itin the shade Seat belt Clean the seat belts with a mild soap and water only No bleach or dye should be used as this may weaken the belt fabric The belts should be allowed to dry in the shade Upholstery Prepare a solution of soap or neutral detergent mixed with warm water Apply solution with a sponge or soft cloth and let it soak fora few minutes to loosen dirt Wipe the surface with a clean damp cloth to remove dirt and soap solution If some dirt still remainson the surface repeat the procedure VEHICLE MAINTENANCE cAREAND CLEANING OF VEHICLE Carpets Remove dirt as much as possibl
27. bocharger 1 Tighten the following fasteners at PDI and thereafter at every U 10 000 km Turbocharger mounting Turbochargerhose connections and its mountings 2 Check intercooler fins for any dust accumulations and clean by compressed air at every 20 000 km if fitted Air in mile 3 It is advisable to run the engine at idle speed for about one mE minute after starting and before stopping the engine This ensures adequate lubricating oil supply to the turbocharger Turbine wheel assembly Oil drain to engine 54 HANDLING POWER STEERING When provided Power steering is fitted for lighter steering effort and easy manoeuvrability The system consists of steering gear box hydraulic pump and hydraulic reservoir suitably mounted and connected by piping Pump drive is through belt from engine Power assistance is available during normal functioning of the power steering system In case of any failure in hydraulic system the steering can be operated mechanically with increased steering effort for bringing the vehicle to a repair station Procedure for oil filling and bleeding the power steering system Ensure that the reservoir is totally cleaned before starting the work 1 Fill the reservoir nearly full Crank the engine for 10 seconds without if possible allowing it to start If the engine does start shut off immediately Check and refill the reservoir Repeat atleast three times each time checking and
28. bsorbers otherwise suspension is likely to be damaged If your vehicle has a turbocharged engine do not stop the engine at once allow it to run at idling speed for atleast 1 minute Also do not 13 10 Dont s accelerate engine till the engine oil pressure has built up Do not cause heating of A C pipe where fitted while welding brazing in its viscinity Do not disturb the fast idling control device actuator setting where fitted Do not open any hose pipe points of A C system where fitted Do not put your hand inside the condenser fan when the grille is removed Disconnect power supply to fan and switch off engine before any maintenance work where applicable LOCATION OF CHASSIS AND AGGREGATE SERIAL NUMBERS HANDLING 1 Chassis number plate 2 Body Shell Cab number Vias F i FIP number MICO Engine number 14 HANDLING LOCATION OF CHASSIS AND AGGREGATE SERIAL NUMBERS Rear axle number Tata Motors Gearboxnumber 15 KEY amp CENTRAL DOOR LOCKING Key Your vehicle comes with two identical keys With this key you can operate 1 Door Locks 2 Steering Lock cum Ignition switch 3 Tail gate Lock 4 Glove Box 5 Fuel Flap lock if fitted It is advisable to keep one of the keys in a safe place for use in case of an emergency A CAUTION Do not use a locally made key but obtain a duplicate through your Tata Motors dealer Do not leave the key inside the car Anti the
29. ch E Suitably as explained Quick Cooling If your car is left in the sun with window closed inside temperature increases To achieve quick cooling effect open the windows briefly while you operate the air conditioner with air circulation switch is in Fresh mode fan at higher speed and air direction towards FACE All vents to be opened completely HANDLING Once temperature inside has come down sufficiently close the windows and change air circulation suitably to fresh recirculation Demisting In rainy season or in areas of high humidity mist formation inside windshield glass is observed To clear mist dehumidified air is passed on the windshield glass The position of control knobs should be adjusted as follows ON Knob B Desired speed position Knob C Towards windshield Knob for vehicles fitted with HVAC at suitable temperature Air circulation at suitable position NOTICE When mist gets cleared switch the knob C position to Face mode In high humidity areas if cold air continues to flow over windshield it may cause sudden fogging on outside surface of windshield AIR CONDITIONING Defrosting For vehicles fitted with HVAC unit In low temperature areas to clear frost formation outside the windshield glass this setting is used First start the engine and accelerate to warm up Knob A Maximum hot position Knob B Very High Knob Towards windshield
30. clutch fluid container is upto maximum level Remove dust cap from slave cylinder bleed screw and clean the screw thoroughly Attach bleeding tube to bleed screw and place other end of tube in a clean glass jar containing sufficient clutch fluid to submerge tube end holding the jar just above the bleed screw level Pump clutch pedal twice or thrice slowly throughout its stroke and by holding clutch pedal in depressed condition loosen bleed screw on slave cylinder Watch for air bubbles in glass jar Retighten bleed screw on slave cylinder and repeat the process until air bubbles cease to appear at the end of tube in glass jar allowing only fluid to flow After completing bleeding operation ensure that bleed screw on slave cylinder is fully tightened Replace dust cap on the bleed screw During bleeding process keep a watch on fluid level in container and top up TI 1 Brake Fluid Container 2 Clutch Fluid Container Bleeding clutch slave cylinder BELT TENSION ADJUSTMENT VEHICLE MAINTENANCE __ Cooling system If engine overheating occurs there could be a fault in the cooling system which may be on account of 1 Less coolant in the system or dirt scale having accumulated inside coolant passages especially in the radiator core Chocking of radiator passages due to foreign material or damages Defective stuck thermostat Loose fan drive belt Coolant leakage from system Always use genuine radiator cap of 1 0
31. d inspection should be carried Use only the genuine company branded oils out at an authorised service outlet 60 HANDLING Engine Coolant Container NOTICE Always use genuine radiator cap only of 1 0 kg cm2 14 psi if required to be replaced 4 Ensure battery electrolyte level is 10 12 mm above top of battery plates Top up with distilled water if required NOT ACID Keep battery terminals clean and tight Apply petroleum jelly vaseline on terminals for protection against corrosion Secure covers provided over terminals Check all lights horn gauges switches and wiper for proper functioning Battery 6 7 61 PREPARING THE VEHICLE FOR THE DRIVE 1 Brake Fluid Container 2 Clutch Fluid Container Check condition and tension of fan belt Adjust tension if necessary Check leakages of coolant fuel and oil at all joints of hoses and pipes and rectify if any If coolant leakages is noticed rectify the leakages and top up radiator also with recommended coolant Check level of brake fluid in pe container Top up if necessary Do not overfill n only genuine company branded brake uid Check level of clutch fluid in plastic container Top up if necessary Do not overfill as this would result in spillage during clutch operation Use only genuine company branded clutch fluid PREPARING THE VEHICLE FOR THE DRIVE 10 11 12 Windshield washer reservoir
32. d request you to acquainted with the details in this owner s manual which will enable you to derive optimum performance from your Tata Sumo Victa DI Turbo We look forward to having you as a satisfied customer and hope to have you retain us as your first choice for any of your motoring needs We are privileged to have you as our customer TATA MOTORS LIMITED FOREWORD Thank you for selecting TATA Sumo Victa DI Turbo vehicle of your choice We welcome you to the world of advanced automotive engineering in a form especially suited to our operating conditions This book gives you all the information necessary for making your ownership of the vehicle a thoroughly satisfying experience To assist you in maintaining your vehicle as per recommended schedule we havea widespread network of dealers and service centres The list is included in this book foryour convenience Should you need any special assistance please call on our Authorised dealer Please note that by adhering to the correct operating procedures and by availing the scheduled maintenance services at our authorised service outlets you can obtain the maximum performance from your vehicle We request you to go through the book and drive many miles of motoring pleasure TATA MOTORS We provide safe high quality high performance vehicles In order to maintain the level of performance and reliability in the vehicle it is important that only Tata motors genuine acce
33. derside of your vehicle This is especially important in areas near chemical and other industries Have corrosion preventive coatings done on the underside of your vehicle using Tata Motors co branded anti corrosive treatment Fuel High speed diesel conforming to IS 1460 2000 or DIN 51601 or equivalent is recommended to be used as fuel At very low temperature fluidity of diesel may become insufficient due to paraffin separation It is therefore necessary to mix supplementary fuel with summer or winter grade diesel The supplementary fuel to be used is kerosene or aviation turbine fuel Ratios for mixing of supplementary fuel and diesel are shown in table Ambient temperature upto Summer Supplementary grade diesel fuel upto 0 0 to 10 10 to 15 50 FUEL LUBRICANTS Ambient temperature upto Winter Supplementary Wc grade diesel fuel upto 15 15 to 20 20 and below Care should be taken that diesel and supplementary fuel are thoroughly mixed before filling Lubricants Recommended lubricants conform to the following specifications 1 SAE 15W40 to API CF4 Engine oil 2 75W90 Synthetic GL 4 Gearbox oils Rear axle and mechanical steering gear box oils 3 APIGL 5 Please use only recommended brands for good performance 91 LUBRICANTS amp COOLANTS The oil change periods recommended in maintenance schedule should be adhered to Use of reclaimed oil is not recommended
34. dicator switch on the combi switch The direction indicator arrow LHS and RHS on the instrument cluster flashes along with external indicator lights as selected High Beam Indicator Symbol lights up when the headlamp high beam is ON When the ignition key is turned to the IGN position symbol lights up and goes off as soon as the required engine oil pressure is developed after starting the engine Turn Signal Low Oil Pressure Indicator If the low oil pressure indicator does not glow or remains ON with the IGN on and engine is running it indicates a fault in the electrical circuit lubrication system Check amp get the problem attended to at an Authorised Service outlet HANDLING Battery Indicator Symbol lights up when the IGN is turned ON and should go OFF after the engine starts NOTICE If it remains ON while the engine is running It indicates that the battery is not getting charged Switch off all unnecessary electrical equipment and get the problem attended to at an Authorised Service outlet Parking Brake Indicator cum Low Brake Fluid Warning Light This indicator has multiple functions as follows e It lights up when the parking brakes is applied and goes off when parking brake is released It also lights up when brake fluid level is low e When ignition key is turned to IGN position this indicator lights up and goes off when engine starts in
35. e Air Filter 74 Coolants 92 Engine Compartment Lamp 41 Cooling System 78 Engine Compartment 72 Environment Protection 6 Indicators Inner Rear View Mirror Instrument Panel Interior Roof Lamps J Jack amp Tools K Key L Lubricants M Manual Window Winding Middle Seat Music System Outer Rear View Mirrors 32 20 29 43 52 16 91 20 Parking Brake 52 Power Socket 48 Power Steering 55 Power Windows 18 Preparing the vehicle forthe drive 60 Priming Fuel System 75 R Recommended Oils Lubricants 93 Replacing Tyre Rim 83 Replacing Tyre Tube 83 S Safety Checks 70 Seat Belt 25 Seats at Rear 24 Service Schedule 100 Spare Wheel 51 Steering Lock Cum Ignition Switch 37 Sun Visors 19 T Tail Lamp Technical Specification Towing the Vehicle Turbocharger Tyre Pressure Tyre Rotation V Vehicle Care Warranty Terms amp conditions Wheel Alignment Wheel Balancing Wheel Change Wheels amp Tyres 42 94 69 54 82 84 89 82 82 82 TATA MOTORS LIMITED Mumbai Pune
36. e by using a vacuum cleaner Rub the stained area with clean cloth made damp with soap to absorb the stain and removethe soap Repeat until the stain is removed You can use commercially available carpet cleaner In this case carefully follow the manufacturer s instructions and precautions Cleaning exterior of the vehicle Dirt or any other foreign material on the painted surface may result in Faded paint Rust on body due to deteriorated paint film Rust dueto scratches Body rust due to contact with damp dirt trapped in the body Therefore it is important that your vehicle is always kept clean and free from dirt in order to maintain the paint in a good condition and to protect the entire body against corrosion Washing When washing the vehicle follow the instructions given below Flush underside of body and wheel housing with pressurised waterto remove mud and debris Use plenty of water to loosen and remove dirt 89 AND CLEANING OF venice VEHICLEMAINTENANCE _ Remove dirt and mud from body exterior with running water Use a soft sponge brush with water Do not use hard material which can scratch the paint Wash the exterior with water lightly rubbing with sponge or soft cloth The sponge or cloth should fre quently soaked in water When using commercial wash products precautions specified by the manufacturer should be observed Do not use strong household detergents or soaps
37. e fuel filter with top cover from mounting bracket Unscrew fuel filter bowl mounting bolt and replace bow with element Replace fuel tank side filter element at specified intervals and FIP side filter element Assemble fuel filter and fit it on mounting bracket Priming fuel system Unscrew fuel lift pump plunger knob Pull and push it 10 14 times Changing Fuel Filter Element 30 40 times if fuel tank has been completely emptied Tighten fuel lift pump plunger knob Start engine and check for smooth running If erratic fuel supply is still felt check for air suction in fuel pipeline from fuel tank to FIP and rectify Priming Fuel System 75 Fan belt tension adjustment Check the conditions of belts on the engine Examine the edge of the belt for cracks or fraying Check the tension of the belt by pushing on it with your thumb for A C compressor belt and Alternator Power Steering belt as shown in figure The belts should have deflection of 8 to 10 mm If the belt tension is not proper get it attended at the nearest Authorised service outlet 76 Der per Pulley Belt Arrangement Engine with AC compressor and power steering pump VEHICLE MAINTENANCE BLEEDING CLUTCH SYSTEM Bleeding clutch system A dry friction single disc diaphragm type clutch has been fitted which is actuated hydraulically The procedure for bleeding the system is as follows a b Ensure that fluid level in
38. e of HVAC rotating In case of only A C the switch D on the A C control panel provided the blower is ON and the engine is running The indicator lamp will show that the A C is ON E A C ON OFF Switch Air Circulation Switch In HVAC version to put air circulation mode in recirculation press switch E The indicator lamp will show air circulation is in recirculation To put vehicle in Fresh mode release switch E Indicator lamp will be OFF In A C version air circulation mode can be selected by pressing knob E In recirculation mode air inside the vehicle is irculated again and again In Fresh mode air is taken from atmosphere and circulated in the vehicle Recirculation mode can be used While driving in dusty condition To avoid traffic pollution To get quick cooling heating as required Whenever discomfort is felt switch air circulation mode to fresh 58 HANDLING NOTICE 1 The A C can be switched ON only if the blower is ON and engine is running When A C is switched ON engine idling RPM increases marginally to adjust to the A C compressor load When desired temperature is achieved A C trips OFF automatically 2 The A C compressor gets switched OFF automatically when engine gets overheated The A C is automatically switched ON when the engine cools down Normal Cooling A C ON Knob B Desired speed position Knob C Towards face Jf Swit
39. eifnecessary 1 Top wishbone 2 Lower 45000km wishbone 3 Antiroll bars4 Rearlinks 5 Panhard rod Clean breatherin Axle 100 OPERATION FREQUENCY 4 Checkshockabsorberitsbushes amp steering damper bushesreplace if necessary 30000km 5 Greasesteering spindle and sleeve 30000km amp Check amp adjustfrontwheel bearing play amp Changegreaseinfronthubs 45000km Checksteering gearboxoillevel amp top up ifnecessary only formechanical steering 45000km i F eur amp BRAKES Ep Ln EN i Li 8 Changeoilinpowersteering system amp changefilter element 75000km 1 2 1 101 Peele pnr Wei DEL Recommended Odometer Repair Servicing Dealer s Recommended Service reading Signature and Service Odometer Repair Servicing Dealer s reading Order Signature and km No Stamp 102 CHASSIS NO Recommended Odometer ir Servicing Dealer s Recommended Service reading Signature and Service 103 Odometer Repair Servicing Dealer s reading Order Signature and km No Stamp A C ACC Amp Br Brg cc Dia EGR FAW Fig FIP gm GVW IGN Kg Km h LH Max MD Min Air Conditioning mkg Accessories mm Ampere Mtg Branch No Bearing Nm Cubic Centimeters PCBU Centimeter PDI Diagonal PSI Exhaust Gas Recirculation PUC Front Axle Weight RAW Figure RCSM Fuel Injection Pump RH Gram RM Gross
40. ended Oils Lubricants 93 TECHNICAL SPECIFICATIONS 94 SPECIAL INSTRUCTIONS 97 SERVICE SCHEDULE 99 RECORD OF SERVICE PERFORMED 102 ABBREVIATIONS 106 ALPHABETICAL INDEX 107 ENVIRONMENTAL PROTECTION TATA MOTORS is committed to produce vehicles using environmentally sustainable technology A number of features have been incorporated in Tata Motors Passenger Car Vehicles which have been designed to ensure environmental compatibility throughout the life cycle of the vehicle We would like to inform you that your vehicle meets Emission norms and this is being regularly validated at the stage of manufacturing As a user you too can protect the environment by operating your vehicle in a pro active manner A lot depends on your driving style and the way you maintain your vehicle We are giving below a few tips for your guidance Driving Avoid frequent and violent accelerations Do not carry any unnecessary weight on the vehicle as it overloads the engine Avoid using devices requiring high power consumption during slow traffic condition Monitor the cars fuel consumption regularly and if it shows a rising trend get the car immediately attended at our Authorised Service Centre Switch off the engine during long stops at traffic jams or signals If the situation demands that engine be kept running avoid frequent revving up of the engine Also avoid frequent stopping and restarting if uncalled for t is no
41. eply Operation should be done at slow speed only If possible get down and check the path conditions before proceeding In case the traction on the wheels is sufficient you may be able to proceed it is better to select the lower gear and proceed in the normal manner To match your power and speed requirements you can shift up in any of the 5 forward gears or the reverse gear NOTICE You may choose to reduce the tyre pressure marginally for additional grip on loose surfaces though with a slight loss of ground clearance e Try to maintain a constant engine speed and avoid sudden acceleration which can cause wheel spin and loss of traction possibly leading to bogging down of the vehicle e ifthe vehicle gets stuck in loose sand do not keep on accelerating as the wheel spin will only result in the wheels sinking deeper DRIVING IN ADVERSE CONDITION 0 5 Driving Through Water Never venture to drive through water when it flows over guard stones Engine may get seriously damaged if attempted to cross over through deep water fatall the situation demands that you have to drive through water then Keep enginein fast idling and crawl the vehicle in low gear After driving through water apply brakes several times to dry liners and to regain original braking Do not attempt to start the engine if vehicle gets flooded due to water Tow the vehicle to a safe place Take the vehicle to nearest AUTHORISED
42. for illumination of the rear registration plate High Mounted Stop Lamp High mounted stop lamp is incorporated on the tail gate from inside and it glows whenever service brake is applied 42 AU N HANDLING High Mounted Stop Lamp Registration Plate Lamp HANDLING INTERIOR ROOF LAMPS Interior Lamps Two interior lamps are provided for convenience While one lamp is situated near the inside rear view mirror IRVM the other is located just above the passenger compartment The individual ON OFF switches are provided to operate these lamps Lamp positions Interior Roof lamp Position Function The lamp will remain ON at all times irrespective of whether any of the doors is open The lamp will come ON only when any of the five doors are opened For GX version In this mode the lamp will come ON only when driver s door is opened For EX version The lamp will remain OFF irrespective of 0 whether any of the five doors are opened 1 Lamp off 2 Door contro mode 3 Lamp on 43 HEAD LAMP LEVELING SWITCH Headlamp Leveling Switch If fitted A motorised headlamp leveling arrangement with the setting knob at the LH side of dash board Asand when required headlamp leveling setting is done by roatating the knob to select one of the level marked in theswitch depending upon the loading of vehicle Loading Condition Switch position Marks assigned Unladen One pers
43. from case and assemble Place the triangle on the road behind the vehicle when it stranded on the road The triangle must be at least 50 meters behind the vehicle in the same lane of traffic ENGINE COMPARTMENT E H E M A N E N A N E ENGINE COMPARTMENT 1 Brake Fluid Reservoir 5 Fuse Box 9 Engine Oil Filler Cap 2 Clutch Fluid Reservoir 6 Air Filter 10 Windshield washer Fluid Container 3 Engine Compartment Lamp 7 Dip Stick 11 Power Steering Fluid Reservoir 4 Battery 8 Radiator Cap 12 Engine Coolant Tank 72 VEHICLE MAINTENANCE cuanaincenaine OIL amp OIL FILTER Changing engine oil Change engine oil in the crankcase at recommended interval Engine oil should be drained while it is hot Unscrew engine sump drain plug and allow oil to drain out fully Changing oil filter Unscrew and remove engine oil filter with the help of special tool if necessary Engine oil filter is a spin on type and cannot be re used Change engine oil filter with every oil change Always use genuine engine oil filter for replacement i La Destroy the oil filter to avoid resale of the same by unscrupulous 1 Engine Oil Filler Cap people Fill the new oil filter with fresh engine oil Smear a little 2 Dip Stick engine oil on rubber gasket of new engine oil filter Hand tighten the filter fully and tighten it a further half turn with a special tool Do not overtighten engine oil filter as this may damage oil fil
44. ft Device if installed This is an electronic car security system with remote keyless operation for door Unlock Lock It immobilises the vehicleby disabling vital circuits related to engine Please refer supplier s instruction manual supplied along with the vehicle for further details of operations and features 16 HANDLING 1 Door opening from outside HANDLING DOOR LOCKING amp WINDOW WINDING Door Locking The front doors can be locked and unlocked from the outside with the key orfrom the inside using the door lock lever In your vehicle the driver s door amp co driver s door if provided have separate locking facilities To lock from inside turn the lever 2 towardsthe innerhinged handle 3 Wherethecentral locking system is provided if you lock unlock the driver door with the key the remaining three doors get locked unlocked at atime The tail gate door is not part ofthe central locking provision To open the doorfromthe outside use the swing handle 1 After unlocking the door with the key pull the swing handle upward The swing handles are provided on each door To open the door from the inside pull hinged handle outward Manual window winding For raising and lowering window glasses use handle 1 4 Window winding Lever 17 POWER WINDOWS HANDLING Power Windows if provided Separate knobs are provided on the switch to operate the four door window glasses indi
45. g to effect its reliability nor shall it apply if in our opinion which shall be final and binding the vehicle is subjected to misuse negligence improper or inadequate maintenance or accident or loading in excess of such carrying capacity as certified by us or such services as prescribed in our Owner s Manual and Service Book are not carried out by the buyer through our sales or service establishments our authorised dealers or service centres or service points WARRANTY 6 This warranty shall not cover normal wear and tear or any inherent normal deterioration of the vehicle or any of its parts arising from the actual use ofthe vehicle or any damage due to negligent or improper operation or storage of the vehicle This warranty shall not apply to normal maintenance services viz oils amp fluid changes head lamps focussing fastener retightening wheel balancing tyre rotation adjustment of valve clearance fuel timing ignition timing and consumables like bulbs fuel filters and oil filters etc This warranty shall not apply to any damage or deterioration caused by environmental pollution or bird droppings This warranty shall not apply to V belts hoses and gas leaks in case of air conditioned vehicle Slight irregularities not recognised as affecting the function or quality of the vehicle or parts such as slight noise or vibration defects appearing only under particular or irregular operations are items 7 8
46. g of headlamps Use only recommended type of bulbs Do not usethehigh beam unlessitis inevitable Its dazzle may glare the driver of the oncoming car thuscausing an accident UnLVINMI INA2 fnUVXII WVS DRIVING SAFETY Increase the distance to 150 meters on a highway or if a bad hill top obscures the view Side indicators Hazard warning Ensure that all side indicators hazard warning lights are always in working condition and they are used when required Horn Ensure proper blowing of horn Horn provides safety to other road users by alerting your presence Brakes Ensure proper working of brakes Check brakefluid level in reservoir Do not drive the car when brake warning lamp is ON Tyres Check the condition of tyres for any abnormalities Maintain correct tyre pressure itis very important particularly when subjected to extreme condition such ashigh speed high load and high outsidetemperature Do not use worn orbald tyresonthefront wheels First Aid Kit First aid kit is provided in your vehicle Thisisforusein caseof minorinjuries It is to be regularly checked for any disintegration and should be updated with the new pure contents Advance Warning Triangle There is an advance warning triangle provided along with your vehicle In case there is a breakdown and the vehicleis parked at the side of road then the triangle is to be kept as per instructions given below Remove advance warning triangle
47. gine output Max torque Compression ratio Firing order Air filter Oil filter Fuel filter Fuel injection pump Governor Engine oil capacity Weight of engine Radiator frontal area TECHNICAL SPECIFICATIONS TATA 497 SP TC 42 BS II 497 SP TC 43 BS III Turbo charged Water cooled Direct injection diesel engine 4 inline 97 mmx 100mm 2956cc 51 5 kw at 3000 rpm as per MOST CMVR TAP 115 116 223 N m at 1600 2200 rpm as per MOST CMVR TAP 115 116 19 1 1 3 4 2 Dry Paper type Spin on full flow paper type Two stage fine filtration Mechanical Rotary type with automatic advance Centrifugal type variable speed Min 5 5 litres 315 kg Dry 2260 sq cm 94 Clutch Type Outside diameter of Clutch lining Friction area Gear Box Type No of gears Gear ratios Rear Axle Type Single plate dry friction diaphragm type 240 mm 527 sq cm approximately G 76 5 4 10 with overdrive Synchromesh on all gears 5 forward 1 Reverse Gear Ratio 1st 4 10 2nd 2 22 3rd 1 37 4th 1 00 5th 0 82 Rev 3 75 Single reduction salisbury type with hypoid gears and Semi floating axle shafts Ratio 3 73 Front Axle Independently suspended Steering Ratio Steering wheel Brakes Service brakes Front Rear Parking brake Frame Type Depth Width TECHNICAL SPECIFICATIONS 18 2 1 420 mm dia 380 mm dia Vacuum assisted independent
48. he rear on the left hand side of the vehicle The fuel filler lid can be opened by using a cable operated lever located on the right of the driver s seat Simply push the lid back to its original position to lock it Note This feature is available only in few versions 49 BONNET OPENING CLOSING FUEL LID OPENING amp GEAR SHIFT LEVER NOTICE Remove the fuel filler cap slowly as the fuel inside may be under pressure and may spray out suddenly causing injury To remove the fuel filler cap turn it anti clockwise Turn the cap slowly to allow any residual pressure to escape In few version the fuel lid can be opened by using key The fuel lid is located on the left rear side of the vehicle Gear shift lever The different gear positions are marked on the knob The 5 th gear an overdrive has been provided to obtain better fuel economy while driving on highways 50 HANDLING Gear Shifting Pattern HANDLING SPARE WHEEL Spare Wheel Spare wheel is mounted below the cab at rear Fitment of spare wheel 1 Place the spare wheel on ground below its location with outer side of the wheel rim facing upwards 2 Locate the retaining plate in the central hole of spare wheel 3 Using the wheel spanner the spare wheel can be raised by rotating the wheel winch screw in anticlockwise direction 4 Align one of the wheel mounting screw hole with the locating pin on frame while raising the spare wheel
49. ing brake lever upto second notch 4 Tighten the parking brake adjustment nut 1 till rear wheels start jamming and cannot be rotated 5 Release the parking brake and ensure that wheels are rotating freely thentighten check nut 2 Operate parking brake a few times to ensure proper operation ENSURE THAT ON RELEASING THE PARKING BRAKE BOTH REAR WHEELS ARE FREE 1 Parking Brake Adjustment Nut 6 Lower down the rear axle 2 Check Nut 7 Remove chocks from front wheels 81 Wheels and tyres Always use only recommended size wheel rims and tyres Use of rims and tyres not recommended by us may have adverse effect on vehicle safety and further more could infringe on motor vehicle regulations Wheel change When changing wheels use the jack provided with the vehicle Jack should be placed below chassis long member behind front wheel for changing front tyres and before rear wheel as shown Wheel alignment If uneven tyre wear is noticed get the vehicle examine and 82 attended by Tata Motors authorised workshop Periodically check and maintain correct tyre pressure to obtain longer tyre life Recommended tyre pressures with cold tyres For 185 85 R16 Tyres At Laden At rated GVW 38 psi 2 6 bar 38 psi 2 6 bar 38 psi 2 6 bar 45 psi 3 2 bar The weight distribution Kerb Weight 1810 kg FAW 990 kg RAW 820 kg For Non AC Kerb Weight 1830 kg FAW 1010 kg RAW 820 kg For AC HVAC Check t
50. itches Power Socket Ash Tray Bonnet Opening amp Closing 25 27 28 29 32 36 37 39 41 35 42 42 43 44 45 48 48 49 CONTENTS Fuel Flap Opening Gear Shift lever Spare Wheel Jack amp Tools Parking Brake Catalytic Converter EGR System Turbocharger Power Steering Air Conditioning Preparing the vehicle for the drive DRIVING INSTRUCTION Driving Instruction Braking Fuel Economy Driving on Snowy or Icy Roads Driving on Sandy or Muddy Roads Driving Through Water Driving on a Rainy Day is 51 52 52 53 53 54 55 57 60 53 64 64 65 65 66 66 CONTENTS Driving at Night Driving Climbing Sharp Gradients Driving Descending Sharp Gradients Towing the Vehicle Driving Safety Safety Checks VEHICLE MAINTENANCE Engine Compartment Changing Engine Oil Changing Oil Filter Engine Air Filter Changing Fuel Filter Element Priming Fuel System Fan Belt Tension Adjustment Brake Clutch System Bleeding Cooling System Brake System Brake Adjustment 67 67 68 69 70 70 72 73 73 74 75 75 76 77 78 79 81 Wheels amp Tyres 82 Wheel Change 82 Wheel Alignment 82 Tyre Pressure 82 Wheel Balancing 83 Replacing Tyre Tube 83 Replacing Tyre Rim 83 Tyre Rotation 84 Headlamps 84 Head Lamp Adjustment 85 Head Lamp Bulb Replacement 86 Bulb Specification 87 Fuses 88 Vehicle Care 89 FUEL LUBRICANTS amp COOLANTS Fuel 91 Lubricants 92 Coolants 92 Recomm
51. kg cm2 14 psi if required to be replaced A proper radiator cap firmly fitted Engine Coolant Auxiliary Tank maintains pressure in the cooling system Prevention of rust formation Use genuine co branded premixed coolant in the cooling system to prevent rust formation and freezing of coolant inside the crankcase passages Fill the engine coolant auxiliary tank upto FULL mark Changing of coolant in the cooling system Drain the cooling system and flush it with clean water Pour the genuine co branded coolant into the radiator until it is full Start the engine Top up the radiator with coolant Fill the auxiliary tank upto FULL mark Ensure no leakage in the system Ui UN 78 VEHICLEMAINTENANCE o Brake system The dual circuit service brake system operated through the tandem master cylinder is designed such that one circuit will continue to provide braking action if the other circuit fails This vehicle is fitted with disc brakes at front and drum brakes at rear Stopping the vehicle after loss of the brake fluid in one circuit will require more pedal pressure and pedal travel than normal Also stopping distance will be longer Service brakes are vacuum assisted In case of failure of vacuum the vehicle can still be stooped however with a higher effort Bleeding the brake system If the brake pedal becomes spongy this may be due to air in the hydraulic brake system
52. l Economy A Drive smoothly accelerate gradually and anticipate stops Best fuel consumption is obtained at low engine speeds the highest possible gear without labouring the engine Driving with accelerator pedal fully depressed means using excessive fuel Do not allow the engine labour by too early high gear changes Change to lower gear when engine no longer runs smoothly E If possible do not idle the engine for more than 5 minutes Switch off the engine F Do not ride the clutch Do not use clutch pedal as foot rest G Depending on traffic conditions a constant speed should be maintained The vehicle uses more fuel every time you speed up or slow down H Hard braking abrupt cornering and rapid acceleration use more fuel Avoid these Driving on Snowy or Icy Roads Select the lower gear Gently release the clutch and apply the accelerator for a smooth start and to avoid wheel spin CAUTION Use of snow tyres and or tyre chain is recommended Maintain a safe distance between vehicles to avoid sudden braking and slow down by shifting down the gears Avoid sudden acceleration braking or turning Such sharp manoeuvres can cause loss of traction and thereby loss of vehicle control DRIVING IN ADVERSE CONDITION Driving on Sandy or Muddy Roads The extent of muddy sandy conditions and the traction available is difficult to judge and the vehicle can get bogged down de
53. ngine at idling speed for atleast a minute after starting and also before stopping it to protect the turbocharger against damage due to oil starvation Do s FRIENDLY NOTES Where Air conditioning system is 6 During off season operate the air installed conditioner a few times every month eer to lubricate components 1 After parking in the sun drive with windows rolled down for a few minutes to blow off hot air before switching on A C 2 Keep all windows rolled up when AC system is working J 3 During stop and go city driving use lower gears to obtain efficient O S cooling 4 f you feel irritation in the eyes due to smoke or during long drive stop A C and ventilate for half a minute by winding down door glasses or use fresh air mode provided with HVAC system 5 Before stopping the engine first switch OFF A C and then the blower 12 FRIENDLY NOTE Dont s e S Do not use Clutch Pedal as Foot Rest This will reduce clutch life Do not Coast vehicle in Neutral and engine switched off position This is a safety hazard Do not run engine without Radiator Cap Use genuine Cap only to keep system pressurised Do not overtighten engine oil filter Front and rear suspension shock absorbers fitted on this vehicle have in built rebound stopper There is no separate rebound stopper fitted on the vehicle Hence do not drive the vehicle either without shock absorbers OR with non genuine shock a
54. normal condition If it continueously ON while engine is running get the problem attended to an Authorised Service Outlet INDICATORS Seat Belt Indicator E The indicator initially flashes when the ignition is ON and seat belt is not fastened It will continue to flash until the vehicle exceeds a speed of 20 kmph After that it will remain continuously ON accompanied by a buzzer that will buzz approximately for 100 seconds After that the buzzer goes OFF but the indicator continues to remain ON This indicator lights up when the IGN is switched ON and goes OFF after a few moments automatically depending on the engine temperature indicating readiness to crank the engine NOTICE Do not crank the engine until this light goes OFF The duration of ON time varies with engine block temperature and it glows for longer duration with a cold engine Glow plug Indicator 33 INDICATORS Odometer and Trip meter on LCD The odometer records the total distance the vehicle has been driven The trip meter can be used to measure the distance traveled on each trip or between fuel fillings Keep track of the odometer reading amp follow the maintenance schedule regularly for meeting service requirements Odometer Trip meter and Illumination intensity control on instrument panel LCD The instrument panel has an LCD to display the following Main Odometer Non resettable Counts up to 999999 kms Trip meter A
55. ny one of the split can be folded by releasing the latch on the backrest simultaneously Fig 1 on next page For more luggage space or to access front facing third row seat the folded middle seat can be somersaulted further For fixing the rear seat back upright just push back the seat in position It will get locked by itself 22 HANDLING Middle seat HANDLING Middle seat 60 40 Folding w Press the knob and pull the seat to its position m Rear jump seat Total luggage space where front facing seat is removed amp middle seat folded 23 SEATS Luggage space where rear jump seats are folded SEATS Seats at rear Two rows of seats single or double are provided at rear for passengers Fig 4 on previous page These seats can be folded for carrying bulkier baggage as per procedure given below 1 seat squab and hold against backrest 2 Engage strap with the hook on seat squab 3 Fold the seat stand To open the seats follow the reverse order Ensure stand is fully opened and vertical to the floor Front facing rear seat folding operation For folding back pull the strap as shown in figure Lift the lever and fold the seat further to get maximum luggage space HANDLING Front facing third row seat Optional The foldable and detachable type soft cushioned comfort able bench seat has been provided at the rear Fig 3 on previous page For folding back a sea
56. o provided on co driver s door Inner Rear view mirror Inner rear view mirror is also fitted inside the cab between sun visors In few versions an additional adjustable anti glare rear view mirror is provided inside the cab Provision has been made for two positions 1 Normal position 2 Anti glare position Use anti glare position only if necessary as it reduces the rear view clarity considerably 20 HANDLING 1 Inner rear view mirror 2 Operating Knob HANDLING Driver s amp Co driver s seat Adjustable type seat is provided for driver and co driver The driver seat is fitted with lever and handle to adjust the seat The seat can be adjusted in forward and backward directions In few versions both seats are also provided with lumbar support 3 to give you maximum driving comfort To achieve correct position for proper driving lift the handle 2 and slide the seat either forward or backward Once the desired position is achieved push down the handle to lock the seat Turn the lever 1 to adjust backrest to the desired position Release the lever to lock it Do not adjust seat while driving 21 1 Seat backrest inclination adjustment lever 2 Seat sliding forward amp backward lever 3 Lumbarsupport adjustment knob SEATS Middle seat A cushion bench seat has been provided for the middle passengers In few versions a cushion bench 60 40 split seat has been provided for the middle passengers A
57. olyte level Keep battery terminalsclean and cable joints tight Apply vaseline petroleum jelly on terminals Use distilled water only for topping up Observe correct polarity when connecting battery terminals FRIENDLY NOTES Do s 12 13 1 P 1 16 17 18 Disconnect alternator terminals while carrying out any welding on the vehicle Avoid panic braking Use lower gears while descending gradients Start the vehicle always in the 1st gearto avoid premature clutch wear Keep both foot and parking brakes properly adjusted Before engaging reverse gear ensure that vehicle has come to a stop declutch wait fora few seconds and shift into reverse gear When parking on slopes use wheel chocks apply parking brake and keep vehicle in low gear In case of emergency parking or breakdown on road push the hazard warning switch to flash all the blinker lights to warn other road users 11 19 20 21 22 23 24 25 Do s Release parking brake before driving off Release the ignition key as soon as engine starts Retighten wheel mounting nuts after 100 km of every wheel change Tightening Torque 12 15 mkg Use only recommended FUSES and always keep spare fuses in the box In case of engine not starting first check the fuse of fuel injection pump solenoid Ensure doors are properly closed If your vehicle has a turbocharged engine keep e
58. on in Driver seat Driver Co Driver Driver Co driver all the Seats farthest to rear occupied All the seats occupied Laden All seats occupied Luggage in boot space to achieve permissible load on the rear axle Driver Evenly distributed load in the boot to obtain permissible load on corresponding axle Since the leveling switch takes care of focus patern under different load conditions it is advisable to select the correct position before starting a trip depending on load 44 HANDLING Headlamp Levelling Switch HANDLING ACCESSORY SWITCHES There are six 6 operating switches provided on the centre console of your vehicle s dashboard just above the Music System Rear Windshield Demister Push the operating switch on the fascia to turn the demister ON The demister will switch off automatically after 15 minutes NOTICE Clean the windshield glass carefully from inside to avoid any damage to demister heater element Rear Fog lamp unlatched switch The fog lamps are provided on rear bumper to improve the visibility and warning in foggy weather or during heavy rains The rear fog lamps can be switched on with parking lamp and front fog lamps ON and can be remain ON till the parking lamp is switched OFF The rear fog lamps can also be switched ON even if only headlights are ON NOTICE Use only during foggy conditions or heavy rains if required ACCESSORY SWITCHES ACCESSORY SWITC
59. on switch To locksteering while parking the vehicle as safety against theft Tostartand stop theengine To switch ON and OFF the electrical system other than listed below Horn parking lamps engine inspection lamp and hazard warning indicators are not connected through this switch and operate independently To switch on and off the accessories only The switch is located on the steering column support and has the following key positions LOCK Key can beinserted ortaken out only in this position Steering gets locked only after the key is withdrawn from the switch After withdrawing the key from the switch ensure that steering is locked by turning steering wheel clockwise and anticlockwise To unlock the steering insert the key into the switch and turn it clockwise If any difficulty arises in unlocking tum the steering wheel alittle clockwise or anticlockwise while turning the key ACC By turning the keyto ACC position power supply to accessories is switched ON 37 STEERING LOCK CUM_IGNITION SWITCH Steering Lock Cum Ignition Switch STEERING LOCK CUM IGNITION SWITCH ON By turning the key to this position all remaining electrical systems become operative and lamps of battery charging indicator low oil pressure will come ON In ON position the glow plug controller switches ON the glow plugs and glow indicator lights up After a few seconds depending
60. orewnaterdemng Bey _ CheckAllaccessory Drivebelts adjusttension if required changeif damaged tmmwarnwdg 5 Umw eris 6 Changefuelfiter1st amp 2nd Every30000km 7 Lubricatewater pump with grease 8 Check amp adjust valve clearance Every 15000 km 9 Replaceairfilter element ORifRED band appears on Servicelndicator 45000km 99 tT tT 1 1 LJ eerie ie Tee OO OO Reese eiee LL IH EEREIC Ese ra ep pe pe ENERERERERERENEE Ee e e OPERATION FREQUENCY ef CheckAll accessory Drive belts adjusttension ifrequired changeif damaged zoom S o Change vacuum hosesfotr Vacuum Modulator Turbocharger EGR valve amp throttle valve 60000km GER BOX ee f roeines T SHAT Grease propeller shaft with grease gun at slip joint splinesend amp CheckCentre bracketmounting 15000km boltsforlooseness Tighten if necessary E _ __ T eR MES Ea Change olin axle Firstat 15 000 KM thereafter every 75 000 KM 75000km 2 Change greasein rear hubs amp adjust bearing play only for TMLaxle 45000km SUSPENSION amp STEERING oot Grease idler arm seal type idler arm 15000km Checkwheel alignment amp balancing adjustif necessary 15000km 3 Checkcondition ofrubberbushesin thefollowing amp replac
61. orised Dealer s TASC s TASP s Workshop for servicing All our Authorised Dealer s TASC s Workshops have been equipped with special tools and are manned by technical personnel trained by us Besides they have adequate stocks of genuine spare parts for replacement purposes should the need arise Our Authorised Workshops are therefore in a position to render you any expert advice and service your vehicle may need Please give them an opportunity to serve you so that you may obtain economical and trouble free performance from your vehicle For any technical advice concerning your vehicle please contact the nearest Authorised Dealer 98 FREQUENCY IN km a OPERATION GENERAL Wash the vehicle amp Clean the condenser with compressed air Check amp Top up Fluids if required Coolant Brake Clutch Fluid Battery Electrolyte Power Steering Oil Gear Box Oil Transfer Case amp Front Axle 4X4 Rear Axle Oil Check Engine Compartment for loose Fasteners Low pressure fuel lines Coolant hoses air hoses Vacuum hoses hydraulic line connections forleakagesif any Attend if necessary el CheckUnderbody forloose Fasteners hydrauliclineconnections Exhaustsystem Fuel Pipesfor Damages Leakagesif any Attend if necessary Applygreaseon doorlatches doorlock doorcheckstop striker bonnetopening lever amp lockplate tailgate hinges amp doorlockinner ratchet y 1 GemsrdemertreementChengefredbandappeasonsecemde
62. ot fall low enough to cause air to be drawn into the hydraulic system Maintain absolute cleanliness The brake system must be kept entirely free from petrol kerosene or any form of mineral oil as mineral contamination spreads rapidly in the hydraulic system causing dangerous deterioration of the rubber seals Never under any circumstances use the fluid which has been bled out from the system to top up the container It may be aerated have too much moisture content and or is contaminated Always use recommended brand of brake fluid As brake fluid absorbs moisture from the atmosphere we recommend changing of brake fluid in the system annually Take care to see that the brake fluid is not spilled on the paint work 80 1 VACUUM PUMP 2 VACUUM BOOSTER 3 TANDEM TER CYL NDER 4 FRONT DISC BRAKES 5 REAR WHEEL CYLINDER OF DRUM BRAKES X Brake Fluid Container __VEHICLEMAINTENANCE J S AA Brake adjustment The front wheels are fitted with disc brake and rear wheels are fitted with drum brakes Both these brakes are self adjusting therefore need no adjustment In case you find brake pedal going down excessively while applying the brake please contact our authorised service outlet Adjustment of parking brake Ensure that all four rear brake shoes have been properly adjusted 1 Put chocks on front wheels 2 Jack up the rear axle 3 Loosen check nut 2 Pull park
63. peater Side Panels 2 Front Fog Lamps Front Bumper 2 Rear Fog Lamps Tail lamp 2 Roof Lamp Cab Roof Engine Compartment Lamp Engine Compartment 1 Tell Tale Symbols Turn indicators Instrument Panel 2 Oil Pressure 1 Battery 1 Low Brake fluidl Parking brake 1 Seat Belt Fasten 1 Door Ajar 1 High Beam 1 Diesel Preheat 1 Position Lamps 1 Immobiliser High Intensity LED Fuel Reserve Indicator T5 1 87 ruses CMMI CLE MAINTENANCE _ Fuses In orderto protect the cable harness and other equipments from damage in case of short circuit and overloads fuse links are provided in the fuse box In case of a fault in the electrical system check the respective fuse The particulars of the consumers served by each fuse and amperage are printed on the fuse box cover The fuse link can be identified for amperage by color codes 1 Fuselink Red 10 Amps 2 Fuse link Blue 15 Amps 3 Fuselink lightbrown 5 Amps 4 Fuse link Yellow 20 Amps 5 Fuse link White 25 Amps 6 Fuse link Green 30 Amps 7 Fuse link Orange 40 Amps While fitting fuse box cover ensure that cover knob rests in the slot provided inside the fuse box Spare fuse links are provided inside the fuse box Always use fuses of correct rating Do not use wire in place of fuse Flasher with short circuit protection If flasher circuit is short circuited or overloaded more than 110 W flasher willshut off It can be reset by momentarily centering the indicator
64. r 2 Our obligation under this warranty shall be limited to repairing or replacing free of charge such parts of the vehicle which in our opinion are defective on the vehicle being broughtto usorto ourdealers within the warranty period The parts so repaired or replaced shall also be warranted for quality workmanship but such warranty shall be co terminus with this original warranty Any part which is found to be defective and is replaced by us under the warranty shall be our property As for such parts as tyres batteries amp electrical equipment fuel injection equipment power steering equipment A C equipment amp anti theft device not manufactured by us but supplied by other parties this warranty shall not apply but buyers of the vehicle shall be entitled to so far as permissible by law all such rights as we may have against such parties under their warranties in respect of such parts Our Dealers TASC s will assist the purchaser in taking up the complaint with the WARRANTY respective manufacturers and their decision on the warranty will befinal This warranty shall not apply if the vehicle or any partthereof is repaired or altered otherwise than in accordance with our standard repair procedure or by any person other than our sales or service establishments our authorised dealers or service centres or service points in any way so as in our judgement which shall be final and bindin
65. rack rear 1461 Option II Driver 8 Overall Length 4258 Max width 1700 Front Overhang 827 Rear Overhang 1006 over rear foot step Overall height 2010 1925 Unladen laden Min turning circle dia 100m Min turning clearance 111 circle dia Ground clearance laden 190 96 1 The vehicle has been built to give you thousands of kilometers of economical and trouble free performance This is however possible only if this vehicle is systematically maintained and operated strictly according to the instructions contained in this book The free services should be availed of at the following km range within 18 months 1 Free Service At 1000 1 500 km or 1 month whichever is earlier At 15 000 15 500 km or 12 months whichever is earlier At 30 000 30 500 km or 24 months whichever is earlier At 45 000 45 500 km or 36 months whichever is earlier Besides the service schedule chart detailing the service operations to be performed Service Coupons perforated are incorporated These coupons should be detached and sent to Customer Support Passenger Car Division Tata Motors Pune 411 018 by the servicing dealer after the service is performed The selling dealer should fill up details of chassis particulars on the inside cover page 2 d Free Service 3 Free Service 4th Free Service 4 97 These services be satisfactorily performed only by one of our Authorised Dealers T
66. refilling the reservoir 2 Check for any leakage in the system and if noticed take corrective action 3 Start the engine and steer the vehicle from full left to full right turn 3 4 times Add fluid if necessary to maintain the level up to the filter top 4 With the engine at steady speed check for bubble foaming in the fluid If present it indicates that air is getting sucked into the system 5 6 POWER STEERING Check the suction line fittings and correct if necessary Once the system is bled properly and free from foaming there should not be appreciable change in fluid level in the reservoir when the engine is started stop repeatedly Top up or remove excess fluid so that the final level is at H mark on dipstick Now the system is ready for driving N CAUTION Do not allow the fluid level to drop significantly or run out ofthe reservoir during the above operation This may induce airinto the system Do not start the engine without fluid in the power steering system This will result in serious damage to the pump NOTICE Always use recommended brand of fluid from closed containers Any dirty fluid poured in the system will result in damage to pump gear POWER STEERING HANDLING Power steering pump belt tension Check RED Check the conditions of belts on the engine Examine the edge of the belt for cracks or fraying Check the tension of the belt by pushing on it with your thumb Alte
67. rnator Power Steering belt as shown in Figure The belts should have deflection of 8 to 10 mm X If the belt tension is not proper get it attended at the nearest Authorised service outlet 56 HANDLING HEATING VENTILATION amp AIR CONDITIONING if installed A Temperature Control Knob The air temperature in the car can be controlled by operating the temperature control knob A at the left hand side of the control panel The temperature can be increased by rotating the knob towards the red segment and decreased by rotating it towards the blue segment B Blower Speed Regulation Knob The ventilation system has a three four speed blower The blower speeds can be regulated to any one of the following speeds by operating the knob B at the centre of the control panel LOW MEDIUM HIGH VERY HIGH C Air Direction Control Knob The air flow can be changed by turning the switch C to the desired direction P Towards face pf Towards face and feet gpl Towards feet Ge Towards feet and windshield Recommended for Op clearing fogging on windshield Gm Air demist defrost windshield Recommended for clearing heavy fog and snow AIR CONDITIONING 57 H V A C Controls A Temperature Control Knob B Blower Speed Regulation Knob C Air Direction Control Knob D AC ON OFF Switch E Air Circulation Switch AIR CONDITIONING D The A C can be switched ON by pressing In cas
68. shown in figure on the following page Adjusting head lamps focus with the help of screen The vehicle should be parked 10 meters away from screen with its centre in line with central vertical line on screen and screen at right angle to longitudinal axis of the vehicle The vehicle should be in unloaded condition with no sag in suspension springs and all tyres equally inflated On the marked up screen as shown in figure area above horizontal and inclined lines shaded is called Dark zone and the area below it is called The illuminated zone CENTRE LINE 4000 CHEER SCREEN FOR LEFT HAND TRAFFIC CENTR E LINE OF BULB Each headlamp is aligned individually by masking the other headlamp Headlamp is first adjusted for proper height of low beam by adjusting knob at itstop Light from low beam should fall below horizontal and inclined lines No light should fall above these linesi e in Dark zone Thereafter lateral adjustment is done by adjusting knob at bottom of headlamp so that contour of low beam coincides with contour formed by horizontal and inclined lines below Dark zone When properly adjusted most brightly illuminated area will be just below the intersection point A of these two lines The Second head lamp is adjusted in a similar manner OF VEHICLE OF BULB without disturbing the position of the vehicle and the screen Now switch ON high beam They will be symmetrical above points
69. ssories are to be fitted Any accessory that is fitted or modification that is carried out without authorisation can hamper the safety and performance of the vehicle besides depriving you of your warranty benefits Use of genuine parts designed and manufactured to our exacting standards are the best way to maintain your vehicle in peak operating condition Please do not use substitutes They always prove costlier in the long run Failure to use genuine parts can invalidate any future warranty claims The information and specification given in this book are valid as on the date of printing Tata Motors reserves the right to make changes in design and specifications and or to make additions to or improvements in this product without obligation to install them on products previously sold FOREWORD ENVIRONMENT PROTECTION WARRANTY TERMS amp CONDITION DO S DONT S AGGREGATE NUMBERING HANDLING Key Anti theft Device Door Locking Manual Window Winding Power Windows Sun Visors Outer Rear View Mirrors Inner Rear View Mirror Driver s Seat Middle Seat Seats at Rear 3 6 8 10 13 14 16 16 17 17 18 19 20 20 21 22 24 Seat Belt Head restraint Driving Controls Instrument Panel Indicators Gauges Steering Lock Cum Ignition Switch Combi Switch Music System Engine Compartment Lamp Hazard Warning Switch Tail Lamp High Mounted Stop Lamp Interior Roof Lamps Headlamp Leveling Switch Accessory Sw
70. t necessary to rev up the engine before turning it off as it unnecessarily burns the fuel Shift to higher gears as soon as possible Use each gear upto 2 3rd of its maximum engine speed A chart indicating gear shifting speed is given in this book Maintenance of the vehicle Ensure that recommended maintenance is carried out on the vehicle regularly at our Authorised Service Outlets As soon as you see any leakages of oil or fuel in the car get it attended immediately Use only recommended brands and grades of lubricants and clean uncontaminated fuels Get your vehicle checked for emission periodically by authorised dealer and regularly renew the P U C certificate Ensure that fuel filter oil filter and breathers are periodically checked and if required replace the same by only genuine Tata Motor s recommended brands Do not pour used oils or coolants into the sewage drains garden soil or open streams Dispose the used filters and batteries in compliance with the current legislation Do not allow any unauthorised person to tamper with engine settings or to carry modifications on the vehicle Never allow the vehicle to run out of fuel Parts like brake liners clutch disc should be vacuum cleaned Do not use the compressed air for cleaning these parts which may spread the dust in the atmosphere While carrying out the servicing or repairs on your vehicle you should pay keen attention
71. t pull strap has been provided be hind seat back as shown in Fig 1 For detaching seat operate two levers provided over wheel house area Fig 3 pus For detaching seat operate two levers provided on wheel house area and pull it out HANDLING SEAT BELT The vehicle has been fitted with three point belt for extra safety for driver co driver and passengers on middle seat If not fastened with key in IGN position audio alarm only for GX and visual indication is given on instrument panel Fastening the belt Insert belt tongue into buckle a positive locking click indicates correct and safe assembly Releasing the belt Press the release button the tongue will be ejected clear of the locking mechanism within the buckle Belt adjustment When the vehicle is at rest adjust the length of the belt to suit convenience Insert belt tongue in buckle A positive click indicates correct assembly Adjust length of the belt to suit you and fasten The lap section should be comfortably tight the diagonal sections should be adjusted so that a flat hand will pass between the chest and the strap To tighten shorten the belt Pull free end of webbing through adjuster until required adjustment is achieved To loosen lengthen the belt Tilt the adjuster by means of the grip and slide it along the strap until suitably adjusted SEAT BELTS Aik 1 Seat Belt 2 Tongue 3 Lock Buckle 4 Lap Belt 1 i I
72. ter and oil may leak out Before filling in fresh oil in the engine refill the sump drain plug using new sealing washer Tighten drain plug to 4 mkg torque Fill in specified quantity of fresh engine oil in the engine crankcase Start engine and run for a few minutes Stop the engine and re check oil level after approx 20 minutes Top up if oil level is less than midway between upper and lower marks on the dipstick Engine Oil Filter 73 AIRFILTERS FUELTANK VEHICLE MAINTENANCE _ Engine Air Filter Periodically clean air filter element and replace it with a new one when air cleaner service indicator shows red band even after cleaning the air filter element or at 40 000 km in clean condition or 25 000 km in dusty condition Always use genuine air filter element Remove the cover and the filter element Clean it gently by tapping and rolling on a table Clean the cover and air ducting Check the element for puncture and pin holes by a light source If found okay refit the filter element and the cover Reset service indicator by pressing rubber cap red band will disappear from service indicator On starting the engine if service indicator continues to show red band replace the paper filter element with new one and reset the service indicator Service Indicator 74 _VEHICLE MAINTENANCE 6 rur furer ann FUEL system Changing fuel filter element Unscrew drain plug and drain fuel from fuel bowls Remov
73. ter first 100 km of running of a new vehicle and after every wheel change Driving Tips DRIVE SAFELY AND JUDICIOUSLY REMEMBER SAFETY FIRST Depress clutch pedal fully before shifting gears This will ensure longer synchro cone life Forsmooth starting of vehicle without jerks synchronise release of clutch pedal with pressing of accelerator pedal Start the vehicle in first gear only Change gear at appropriate speed and do not lug the engine by too early shifting to higher gear at low speeds Recommended speeds for gear changes Ist to 2nd 2nd to 3rd 3rd to 4th Ath to 5th Engage reverse gear only when vehicle is stationary Depress clutch pedal fully before engaging the reverse gear Wait for a few seconds then engage the gear If gear shifting does not occur then release the clutch pedal once again press the clutch pedal and engage the reverse gear Braking While braking on turns apply brakes gently Before driving down along steep gradient reduce vehicle speed by changing to lower gear Do not ride the brakes as they may overheat and their performance may be impaired Do not use half engaged clutch to hold the vehicle on up gradient as this will result in premature clutch failure After driving through pockets of water apply the brake a few timesat low speed to get rid of moisture inside the brake drums When it beings to rain reduce vehicle speed and avoid sudden braking Fue
74. to some of the important aggregates which greatly affect emission These components are 1 Fuel injection pump Injectors Nozzles 2 Air intake amp Exhaust system especially for leakages 3 Cylinder head for valve leakage 4 All filters such as air oil and fuel filters check periodically 5 Turbocharger and intercooler if fitted 6 Catalytic converter if fitted 7 EGR System and components 8 Electrical Connections for EGR ENVIRONMENTAL PROTECTION This Owner s Manual contains further information on driving precautions and maintenance care leading to environment protection Please familiarise yourself with these aspects before driving TERMS AND CONDITIONS We WARRANT each TATA SUMO VICTA DI TC vehicles amp parts thereof manufactured by us to be free from defect in material and workmanship subject to the following terms amp conditions 1 The warranty for the rest of the vehicle shall be for 18 months from the date of sale of the vehicle irrespective of the distance covered However for the cars used for commercial applications including those used for hire or reward viz those operating with a yellow number plate the warranty shall be limited to 18 months or 50 000 kms whichever occurs earlier This warranty for the engine Tata 497SP fitted in the vehicle shall be for a period of three years from the date of sale of the vehicle or 3 00 000 kms of its running whichever occurs earlie
75. to use Diesel fuel with sulphur content less than 0 25 Use of any other diesel fuel can increase the pollutants WARNING Avoid parking the vehicle over inflammable materials such as dry leaves grass etc asthe exhaust system is hot enough to initiate FIRE TAKING CARE OF ENVIRONMENT Your vehicle is equipped with the EGR Exhaust Gas Recirculation System EGR System The 497SPTC engine has an Exhaust Gas Recirculation system comprising of EGR valve EGR Tube Vacuum hoses Electroneumatic switch Potentionmeter on FIP throttle lever EGR control unit and associated electrical circuitry With this controlled amount of exhaust gas is mixed in air intake of the engine which helps in reducing harmful pollutants 53 TURBO CHARGER IF FITTED HANDLING Turbocharger Turbocharger is an efficient supercharging device used in our engine It makes use of thermal energy of engine exhaust gases to run a turbine which in turn drives a compressor to force air under pressure into the inlet manifold Lubrication of Turbocharger The rotor assembly of the turbocharger is supported by two floating lead bronze sleeve bearings in the bearing housing These bearings are lubricated with the linest filtered and cooled oil from the lubrication system of the engine There isa heat shield arrangement provided between the gas chamber of the turbine and the bearing housing to avoid heating of the bearings fone ending Maintenance of Tur
76. vacuum for the brakes g e In case of brake failure use parking brake to control the vehicle RearTowing Hook DRIVING SAFETY Seat Belt Seat belts are life saving equipment use of seat belt reduces the chance of injury and severity of injury in case of an accident It is strongly recommended that all the caroccupants should always wear seat belt while carisin motion Influence of Alcohol Avoid driving under the influence of alcohol or other drugs Alcohol and drugs will severely impair your control of the vehicle and increase the risk of injury to yourself and others Non use of mobile phones Avoid using mobile phones while driving a car This could divert your attention from road and result into an accident Fatigue Rest Revive survive Do not attempt driving when you feel tired sleepy long distance driving can tire you very much and fatigue can dull your reflexes and judgment Take a break and get refreshed at intervals SAFETY CHECKS Windshield wiper windshield washer Always keep windshield glass clean to avoid any distraction in visibility Ensure properworking of wipersand condition of wiper blade Ensure that windshield washer reservoiris full Do not operate wiperalone when the windshield glass isdrythiswould damagethe windshield Headlights Keep headlight lenses clean Check for operation of headlamp in both high low beam condition Check for correct focusin
77. vidually To open the door window glass push the respective knobs down To close the door window glass pull the respective knobs up In the lock position the rear window switches become inoperative However the rear windows can be operated by the switches on the console Illumination on rear window switches goes OFF in locked position press down the lock button to unlock Individual window winding switches have been provided only on the Switches on the central console rear doors for operating the door glasses Front Left Front Right Rear Left Rear Right Push type 4 Lock Unlock or T E Switch Individual Switches on the rear doors for operating the rear door glasses 18 HANDLING SUN VISORS Sun visors Two adjustable sun visors are provided inside the cab to prevent sun glare Lower the sun visors to protect the eyes from bright sunlight The sun visors also moves sideways towards the door A vanity mirror has been provided on the co driver s sun visor Sun Visors Vanity Mirror 19 OUTER amp INNER REAR VIEW MIRRORS Outer Rear view mirrors Outer rear view mirror is fitted on the driver s door from the outside It can be adjusted to the desired positions by hand In few versions it can be adjusted by the lever provided inside the door The mirror can be folded backwards for convenience when the vehicle is to be driven through narrow passages In few versions the same rear view mirror is als
78. y change or modification in the design of the vehicle or its parts or to introduce any improvement therein or to incorporate in the vehicle any additional part or accessory at any time without incurring any obligation to incorporate the same in the vehicles previously sold TATA MOTORS Do s Do s Clean air filter FRIENDLY NOTES Use recommended oils and lubricants only Change oil in engine gear box steering system and rear axle at prescribed intervals Use only genuine oil filter and fuel filter elements Replace them at regular intervals element regularly Replace filter element when service indicator shows red band even after cleaning the filter element Ensure periodic servicing as per maintenance schedule Insist on use of genuine spare parts Ensure that caps of auxiliary tank and radiator are firmly fitted to keep the cooling system pressurised and to maintain coolant level Always use genuine radiator cap 10 8 10 1 only of 1 0 kg cm 14 PSI for replacement Check tyres for damage from time to time and remove any foreign bodies embedded in treads In case oftyre replacement or repairs due to puncture have the wheel balanced Keep grease oil and fuel away from the tyres In case of uneven tyre wear get the vehicle attended to by any of our authorised service set ups Maintain correct tyre pressure B Check battery every week and top up electr
79. yres for damage from time to time and remove any foreign bodies nails stones metal chips etc embedded in treads While fitting wheels on the vehicle make sure that wheel bolts are free from dust scratches dirt dents etc Do not oil wheel bolts and nuts Wipe off any adhering oil on bolts nuts Tightening torque of wheel nuts 12 15 mkg Retighten wheel nuts after 100 km of every wheel change New tyres do not give maximum grip straightway and should therefore be run in at moderate speed for the first 100 km This will help to make the tyres last long To avoid damage to tyres and wheels drive slowly over speed breakers bumps rough roads Wheel balancing Wheels of your vehicle are balanced The same should be maintained when repairing a tyre or tube and replacing the tyre or rim Repairing a tyre tube Mark suitably the tyre position If original colour dot mark is not visible with respect to valve stem hole to ensure that tyre is refitted in original location Ensure that the balancing weights are not disturbed during removal of tyres Check the balance weight prior to removal of tyre if found loose mark its location on the rim and refit properly _VEHICLE MAINTENANCE O0O wae amp s AND tyres Replacing a tyre rim When the tyre or rim is changed the wheel should be properly balanced on a machine after inflating to the specified value as per the following norms 1 Permissible imbalance for tyre with rim

TATA Sumo Victa Di Turbo Owners Manual and Service Book - Team-BHP

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