TATA Motors Sumo Gold CR-4 Owner's Manual & Service Book

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TA T T T T T A SUMO GOLD
TA
TA
TA
TA
CR-4 (BS-IV) & 4SPTC (BS-III)
Owner's Manual & Service Book
The contents given in this book are not binding, subject to change without notice and are for illustration purpose only.
A SUMO GOLD
A SUMO GOLD
A SUMO GOLD
A SUMO GOLD
Mumbai
Pune
1

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Summary of Contents for TATA Motors Sumo Gold CR-4

  • Page 1 TA T T T T T A SUMO GOLD A SUMO GOLD A SUMO GOLD A SUMO GOLD A SUMO GOLD CR-4 (BS-IV) & 4SPTC (BS-III) Owner’s Manual & Service Book • • • Mumbai Pune The contents given in this book are not binding, subject to change without notice and are for illustration purpose only.
  • Page 2 You are also entitled for : • 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).
  • Page 3 DO YOU KNOW ? Dear Customer, Thank you for choosing the Tata Sumo Gold another quality offering from the company’s growing range of passenger vehicles. We would request you to get acquainted with the details in this owner’s manual, which will enable you to derive optimum performance from your Tata Sumo gold. 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.
  • Page 4 DO YOU KNOW ?
  • Page 5: Foreword

    The information and specification given in this book are valid Please note that by adhering to the correct operating as on the date of printing. Tata Motors reserves the right to procedures and by availing the scheduled maintenance make changes in design and specifications and / or to make...
  • Page 6: Table Of Contents

    CONTENTS Driving Controls Gear Shift lever FOREWORD Instrument Panel Parking Brake ENVIRONMENT PROTECTION Indicators Bonnet Opening & Closing WARRANTY TERMS & CONDITION Gauges Fuel Filling Cap Opening DO'S Steering Lock Cum Ignition Spare Wheel Switch Vehicle Jack & Tools DONT'S Combi-Switch Catalytic Converter HANDLING...
  • Page 7 CONTENTS VEHICLE MAINTENANCE Headlamps Engine Compartment - CR-4 Head Lamp Adjustment Engine Compartment - 4SPTC Head Lamp Bulb Replacement Changing Engine Oil Bulb Specification Changing Oil Filter Fuses Engine Air Filter Vehicle Care Fuel Filter & Priming CR-4 FUEL, LUBRICANTS & COOLANTS Fuel Filter &...
  • Page 8 ENVIRONMENT AL PROTECTION TATA MOTORS is committed to overloads the engine. Avoid using Maintenance of the vehicle produce vehicles using devices requiring high power • Ensure that recommended environmentally sustainable consumption during slow traffic maintenance is carried out on the technology.
  • Page 9 ENVIRONMENT AL PROTECTION filters and batteries in compliance 3. Cylinder head for valve leakage with the current legislation. 4. All filters such as air, oil and fuel • Do not allow any unauthorised filters (check periodically) person to tamper with engine 5.
  • Page 10 WARRANTY TERMS & CONDITIONS establishments, our authorised We WARRANT each TATA SUMO under the warranty shall be our dealers or service centres or GOLD vehicles & parts thereof property. service points in any way so as, in manufactured by us to be free from 4.
  • Page 11 TERMS & CONDITIONS WARRANRY vehicle. This warranty shall not racing or participation in any other of time, otherwise, incurred or apply to normal maintenance competitive sports. This warranty accrued. services viz. oils & fluid changes, shall not apply to any repairs or 10.Any claim arising from this head lamps focussing, fastener replacement as a result of accident...
  • Page 12 DO’S FRIENDLY NOTES 1. Use recommended oils and radiator cap only of 1.0 lubricants only. PSI), replacement. 2. Change oil in engine, gear box, steering system and rear axle at 8. Check tyres for damage from time prescribed intervals. to time and remove any foreign bodies embedded in treads.
  • Page 13 FRIENDLY NOTES DO’S 12.Disconnect alternator terminals 19.Release parking brake before while carrying out any welding on driving off. the vehicle. 20.Release the ignition key as 13.Avoid panic braking. Use lower soon as engine starts. gears while descending gradients. 21.Retighten wheel mounting nuts 14.Start the vehicle always in the after 100 km of every wheel 1st gear to avoid premature clutch...
  • Page 14 DO’S FRIENDLY NOTES Where Air conditioning system is installed 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. 3.
  • Page 15: Dont's

    FRIENDLY NOTES DONT’S 1. Do not use Clutch Pedal as Foot 7. Do not cause heating of A/C pipe Rest. This will reduce clutch life. (where fitted), while welding/ brazing in its viscinity. 2. Do not Coast vehicle in Neutral and engine switched-off position.
  • Page 16: Handling

    HANDLING LOCATION OF CHASSIS & AGGREGATE SERIAL NUMBERS 1. Chassis number plate (4SPTC- BS-III) 1. Chassis number plate (CR-4 BS-IV) 2. Body Shell (Cab) no. plate (4SPTC- BS-III) 2. Body Shell (Cab) no. plate (CR-4 BS-IV) Chassis number on frame FIP number...
  • Page 17 LOCATION OF CHASSIS & AGGREGATE SERIAL NUMBERS HANDLING Engine number Gear box number Rear axle number (Tata Motors)
  • Page 18: Anti-Theft Device

    It is advisable to keep one of the keys in a safe place for use in case of an emergency. 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. A. Key B. Remote - Anti Theft Device Anti-theft Device (if installed) This is an electronic car security system with remote (keyless) operation for door Unlock/Lock.
  • Page 19: Door Locking

    DOOR LOCKING & WINDOW WINDING HANDLING Door Locking The front doors can be locked and unlocked from the outside with the key or from the inside using the door lock lever. In your vehicle, the driver’s door & co-driver’s door (if provided) have separate locking facilities. To lock from inside turn the lever (2) towards the inner hinged handle (3).
  • Page 20: Power Windows

    HANDLING POWER WINDOWS Power Windows : (if provided) Separate knobs are provided on the switch to operate the four door window glasses individually . 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.
  • Page 21: Sun Visors

    SUN VISORS HANDLING 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...
  • Page 22: Outer Rear View Mirrors

    HANDLING OUTER & 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.
  • Page 23: Driver's & Co-Driver's Seat

    SEATS HANDLING Driver’s & 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.
  • Page 24: Middle Seat

    HANDLING OUTER & INNER REAR VIEW MIRRORS 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. Any one of the split can be folded by releasing the latch, on the backrest simultaneously (Fig.
  • Page 25: Seat Belt

    SEATS 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.
  • Page 26 HANDLING SEATS 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.
  • Page 27: Adjustable Head Restraint

    ADJUSTABLE HEADRESTRAINT HANDLING Adjustable Headrestraint 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.
  • Page 28: Driving Controls

    HANDLING DRIVING CONTROLS DRIVING CONTROLS 1. A.C. Side Vents 2. Glove Box 3. A.C. Middle Vents 4. Steering Wheel 5. Instrument Cluster 6. Headlamp leveling Switch 7. Horn Pad 8. Accelerator Pedal 9. Brake Pedal 10. Clutch Pedal 11. Parking Brake 12.
  • Page 29: Instrument Panel

    INSTRUMENT PANEL HANDLING INSTRUMENT PANEL (CR-4 BS-IV) All indicators may not be provided on some instrument cluster and may not be applicable to all models.
  • Page 30 HANDLING INSTRUMENT PANEL INSTRUMENT PANEL (4SPTC BS-III) All indicators may not be provided on some instrument cluster and may not be applicable to all models.
  • Page 31: Indicators

    INSTRUMENT PANEL & INDICATORS HANDLING Immobiliser Warning 1. Speedometer Indicator : 2. Brake Fluid Level Check/Parking Brake Indicator (Red) This system disables engine starting if original key is not 3. Battery Charging Indicator (Red) used.The user has to use original key for authentification 4.
  • Page 32 HANDLING INDICATORS Low Oil Pressure • When ignition key is turned to “IGN” position, this Indicator: indicator lights up and goes off when engine starts in normal condition. If it continueously ON while engine When the ignition key is turned to the ‘IGN’ position, symbol is running, get the problem attended to an Authorised lights up and goes off as soon as the required engine oil Service Outlet.
  • Page 33 INDICATORS HANDLING Glow plug Indicator Malfunction Indication Lamp (MIL): (if fitted) : This symbol comes ON when the ignition is turned This indicator lights up when the ‘IGN’ is switched ‘ON’ “ON” and goes “OFF” once the engine is cranked. and goes ‘OFF’...
  • Page 34: Gauges

    NOTICE panel illumination In case the fault occurs and MIL on the instrument cluster comes ON, contact nearest TATA MOTORS authorized service center. After eliminating the inconvenience, to check the system completely, TATA MOTORS authorized service centers are obliged to run a bench test and if...
  • Page 35 GAUGES HANDLING • Main Odometer (Non- resettable) - Counts up to 999999 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 •...
  • Page 36 HANDLING GAUGES Temperature gauge: RPM meter (if provided) : The gauge indicates the temperature of the engine coolant. The meter indicates engine speed in revolutions per minute The red zone at ‘H’ indicates temperature higher than the (rpm) Change gears at appropriate engine rpm and vehicle normal.
  • Page 37: Steering Lock Cum Ignition Switch

    STEERING LOCK CUM IGNITION SWITCH HANDLING Steering lock cum ignition switch : 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...
  • Page 38 HANDLING STEERING LOCK CUM IGNITION SWITCH 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.
  • Page 39: Combi-Switch

    COMBI-SWITCH HANDLING COMBI-SWITCH...
  • Page 40 HANDLING LIGHTS & WIPER CONTROL LEVER WIPER CONTROL LEVER - LEFT LIGHTS CONTROL LEVER - RIGHT A. Head lamp 'OFF' position B. Position lamp 'ON' A. Wiper 'OFF' position C. Position lamp & head lamp 'ON' B. Slow Wipe D. Push down the lever for high beam C.
  • Page 41: Antenna

    MUSIC SYSTEM & LAMPS HANDLING Music System with blue tooth and USB port (If installed) : The music system with USB connector (1) and blue tooth connector (2) is fitted in the centre console. Two speakers are provided in the dashboard as well as two speakers are in the rear.
  • Page 42: Tail Lamp

    HANDLING TAIL LAMP, REGISTRATION PLATE LAMP & HIGHMOUNTED STOP LAMP Tail Lamp : High Mounted Stop Lamp The tail lamp assembly incorporates the following : 1. Rear direction indicator 2. Parking / Rear stop lamp 3. Reverse light 4. Reflex reflecor 5.
  • Page 43: Interior Roof Lamps

    INTERIOR LAMPS HANDLING 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.
  • Page 44: Headlamp Leveling Switch

    HANDLING HEADLAMP LEVELING SWITCH Headlamp Leveling Switch A motorised headlamp leveling arrangement with the setting knob at the RH side of dash board. As and 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.
  • Page 45: Accessory Switches

    ACCESSORY SWITCHES HANDLING ACCESSORY SWITCHES Rear Windshield Wash and Wipe (unlatched switch) (if fitted) There are six (6) operating switches provided on the centre console of your vehicle’s dashboard, just above the Music Push and hold the switch knob for the System.
  • Page 46 HANDLING ACCESSORY SWITCHES 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...
  • Page 47: Power Socket

    POWER SOCKET & MOBILE HOLDER HANDLING Power Socket : A power socket is provided on the central console below music system. This can be used connecting loads upto 10A maximum. To use this socket, remove the cap first. CAUTION Always keep this socket covered with the cap when not in use. Power Socket Mobile Holder : A mobile holder is provided on the central console below music system...
  • Page 48: Grab Handle

    HANDLING GRAB HANDLE & GLOVE BOX WITH CUP HOLDER Grab handles : Grab handles are provided in the vehicle at various locations (Co-driver side, Middle passenger and third row passenger compartment) for comfortable positioning of passengers during journey. Grab Handle Glove Box with Cup Holder : The glove box is located on the dash board in front of the codriver's seat.
  • Page 49: Gear Shift Lever

    GEAR SHIFT LEVER & PARKING BRAKE HANDLING 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. Gear Shift Lever Parking brake : The parking brake is mounted on floor console between driver’s seat and co-driver’s seat.
  • Page 50: Bonnet Opening & Closing

    HANDLING BONNET / FUEL FLAP OPENING & CLOSING 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.
  • Page 51 FUEL FLAP OPENING & CLOSING HANDLING 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.
  • Page 52: Spare Wheel

    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.
  • Page 53: Vehicle Jack & Tools

    VEHICLE JACK & TOOLS HANDLING Vehicle Jack & Tools Vehicle tool bag, jack and handle is kept below driver’s seat. Jack is mounted on floor over studs by wing nuts screwed on them. Jack & tools location (Below driver’s seat) Locking Wing Nuts...
  • Page 54: Catalytic Converter

    HANDLING CATALYTIC CONVERTOR & EGR SYSTEM 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...
  • Page 55: Turbocharger

    TURBO CHARGER HANDLING TURBOCHARGER : Pressure oil from engine 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. Exhaust Air in gas out...
  • Page 56: Power Steering

    HANDLING POWER STEERING POWER STEERING (When provided) 4. With the engine at steady speed check for bubble / foaming in the fluid. If present it indicates that air is Power steering is fitted for lighter steering effort and easy getting sucked into the system. manoeuvrability.
  • Page 57 POWER STEERING HANDLING Power steering pump belt tension Check 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 Alternator/Power Steering belt as shown in Figure. The belts should have deflection of 8 to 10 mm.
  • Page 58: Air Conditioning

    HANDLING AIR CONDITIONING HEATING, VENTILATION & 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.
  • Page 59 AIR CONDITIONING HANDLING D. A.C. ON/OFF Switch : Whenever discomfort is felt switch air circulation mode to fresh. The A.C. can be switched 'ON' by pressing(In NOTICE case of HVAC) / rotating (In case of only A.C.) the switch (D) on the A.C. control panel 1.The A.C.
  • Page 60 HANDLING AIR CONDITIONING Once temperature inside has come down sufficiently, close Defrosting : (For vehicles fitted with HVAC unit) the windows and change air circulation suitably to fresh/ In low temperature areas, to clear frost formation outside recirculation. the windshield glass, this setting is used. Demisting : First start the engine - Maximum hot position In rainy season or in areas of high humidity, mist formation...
  • Page 61 AIR CONDITIONING HANDLING Roof A. C. Where roof mounted air conditioner unit is installed, the blower switch has 4 positions “HIGH”, “MED”, “LOW” and “OFF”. The switch is located on left hand side on the roof A.C Air flow direction can be adjusted by adjusting the air vents.
  • Page 62 HANDLING PREPARING THE VEHICLE FOR DRIVE 1. Engine Oil Filler Cap (CR-4) 1. Engine Oil Filler Cap (4SPTC) Fuel Filler Cap 2. Dip Stick (CR-4) 2. Dip Stick (4SPTC) Check the following regularly, midway between upper and lower level upto the ‘FULL’ mark. The particularly before starting on a marks on the dipstick.
  • Page 63 PREPARING THE VEHICLE FOR DRIVE HANDLING 1. Brake Fluid Container 2. Clutch Fluid Battery (CR-4) Battery (4SPTC) Container 3. Power Steering Container 5. Check all lights, horn, gauges, 8. Check level of brake fluid in plastic NOTICE switches and wiper for proper container.
  • Page 64 HANDLING PREPARING THE VEHICLE FOR DRIVE Windshield Washer Container Windshield Washer Container (CR-4) (4SPTC) 10. Check level of water in Windshield washer reservoir. Top up with clean water if required. Use good quality cleaning solvent available in the market in the ratio as specified by its manufacturer.
  • Page 65 DRIVING & GEAR SHIFTING DRIVING INSTRUCTION BEFORE DRIVING START THE ENGINE AND OBSERVE During running - in period : THAT : i.e. first 2,000 km of operation : CHECK Do not exceed the following vehicle • LOW OIL PRESSURE INDICATOR •...
  • Page 66: Braking

    DRIVING INSTRUCTION DRIVING TIPS, BRAKING & FUEL ECONOMY • DRIVING TIPS Engage reverse gear, only when timesat low speed to get rid of vehicle is stationary. moisture inside the brake drums. DRIVE SAFELY AND JUDICIOUSLY. • • Depress clutch pedal fully before When it beings to rain, reduce REMEMBER SAFETY FIRST.
  • Page 67: Driving In Adverse Conditions

    DRIVING IN ADVERSE CONDITIONS DRIVING INSTRUCTION F. Do not ride the clutch. Do not use DRIVING IN ADVERSE CONDITION: In case the traction on the wheels is clutch pedal as foot rest. sufficient, you may be able to proceed, Driving on Snowy or Icy Roads : it is better to select the lower gear and G.
  • Page 68 DRIVING INSTRUCTION DRIVING IN ADVERSE CONDITIONS Driving Through Water liners and to regain original Driving on a Rainy Day braking. Do not attempt to start the engine if vehicle gets flooded due to water. • Tow the vehicle to a safe place. •...
  • Page 69 DRIVING IN ADVERSE CONDITIONS DRIVING INSTRUCTION • Night Driving Climbing Sharp Gradients Under no conditions should 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.
  • Page 70: Towing The Vehicle

    DRIVING INSTRUCTION DRIVING IN ADVERSE CONDITIONS Descending Sharp Gradients 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.
  • Page 71: Driving Safety

    DRIVING SAFETY DRIVING INSTRUCTION DRIVING SAFETY Mobile phones Parking on slopes Seat Belt Due care should be exercised while applying parking brakes on steep Seat-belts are life saving equipment. slopes. It is advicable to switch off the Use of seat-belt reduces the chance engine and shift gear lever in Low of injury and severity of injury in case Forward Gear before parking the car...
  • Page 72: Safety Checks

    DRIVING INSTRUCTION SAFETY CHECKS SAFETY CHECKS working condition and they are used It should be regularly checked and when required. updated. Windshield/wiper/windshield washer Horn Documents Always keep windshield glass clean Ensure the horn is working properly. Always carry car registration papers, to avoid any distortion in visibility.
  • Page 73: Vehicle Maintenance

    ENGINE COMPARTMENT VEHICLE MAINTENANCE ENGINE COMPARTMENT (CR-4) 9. Engine Coolant Tank 1. Brake Fluid Reservoir 5. Air Filter 10. Windshield washer Fluid Container 2. Clutch Fluid Reservoir 6. Dip Stick 11. Power Steering Fluid Reservoir 3. Engine Compartment Lamp 7. Radiator Cap 12.
  • Page 74: Engine Compartment - 4Sptc

    VEHICLE MAINTENANCE ENGINE COMPARTMENT ENGINE COMPARTMENT (4SPTC) 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.
  • Page 75: Changing Engine Oil

    CHANGING ENGINE OIL VEHICLE MAINTENANCE Changing engine oil minutes. Top up if oil level is less than midway between upper and lower marks on the dipstick. Change engine oil in the crankcase at recommended interval. Engine oil should be drained while it is hot. Unscrew For Engine oil filling cap and dip stick, please refer engine sump drain plug and allow oil to drain out fully.
  • Page 76: Engine Air Filter

    VEHICLE MAINTENANCE AIR FILTER, FUEL FILTER & FUEL SYSTEM-CR-4 Engine Air Filter Priming Pump / Pear Pump (CR-4): 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. Always use genuine air filter element.
  • Page 77: Fuel Filter & Priming 4Sptc

    FUEL FILTER & FUEL SYSTEM-4SPTC VEHICLE MAINTENANCE Changing fuel filter element (4SPTC) : Priming fuel system (4SPTC) : Unscrew drain plug and drain fuel from fuel bowls. Remove Unscrew fuel lift pump plunger knob. Pull and push it 10-14 fuel filter with top cover from mounting bracket. times (30-40 times if fuel tank has been completely emptied).
  • Page 78: Fan Belt Tension Adjustment

    VEHICLE MAINTENANCE BELT TENSION ADJUSTMENT 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.
  • Page 79: Brake Clutch System Bleeding

    BLEEDING CLUTCH SYSTEM VEHICLE MAINTENANCE Bleeding clutch system During bleeding process keep a watch on fluid level in container and top-up. A dry friction, single disc, diaphragm type clutch has been fitted which is actuated hydraulically. For Clutch Fluid Container location, please refer respective Engine Compartment pages (Page 73 &...
  • Page 80: Cooling System

    VEHICLE MAINTENANCE ENGINE COOLING SYSTEM & BRAKE SYSTEM Cooling system : Changing of coolant in the cooling system : If engine overheating occurs, there could be a fault in the a. Drain the cooling system and flush it with clean water. cooling system which may be on account of : b.
  • Page 81 BRAKE SYSTEM VEHICLE MAINTENANCE...
  • Page 82: Brake Adjustment

    VEHICLE MAINTENANCE BRAKES 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.
  • Page 83: Wheels & Tyres

    Jack location at front Jack location at rear Tightening wheel nuts Wheels and tyres attended by TATA MOTORS authorised workshop. Periodically check and maintain correct tyre pressure to Always use only recommended size wheel rims and tyres. obtain longer tyre life.
  • Page 84: Wheel Balancing

    VEHICLE MAINTENANCE WHEELS & TYRES Check tyres for damage from time to time and remove any weights are not disturbed during removal of tyres. Check foreign bodies (nails/stones, metal chips etc.) embedded the balance weight prior to removal of tyre, if found loose, in treads.
  • Page 85: Tyre Rotation

    WHEELS & TYRES AND ELECTRICAL SYSTEM VEHICLE MAINTENANCE Tyre rotation Headlamps The head lamp provides two types of light beams; a high Tyre rotation is recommended for achieving identical wear beam to give maximum light well ahead of vehicle, and a on each tyre.
  • Page 86: Head Lamp Bulb Replacement

    VEHICLE MAINTENANCE ELECTRICAL SYSTEM Each headlamp is aligned individually by masking the other Now switch ‘ON’ high beam. They will be symmetrical above headlamp. Headlamp is first adjusted for proper height of points. ‘A’ and ‘B’ of intersection of vehicle lines and horizontal low beam by adjusting knob at its top.
  • Page 87: Bulb Specification

    BULB SPECIFICATION VEHICLE MAINTENANCE DESCRIPTION LOCATION TYPE SPECIFICATIONS QTY. Headlights Headlamp Halogen P43t 60 / 55 W Turn indicator light Front BAU15 S 21 W Tail lamp BAU15 S 21 W Stop lights / Tail lights Tail lamp BAY 15 S 21 / 5 W Parking lights Head lamp...
  • Page 88: Fuses

    VEHICLE MAINTENANCE ELECTRICAL SYSTEM Fuses Flasher with short circuit protection In order to protect the cable harness and other equipments If flasher circuit is short circuited or overloaded (more than from damage in case of short circuit and overloads, fuse 110 W) flasher will shut off.
  • Page 89: Vehicle Care

    CARE & CLEANING OF VEHICLE VEHICLE MAINTENANCE Care and cleaning of the vehicleCAUTION dirt and soap solution. If some dirt still remains on the surface, repeat the procedure When cleaning the interior / exterior of the vehicle, • NEVER USE volatile solvents such as thinner, petrol or Carpets any other cleaning materials such as bleaches or strong Remove dirt as much as possible by using a vacuum...
  • Page 90 VEHICLE MAINTENANCE CARE & CLEANING OF VEHICLE Washing : Warning When washing the vehicle, follow the instructions given After washing, check that the brakes are dry. If brakes are below. not dry, dry them by gently, repeatedly applying while driving •...
  • Page 91 • Use a high pressure spray to clean the underside 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.
  • Page 92: Fuel, Lubricants & Coolants

    FUEL, LUBRICANTS & COOLANTS FUEL Fuel : High speed diesel conforming to IS 1460 OR EN Care should be taken that diesel and supplementary fuel 590 OR equivalent is recommended to be used as fuel. are thoroughly mixed before filling. At very low temperature fluidity of diesel may become WARNING insufficient due to paraffin separation.
  • Page 93: Lubricants

    LUBRICANTS & COOLANTS FUEL, LUBRICANTS & COOLANTS Lubricants Hub bearing grease (Tata Motors axles & front hub). Recommended lubricants conform to the following Use Lithium base multipurpose grease. specifications : Quantity 25 gms per hub. (Rear) - Engine oil (CR-4 / 4SPTC) 1.
  • Page 94: Recommended Oils, Lubricants

    FUEL, LUBRICANTS & COOLANTS RECOMMENDED OILS, LUBRICANTS, COOLANTS & FILLING CAPACITY PLEASE USE ONLY FOLLOWING GENUINE OILS, COOLANTS , LUBRICANTS , ANTI RUST & SOUND DEADENING COATS, WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS FOR OPTIMUM PERFORMANCE ITEM COMPANY...
  • Page 95 TECHNICAL SPECIFICATION ENGINE CR-4 (BS-IV) ENGINE 4SPTC (BS-III) Model : TATA 3.0 CR4 Model : TATA 497 SPTC 43 Type : Turbo-charged,Intercooled, Direct Type : Turbo-charged, Water cooled, injection diesel engine. Direct injection diesel engine. No. of cylinders : 4-inline No.
  • Page 96 TECHNICAL SPECIFICATION CLUTCH FRONT AXLE : Independently suspended STEERING : Type : Single plate dry friction Type : Power Steering, Victa type steering diaphragm type Ratio : 18.2 :1 (EX / GX /FX) Outside diameter of : 260 mm - ( For CR-4 - BS-IV) Clutch lining 240 mm - ( For 4SPTC - BS-III) 32.5:1 to 36.5:1 (LX / CX)
  • Page 97 TECHNICAL SPECIFICATION SUSPENSION PERFORMANCE Front : Double wishbone type with coil Max. speed at rated GVW : 120 km / hr springs. Max gradeability at rated GVW : 32 % Rear : Parabolic leaf springs. Grade Restartability : 32 % (CR-4) 26 % (4SPTC) Shock Absorber : Hydraulic double acting telescopic...
  • Page 98 TECHNICAL SPECIFICATION WEIGHT (kg) : (Tolerances as per INTEREUROPE STVZO) Complete vehicle kerb : 1820 (FAW- 997 RAW- 823) weight as per ISO:1176 - For AC / HVAC (With spare wheel & tool): 1800 (FAW- 987,RAW- 813) - For Non-AC Gross Vehicle weight : 2600 ( FAW 1080 ,,RAW 1520 ) Max.
  • Page 99 Customer Support, Passenger Car the vehicle is sent to them next. Should a major service Division, Tata Motors, Pune - 410062 by the servicing have been missed, all the works listed for such service dealer after the service is performed. The selling dealer...
  • Page 100 SERVICE INSTRUCTIONS 6. 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.
  • Page 101: Service Schedule

    SERVICE SCHEDULE FREQUENCY OPERATION (In km) GENERAL Wash the vehicle & Clean the condenser with compressed air. Every Service Check & Top up Fluids if required: Brake/Clutch Fluid, Battery Electrolyte, Power Steering Every Service Oil Gear Box Oil, Transfer Case & Front Axle (4X4) / Rear Axle Oil Check engine compartment for loose fasteners, low pressure fuel lines, coolant hoses,air Every Service hoses, vacuum hoses, hydraulic line connections for leakages if any, Attend if necessary.
  • Page 102 SERVICE SCHEDULE FREQUENCY OPERATION (In km) Replace air cleaner element 45000km Inspect vacuum hose connection and rectify if necessary 15000 km Replace EVRV filters 15000 km Vacuum hoses for EVR, EGR, Turbo charger, Throttle (if applicable) to be replaced 60000km ENGINE ( 4 SP TURBO) Check service indicator red band as per recommended procedure &...
  • Page 103 SERVICE SCHEDULE FREQUENCY OPERATION (In km) PROPELLER SHAFT Grease propeller shaft with grease gun (at slip joint - splines end) & Check Centre bracket 15000 km mounting bolts for looseness. Tighten if necessary AXLE Change oil in axle (First at 15,000 KM, there after every 75,000 KM) 75000 km Change grease in rear hubs&...
  • Page 104 SERVICE SCHEDULE FREQUENCY OPERATION (In km) ELECTRICALS Check headlamp focussing & functionir of other electrical equipment 15000 km Check speci& gravity of battery electrolyte 30000km HVAC Check the HVAC system for satisfactory performance & attend if required Every Service WHEELS & TYRES Tyre rotation 15000 km * Under severe driving conditions, additional maintenance is required.
  • Page 105: Record Of Service Performed

    RECORD OF SERVICE PERFORMED Chassis No............Recommended Odometer Repair Servicing Dealer’s Recommended Odometer Repair Servicing Dealer’s Service Date reading Order Signature and Service Date reading Order Signature and Stamp Stamp At km. 1,50,000 PDI * 1,65,000 5,000* 1,80,000 15,000* 1,95,000 30,000* 2,10,000...
  • Page 106 RECORD OF REPAIRS CARRIED OUT Date Odometer Repair Particulars of Repair Servicing Dealer’s Signature & reading (km) Order No. Stamp...
  • Page 107: Record Of Repairs Carried Out

    RECORD OF REPAIRS CARRIED OUT Date Odometer Repair Particulars of Repair Servicing Dealer’s Signature & reading (km) Order No. Stamp...
  • Page 108: Alphabetical Index

    ALBHABETICAL INDEX Combi-Switch Coolants Abbreviation Fan Belt Tension Adjustment Cooling System Accessory Switches Foreward Adjustable Head Restraint Fuel Filter & Priming 4SPTC Aggregate Numbering Dont's Fuel Filter & Priming CR-4 Air Conditioning Door Locking Fuel Economy Alphabetical Index Do's Fuel Filling Cap Opening Antenna Driver's &...
  • Page 109: Technical Specifications

    ALBHABETICAL INDEX Power Steering Power Windows Indicators Tail Lamp Preparing the vehicle for the drive Inner Rear View Mirror Technical Specification Instrument Panel Towing the Vehicle Interior Roof Lamps Recommended Oils, Lubricants Turbocharger Record of Repairs Carried Out Tyre Pressure Record of Service Performed Tyre Rotation Registration Plate lamp...
  • Page 110: Abbreviations

    Gram Regional Manager Gross Vehicle Weight Revolution Per Minute Ignition Seconds Kilogram Sq.cm. Square Centimeter Kilometer TASC Tata Motors Authorised Service Centre Km/h Kilometer per hour TASP Tata Motors Authorised Service Point Left Hand Volts Maximum Watts Main Dealer Weight...

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