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A Note
Q This book will help you to understand the vehicle better, maximise uptime of the vehicle & obtain
better performance at optimum cost.
Q The recommended routine maintenance servicing along with any running repairs that may be required, should
be entrusted to TATA Authorised Workshop to ensure that only latest methods and genuine TATA MOTORS
replacement parts are used for the continued reliability, safety and performance of the vehicle.
Q Some of the items / accessories / features shown / given in this book may not be fitted on your vehicle, but
they are applicable for other versions of Sumo Grande.
Q All rights reserved. The material in this manual may not be reproduced or copied, in whole or in part, in any
form without written permission from TATA MOTORS.
Q The information and specifications given in this book are valid as on the date of printing. TATA MOTORS
Limited 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.
Q In the event of the Vehicle being sold, please ensure that this manual is left in the vehicle for the reference of
the new owner.
Foreword
D ear C ust
Cust omer
omer,,
ustomer
Thank you for selecting Tata Sumo Grande - the vehicle of your choice
We welcome you to the world of advanced automotive engineering in a form especially suited to
your operating conditions.
This book gives you all the information necessary for making your ownership of this vehicle a
thoroughly satisfying experience.
To assist you in maintaining your vehicle as per recommended schedule, we have a widespread
network of dealers and service centres. The list is included in this book for your convenience.
Should you need any special assistance, please call on our Regional / Zonal level offices which
are also listed in this book.
Please note that by adhering to the correct operating procedures and by availing the scheduled
maintenance services at our authorised service centres, you can obtain the maximum performance
from your vehicle.
We request you to go through the book and derive many miles of motoring pleasure.
Customer Assistance
IMPOR
IMPORTTANT INFORMATION ABOUT THIS MANUAL
MANUAL
Safety and vehicle damage warnings
In this manual, you will see CAUTION and NOTICE warnings.
CAUTION
This is a warning. May cause injury to people if the warning
is ignored. You are informed what you must or must not do
in order to avoid or reduce the risk to yourself and other
people. 1800 209 6688
NOTICE
This is a warning. May cause damage to the vehicle or its
equipment if the warning is ignored. You are informed what
you must or must not do in order to avoid or reduce the risk
of damage to your vehicle and its equipment.
WARNING
Indicates a strong possibility of severe personal injury or
death if the instructions are not followed.
Safety symbol
In this manual, you will also see a circle with
a slash. This means "Do not", "Do not do
this", or "Do not let this happen".
Contents
Music System, Antenna & Clock 27 Starting & Stopping the Engine 59
Contents
Air Filter, Engine, Oil & coolant 90 Service Maintenance Schedule 117
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WARR ANT
ARRANT
ANTYY - TERMS & C ONDITIONS
CONDITIONS
We WARRANT each TATA Sumo such warranty shall be co- repaired or altered otherwise than
Grande vehicles & parts thereof terminus with this original in accordance with our standard
manufactured by us to be free from warranty. repair procedure, or by any
defect in material and workmanship, person other than our sales or
subject to the following terms & 3. Any part which is found to be service establishments, our
conditions : defective and is replaced by us authorised dealers or service
under the warranty shall be our centres or service points in any
1. This warranty shall be for 24 property. way so as, in our judgement
months OR 75000 kms, which shall be final and binding,
whichever is earlier from the date 4. As for such parts as tyres,
batteries, transfer case, rubber to effect its reliability, nor shall it
of sale of the vehicle, However, apply if, in our opinion which shall
for the vehicles used for parts, electrical equipment and
fuel injection equipment, power be final and binding the vehicle is
commercial applications subjected to misuse, negligence,
(including those used for hire or steering equipment, A.C.
equipment not manufactured by improper or inadequate
reward viz those operating with maintenance or accident or
a yellow number plate), the us but supplied by other parties,
this warranty shall not apply, but loading in excess of such
warranty shall be limited to 24 carrying capacity as certified by
months or 50,000 kms, buyers of the vehicle shall be
entitled to, so far as permissible us, or such services as
whichever occurs earlier. prescribed in our Owner ’s
2. Our obligation under this by law, all such rights as we may Manual and Service Book are not
warranty shall be limited to have against such parties under carried out by the buyer through
repairing or replacing, free of their warranties in respect of our sales or service
charge, such parts of the vehicle such parts. Our Dealers/TASC’s establishments, our authorised
which, in our opinion, are will assist the purchaser in taking dealers or service centres or
defective, on the vehicle being up the complaint with the service points.
brought to us or to our dealers respective manufacturers and
their decision on the warranty will 6. This warranty shall not cover
within the warranty period. The normal wear and tear or any
parts so repaired or replaced be final.
inherent normal deterioration of
shall also be warranted for 5. This warranty shall not apply if the the vehicle or any of its parts
quality and workmanship but vehicle or any part thereof is arising from the actual use of the
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WARR ANT
ARRANT
ANTYY - TERMS & C ONDITIONS
CONDITIONS
vehicle or any damage due to to abnormal use such as damages, loss of vehicle, or
negligent or improper operation rallying, racing or participation loss of time, otherwise,
or storage of the vehicle. This in any other competitive incurred or accrued.
warranty shall not apply to normal sports. This warranty shall not
maintenance services viz. oils & apply to any repairs or 10. Any claim arising from this
fluid changes, head lamps replacement as a result of warranty shall be recognised
focussing, fastener retightening, accident or collision. only if it is notified in writing to
wheel balancing, tyre rotation, us or to our concerned dealer
adjustment of valve clearance, 8. This warranty is expressly in without any delay soon after
fuel timing, ignition timing and lieu of all warranties, whether such defect as covered and
consumables like bulbs, fuel by law or otherwise, expressed ascertained under this
filters and oil filters etc. This or implied, and all other warranty.
warranty shall not apply to any obligations or liabilities on our
part and we neither assume nor 11. T h i s w a r r a n t y s h a l l s t a n d
damage or deterioration terminated if the vehicle is
caused by environmental authorise any person to
assume on our behalf, any transferred or otherwise
pollution or bird droppings. This alienated by the buyer without
warranty shall not apply to V- other liability arising from the
sale of the vehicle or any our prior written consent.
belts, hoses and gas leaks in
case of air conditioned vehicle. agreement in relation thereto. 12. We reserve our rights to make
Slight irregularities not 9. The buyer shall have no other any change or modification in
recognised as affecting the rights except those set out the design of the vehicle or its
function or quality of the vehicle above and have, particular, no parts or to introduce any
or parts such as slight noise or right to repudiate the sale, or improvement therein or to
vibration and defects appearing any agreement or to claim any incorporate in the vehicle any
only under particular or reduction in the purchase additional part or accessory at
irregular operations or items price of the vehicle, or to any time without incurring any
considered characteristic of demand any damages or obligation to incorporate the
the vehicle. compensation for losses, same in the vehicles previously
incidental or indirect, or sold.
7. This warranty shall be null and
void if the vehicle is subjected inconvenience or consequential
10
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ENVIR ONMENT
ENVIRONMENT AL CARE
ONMENTAL
TATA MOTORS LTD. is DRIVING the engine before turning it
committed to produce the vehicles off as it unnecessarily burns
using environmentally sustainable
¾ Avoid frequent and violent the fuel.
accelerations.
technology. A number of features
¾ Do not carry any ¾ Shift to higher gears as soon
have been incorporated in Tata as it is possible. Use each
unnecessary weight on the
Motors passenger vehicles which gear upto 2/3 rd of it’s
vehicle as it overloads the
have been designed to ensure maximum engine speed. A
engine. Avoid using devices
environmental compatibility requiring high power chart indicating gear shifting
throughout the life cycle of the consumption during slow city speeds is given in this book.
vehicle. We would like to inform traffic condition. MAINTENANCE
you that your vehicle meets
emission norms and this is being ¾ Monitor the vehicle’s fuel
¾ Ensure that recommended
consumption regularly and if
regularly validated at the maintenance is carried out
showing rising trend get the
manufacturing stages. on the vehicle regularly at the
vehicle immediately attended
Authorised Service Outlets.
at the Company’s Authorised
As a user you too can protect Service Outlets. ¾ As soon as you see any
the environment by operating leakages of oil or fuel in the
your vehicle in a proactive ¾ Switch off the engine during vehicle we recommend to get
manner. A lot depends on your long stops at traffic jams or
it attended immediately.
driving style and the way you signals. If you need to keep
maintain your car. We have the engine running, avoid ¾ Use only recommended
unnecessary revving it up or grades and quantity of
given few tips below for your
stopping and starting. lubricants and clean/
guidance. uncontaminated and correct
¾ It is not necessary to rev up fuels.
10
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ENVIR ONMENT
ENVIRONMENT AL CARE
ONMENTAL
¾ Get your vehicle checked for the compressed air for 5. Turbocharger & Vacuum
emission periodically by cleaning these parts which Modulator OR it’s vacuum
authorised dealer may spread the dust in the hoses.
¾ Ensure that fuel filter, oil filter atmosphere. 6. EGR System &
and breather are checked ¾ While carrying out the components.
periodically and replaced, if servicing or repairs of 7. Electrical connections
required, as recommended your vehicle you should 8. ‘Service’ lamp
by Tata Motors. pay keen attention to contineously glows, please
some of the important take the vehicle to Service
¾ Do not pour the used oils or
Station.
coolants into the sewage engine aggregates and
drains, garden soil or open wiring harness which 9. Catalytic Convertor
streams. Dispose the used greatly affect emission. 10. EMS wiring harness i.e.
filters and batteries in These components are :- electrical connections to
compliance with the current 1. Fuel injection equipments all sensors and actuators.
legislation. - pump, rail,Injectors,
Nozzles and high pressure This owner’s manual contains
¾ Do not allow unauthorised further information on driving
person to tamper with pipes.
precautions and maintenance
engine settings or to carry 2. Air Intake & Exhaust
care leading to environment
modifications on the vehicle. system especially for
protection. Please familiarise
leakages.
¾ Never allow the vehicle to run yourself with these aspects
out of fuel. 3. Cylinder head for valve before driving.
leakage.
¾ Parts like brake liners,
4. All filters such as air, oil &
clutch disc should be
fuel filters (check
vacuum cleaned. Do not use
periodically).
12
1. Steering Wheel
2. Instrument Cluster
3. Mirror Adjustment Switch
4. Horn Pads
5. Operating Switches
6. Bonnet Opening Lever
7. Gear Shifting Lever
8. Parking Brake
9. Cigar Lighter (Rear)
10. Cigar Lighter (Front)
11. Music System
12. A.C.Controls
13. Glove Box
14. A.C. Air Vents
15. Analog Clock
16. Central Air Vents
12
21 13 12 9 10 9 11 22
1 6
3 7
14
4
5 8
16
24 18 19 15 17 20 23
All indicators may not be provided on some instrument cluster and may not be applicable
to all models.ca
14
21 13 12 9 10 9 11 24
1 6
7
3
14
4
5 8
16
18 15 17 23
All indicators may not be provided on some instrument cluster and may not be applicable
to all models.ca
14
16
17
18
20
Temp
Guage
High
Temperature Low Fuel
Warning Warning
Temp er
emper
eraa tur
turee G uage
Guage Fuel Guage Fuel Guage
21
22
The fog lamps are provided on The fog lamps are provided on rear
front bumper to improve the bumper to improve the visibility and
visibility in foggy weather or during warning in foggy weather or during
heavy rains. The front fog lamps heavy rains. The rear fog lamps
can be switched ON with parking can be switched on with parking
lamp ON and can be remain on till lamp and front fog lamps ON and
the parking lamp is switched OFF. can be remain ON till the parking
NOTICE lamp is switched OFF. The rear fog
lamps can also be switched ON
Use only during foggy even if only headlights are ON.
conditions or heavy rains if
required. NOTICE
Use only during foggy conditions
or heavy rains if required.
23
24
25
2) Light stalk:
Outer rotary switch on right hand
stalk is provided for selecting
Inner rotary switch on right hand Position or Head lamp High/Low Position (Parking) lamp and tail
stalk is provided for head lamp beam. It operates with Ignition lamp will be ON in this position.
leveling. Setting is done by rotating switch in “IGN” position. c) Head / Position lamp ON.
the knob to select one of the 3 level
positions depending upon the a) Head / Position lamp OFF.
loading of the vehicle. Head lamp
leveling can be done with head
lamp in Low Beam and in ON
position.
Setting should be done only Head lamp, position (Parking) lamp
when vehicle is stationary and tail lamp will be ON in this
position. Toggling the lever (Stalk)
26
27
Setting
Knob
Speaker Location on doors
28
A.C. Controls
A D B E C
Central Console
29
Towards face
Towards face and feet
Towards feet
Towards feet & windshield
(Recommended for clearing
mist on windshield)
Air demist/defrost windshield
(Recommended for clearing
heavy fog or snow
30
31
32
NOTICE
• AC Gas charging Quantity
should be 780 + 20 gms.
(R 134a-Non CFC)
Side Ventilators
33
Rear AC:
Rear AC is provided for rear
seats passengers. When front
AC is ON, it will provide cool air
from front AC. When front AC is
OFF, it can be used as blower
(supplying normal air). Rear AC
switch is provided on roof and
can be used to switch ON the
blower and select the blower
speed. four adjustable air vents
are provided on roof. Air flow
and direction can be adjusted
on each air vent.
34
1 Reverse Lamp
2 Direction Indicator
1 Main/Dip Beam
3 Tail / Brake Lamp F r on
ontt FFo
o g Lamp
2 Position/Parking Lamp
3 Direction Indicator Side Repeater Indicator Lamp
provided with H4 halogen lamp with
double fitment for providing straight
ahead illumination of the road for
the long distance or deep beam
which illuminates the road
immediately ahead for short
distance visibility. It also contains
side indicator lamp and a parking R ear FFo
o g Lamp
lamp.
35
36
Sunvisor
NOTE
When not in use keep the
sunvisors in their original position
otherwise they may block the
driver’s vision.
38
39
40
CAUTION
Handle the lighter carefully to
avoid personal injury.
If lighter does not pop out,
remove it to avoid overheating.
Avoid smoking inside the
vehicle; it may spoil inside Cup Holder for rear passengers
ambience, interiors, upholstery
etc.
Cigarette Lighter for Rear passengers
41
42
43
WARNING
Fuel vapour is extremely
hazardous. Always stop the
engine before refueling and
never refuel near sparks or open
flames.
CAUTION
Remove the fuel filler cap slowly,
and wait for any hissing to stop, Fuel Flap Openning Lever
then remove it. The fuel may be
under pressure & may spray
out, causing injury if the cap is
opened suddenly.
44
45
46
47
48
49
50
52
53
Getting Started
KEYS & DOOR LOCK
Keys: Front Doors (Driver & Co- Locking without a key from
driver) inside:
The key operates all locks and
Ignition switch. Locking / unlocking doors with All the doors can also be locked or
key from outside : unlocked independently from
A code number is stamped on the inside by pressing or pulling the
plate attached to the key set. Both front doors (drivers & co-
driver) have separate locking knob (1).
Detach this plate and store at safe
place (Not in the vehicle). This facility. Front doors can be locked NOTE
reference number is necessary or unlocked from outside with key. When locking doors this way, do
while getting duplicate keys from not leave the key inside the
your Authorised Dealer. It vehicle.
advisable to keep another key at
safe place for use in case of
emergency.
NOTICE
Do not use locally made keys,
get duplicate key through your
authorized dealer.
54
Getting Started
DOOR LOCK & CHILD LOCK
Opening the doors from inside : Childproof lock : Tail gate Locking / Unlocking :
All doors can be opened from Both the rear doors of the vehicle Insert the key and turn it anti-
inside. To open pull the door are provided with child proof lock. clockwise to open or clockwise to
opening lever / latch (2). Push the lock lever located on lock the door. Pull the Door handle
vertical face near the lock to open an unlocked door and just
downward before closing the door. by closing the tail gate to its original
The door which has been locked position, it gets locked.
cannot be opened from inside, it
can be opened only from the
outside.
CAUTION
Deactivate the childproof lock
when not required.
Location of door opening lever/
latch
555 5
56
575 7
58
595 9
60
616 1
62
636 3
64
656 5
66
676 7
68
BRAKING
Brakes distance will increase. At the same Put your foot on brake pedal to
The brake system on your time brake indication light would apply brake. Do not ride the
vehicle is an advanced vacuum glow on dash board. brakes as they may overheat and
assisted hydraulic brake If you observe any abnormality in the performance may be impaired.
system, equipped with: brake system contact your nearest The brake lights may confuse the
Q Brake booster : This assists the TATA Motors authorized workshop. other road users behind you.
driver in braking with an In case of failure of vacuum supply Use engine to assist the brakes by
ergonomic pedal force on to the brake booster the vehicle can shifting to a lower gear and lifting
brake pedal; still be stopped with a higher pedal your foot from accelerator pedal.
Q Tandem Master Cylinder, for fail effort. In case of vacuum failure Constant application of brakes
safe braking. or brake circuit failure, slow down while going down the hill builds
the vehicle by shifting to lower gear heat and reduces braking
Q Twin pot calipers, for efficient
and lifting your foot from the efficiency.
energy absorption.
accelerator pedal. Pull the side of Check your brakes after driving
Q Load Sensing Proportionating the road as soon as it is safe.
Valve, to avoid rear wheel through deep water. Apply the
locking in extreme load CAUTION brakes moderately to feel that they
condition. are normal. If not, apply them gently
Brake system failure is very and frequently until they do. With
Q Auto adjusted rear brakes hazardous. It is best to have
wet brakes you should be extra
which are designed for trouble your vehicle towed, but if you cautious and alert in your driving.
free performance. drive the vehicle in this
The system is designed with an H condition, be extremely
circuit, this has an advantage of cautious.Have your vehicle
providing minimum braking even if attended immediately.
one circuit fails, however the pedal
will be harder to press and stopping
696 9
70
717 1
72
74
757 5
76
777 7
78
ENGINE
1. Engine not cranking Dead battery loose or dirty • Get battery checked&/or changed
battery connections • Clean and tighten battery
connections
2. Engine cranks but does not start Air in the fuel system • Press pear pump for air removal
• Check leakages
Service lamp should glow • Get defect rectified
EMS fuse blown • Replace the fuse
3. Engine overheats Coolant level low • Top up coolant, check and
correct leakages
Hose collapse / torn • Get the hose replaced
Low engine oil level • Add oil
Radiator cap not sealing properly • Fit the radiator cap correctly
A.C. condensers fans not working • Get defect rectified
Brakes binding • Get defect rectified
Electric fan not working • Get defect rectified
High delivery pressure in A.C. • Get defect rectified
refrigerant circuit
4. Charging indicator continuously Battery not getting charged • Get the belt tension adjusted
remains ‘ON’ due to loose belt drive Replace if broken
797 9
1. Clutch does not get disengaged Air in the hydraulic system • Bleed the system
Less fluid in the master cylinder • Get the clutch fluid filled
2. Clutch pedal goes too low Air in the hydraulic system • Bleed the system
Less fluid in the master cylinder • Get the clutch fluid filled
3. Clutch pedal return sluggish Blocking of vent in clutch fluid • Open the cap from the bottle
bottle & clean the breather hole, if
clogged
GEAR BOX
1. Hard gear shifting / Clutch does not disengage • Get the clutch hydraulic system
crash engagement properly attended
80
1. Poor brakes Insufficient brake fluid. • Get the brake fluid filled
Air in the system • Bleed the system
Malfunction of automatic adjuster • Check & rectify auto adjuster
mechanism or replace
Vacuum leakage • Rectify the leakage
Brake fluid contamination • Replace the brake fluid
Brake fluid, grease, oil or water • Replace the leaking line, bleed
on pad /drum the system. Clean pad/lining.
replace seals if leaking
Worn brake lining/pad • Get the liners/pad replaced
Excessive worn drums at rear • Replace rear drums
soft or weak hose • Check & replace
818 1
82
838 3
858 5
86
878 7
88
90
4 5
919 1
92
94
979 7
ENGINE COMPARTMENT
98
999 9
100
101
101
102
103
103
Fuel filter separates dust particles This is used for priming the fuel
from the fuel & allows clean fuel in manually after overhauling of the
to the common rail system. It also engine or after refitment of fuel
separates & stores water. lines or after changing either fuel
filter or sedimenter pump, by
means of priming pump / pear
pump until all air in the fuel line
removed. Before cranking the
engine ensure that there is no air
in the fuel system.
104
105
105
106
107
107
108
BATTERY
BATTERY : 3. When this stops wash it off with NOTICE
plain water. Dry off the battery
During normal operation, the
with a cloth or paper towel.
battery generates gas which is
4. Coat the terminal with petroleum
explosive in nature, a spark or
jelly to prevent future corrosion.
open flame can cause the
Use a proper wrench to loosen and battery to explode causing very
remove cables from the terminals. serious injuries.
Keep all sparks & open flames
Always disconnect the negative
and smoking materials away
(-ve) cable first and reconnect it
from the battery.
Check the battery for proper last.
Getting electrolyte in your eyes
electrolyte level and corrosion on Clean the battery terminals with a or on the skin can cause severe
the terminals. terminal cleaning tool or wire brush. burns. Wear protective clothing
1. Check the battery for Reconnect and tighten the cables, and a face shield or have a
electrolyte level against the coat the terminals with petroleum skilled technician to do the
marking on the battery outer jelly. battery maintenance.
case. The battery contains sulphuric
Ensure that battery securely
2. Check the battery terminals for acid (electrolyte) which is
mounted.
corrosion (a white or yellowish poisonous and highly corrosive
If you need to connect the battery in nature.
powder). To remove it, cover the
to a charger, disconnect both
terminals with a solution of
cables to prevent damage to the
baking soda. It will bubble up
vehicle’s electrical system.
and turn brown.
109
109
110
111
111
112
113
113
114
Type : Direct Injection Common Rail Type : Double Synchromesh on all gears.
Turbo Charged Intercooled No. of gears : 5 forward, 1 reverse.
Diesel Engine Gear Ratios : 1st - 4.10
No. Of Cylinders : 4 Inline 2nd - 2.22
3rd - 1.37
Bore / Stroke : 85 mm x 96 mm 4th - 1.00
5th - 0.77
Capacity : 2179 cc
Rev. - 3.75
Max. Engine Output : 88.3 kW (120 ps) at 4000 rpm as
4. REAR AXLE : Single Reduction, Salisbury Type
per CMVR/TAP-115/116
Rear Axle with Hypoid Gears and
Max. Torque : 250 Nm @1500-2500 rpm as per Semi-Floating Axle Shafts & Without
CMVR/TAP-115/116 limited slip differential.
Firing Order : 1-3-4-2 Ratio : 3.73
Engine Oil Capacity : 5.5 Litre Min. & 7.5 Litre Max. 5. FRONT AXLE
2. CLUTCH Type : Independently suspended
Type : Single plate dry friction diaphragm
type.
Outside diameter : 240 mm
of clutch lining
Friction area : 503 sq. cm. (Approximately)
115
115
116
117
117
118
119
119
120
121
121
122
GENERAL
1 Wash the vehicle & Clean the condenser with compressed air Every Service x x x x x x x x
2 Check & Top up Fluids if required: Coolant, Brake / Clutch Fluid, Battery Electrolyte, Power Every Service x x x x x x x x
Steering Oil, Gear Box Oil, Transfer Case & Front Axle (4X4) / Rear Axle Oil
3 Drain water accumulated in Sedimenter (OR Whenever warning lamp glows) Every Service x x x x x x x x
4 Check Engine Compartment for loose Fasteners, Low pressure fuel lines, Coolant hoses, air Every Service x x x x x x x x
hoses, Vacuum hoses, hydraulic line connections for leakages if any, Attend if necessary
5 Check Underbody for loose Fasteners, hydraulic line connections, Exhaust system / Fuel Pipes Every Service x x x x x x x x
for Damages / Leakages if any. Attend if necessary
6 Apply grease on door latches, door lock, door check stop, striker, bonnet opening lever & lock Every Service x x x x x x x
plate, tailgate hinges & door lock inner ratchet.
7 Check & ensure normal working of engine using Diagnostic Equipment. Every Service x x x x x x x x
2.2L DICOR ENGINE
1 *Clean air cleaner filter element, Change if red band appears on service indicator even after Every Service x x x x x x x
cleaning
2 *Change engine Oil and Oil filter. Use APICH4+MB228.3 or Higher grade Engine Oil. Every Service x x x x x x x
OR 1 Year whichever is earlier
3 Check All accessory Drive belts, adjust tension if required, change if damaged Every Service x x x x x x x
OR 1 Year whichever is earlier
4 Change fuel filter Every Service x x x x x x x
OR 2 Years whichever is earlier
5 *Replace air filter element (OR if RED band appears on Service Indicator) 45,000 km x x
6 Change coolant in the cooling system 60,000 km x
OR 2 Years whichever is earlier
7 Change Sedimenter / Water seperator 1,05,000 km x
8 Change Timing Belt & Timing Belt Idler 1,05,000 km x
123
123
9 Change vacuum hoses fotr Vacuum Modulator, Turbocharger, EGR valve & throttle valve 60,000 km x
OR 4 Years whichever is earlier
GEAR BOX
1 *Change oil in gear box (First at 45,000 KM, there after every 90,000 KM) x x
2 Change oil in transfer case (If fitted) 45,000 KM x x
3 Clean breather in gear box (also Transfer case in case of 4X4) Every Oil Change x x
PROPELLER SHAFT
1 Grease propeller shaft with grease gun (at slip joint - splines end) & Check Centre bracket 15,000 km x x x x x x x
mounting bolts for looseness. Tighten if necessary
REAR AXLE
1 Change oil in axle (First at 15,000 KM, there after every 75,000 KM) x x
2 Clean breather in Axle Every Service x x x x x x x
SUSPENSION & STEERING
1 Grease idler arm (seal type idler arm) 15,000 km x x x x x x x
2 Check wheel alignment & balancing, chassis height & adjust if necessary 15,000 km x x x x x x x
3 Check condition of rubber bushes in the following & replace if necessary. 1)Top wishbone 30,000 km x x x
2)Lower wishbone 3)Anti roll bars 4)Rear links 5)Panhard rod 6) Vibration damper
4 Check shock absorber, its bushes & steering damper bushes, replace if necessary 30,000 km x x x
5 Grease steering spindle and sleeve 30,000 km x x x
6 Check & adjust front wheel bearing play & Change grease in front hubs 45,000 km x x
7 Change oil in power steering system & change filter element 75,000 km x
CLUTCH & BRAKES
1 Check parking brakes, adjust if necessary 15,000 km x x x x x x x
2 Check front brake pads & rear brake linings. Replace if necessary 15,000 km x x x x x x x
3 Change Clutch & Brake Fluid (Or 2 years whichever is earlier) 30,000 km x x x
124
125
125
Service Schedule
SERVICE OPERATIONS TO BE PERFORMED
ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS :
A.. Driving in conditions such as Patrolling, Taxi, Pickup Van, Vehicle Towing, with Trailer Towing
B. Driving on Dusty / Sandy roads
C. More than 50% (in terms of kms) driving in heavy city traffic
D. Frequently operating in mountainous area
ITEM INTERVAL CONDITION
A B C D
1. Engine Oil & Oil Filter Change every 7500 kms. z z z z
2. Air Filter Element Clean at every 7500 kms. & z
replace at 30,000 kms.
3. Rear Axle Oil Change Change First at 15000 kms z z z z
& thereafter at 45,000 kms.
126
15,000 1,80,000
30,000 1,95,000
45,000 2,10,000
60,000 2,25,000
75,000 2,40,000
90,000 2,55,000
1,05,000 2,70,000
1,20,000 2,85,000
1,35,000 3,00,000
1,50,000 3,15,000
127
127
3,45,000 5,10,000
3,60,000 5,25,000
3,75,000 5,40,000
3,90,000 5,55,000
4,05,000 5,70,000
4,20,000 5,85,000
4,35,000 6,00,000
4,50,000 6,15,000
4,65,000 6,30,000
4,80,000 6,45,000
128
Chassis No. -
129
129
Chassis No. -
130