Owner’s Manual

LHD
Rajat Gupta
Head - LCV

Dear Customer,
Thank you for choosing our product. We are proud to have you in the Ashok Leyland family.
This Owner’s Manual has been prepared to acquaint you with the opera on and maintenance of your new
vehicle. Care has been taken to include as much useful informa on as possible.
You are requested to read this manual carefully before opera ng the vehicle. For your convenience, we
have provided a "Record of Maintenance" in this manual.
We, in Ashok Leyland are engaged in con nuously improving our products and it is therefore likely that
some of the specifica ons, dimensions or design referred to herein may change over a period of me.
In order to get op mum performance from your vehicle, we would urge you to get all service and repairs
done at the workshops of Ashok Leyland’s channel partners and use only Genuine Spare Parts.
We have put in considerable efforts to ensure the accuracy of the contents of this book and shall be thank-
-ful for any comments you may have to improve the same.

Yours sincerely
ASHOK LEYLAND LTD
India
(Rajat Gupta)
 FOREWORD

First of all, thank you for placing your confidence in one of our vehicles. We are sure you will not regret your choice.
This Owner’s Manual contains all the information you need to know on the range of performances of your vehicle, as well as advice
for driving it, which no doubt you will find very useful. We advise you to read carefully before operating the vehicle.
Your dealer has already carried out a detailed pre-delivery check-up, to make sure that the vehicle is in perfect working condition.
We stress the importance of contacting your AL dealer whenever the vehicle needs any attention, including periodical check-ups
and maintenance operations or repairs, etc., as your dealer is an expert in its care, with specialized personnel and equipment.
VERY IMPORTANT
In order that both you and the other occupants can benefit from safe driving of the vehicle, we recommend that you follow these
rules:
• Only use EURO IV Diesel. Non compliance to the same or usage of adulterated fuel will severely damage the fuel
system & exhaust system.
• Do not drive while under the influence of alcohol or drugs.
• Observe the speed limits indicated in each case, and taking into account extreme conditions such as rain, fog,
snow, ice, etc.
• Use the seat belts in accordance with the regulations.
• Ashok Leyland Ltd. accepts no responsibility for the consequences of failing to comply with this warning.
• Keep Owner’s Manual in the vehicle at all times.
• This book will help you to understand the vehicle better, maximize uptime of the vehicle & obtain better
performance at optimum cost.
• The recommended routine maintenance servicing along with any running repairs that may be required, should be
entrusted to a AL dealer to ensure that only latest methods and genuine parts are used for the continued
reliability, safety and performance of the vehicle.
• Some of the items / accessories / features shown / given in this book may not be fitted on your vehicle, but they
are applicable for other versions of PHOENIX
Ref. No. : OM PNX 3.49 LHD E4 IC / 03-2022
Version : 001
 READING OF THE MANUAL

This manual has been prepared to provide the user with the necessary information on the maintenance of ASHOK LEYLAND PHOENIX
It is hoped that this will also enable them to acquire working knowledge of the vehicle. Ashok Leyland Ltd. reserves the right to change
the procedures, material specification, dimensions, or design of the vehicles shown described referred herein at any time and without prior
notice in accordance with the company's policy of constant product improvement.

Every reasonable effort is made to ensure that this manual is accurate. Before driving your vehicle for the first time, carefully read
this Owners’ Manual so as to familiarize yourself with all the controls and maintenance requirements, to assist you in the safe
operation of your vehicle.

IMPORTANT
Throughout this manual we have used the symbol followed by the word WARNING/CAUTION. This indicates the presence of
a hazard which may cause the possibility of a personal injury or other damage and must be followed precisely.

CAUTION: This is also used throughout the manual to indicate the presence of a hazard that could cause possible minor injury to
yourself or components. Therefore the procedures must be followed carefully.
NOTE. This indicates additional helpful information. In both cases, their contents must be read carefully.

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.

No part of this publication may be translated, restructured or reproduced without the consent of ASHOK LEYLAND LTD.

ASHOK LEYLAND LTD. reserves the right to alter totally or partially (without prior warning) any of the data and specifications
contained in this publication.
The data contained in this publication are those that are currently applicable.
TRANSFEROR
Name:
Contact No.:
Address:

TRANSFEREE
Name:
Contact No.:
Address:

Reg . No
Engine No.:
VIN No.:
Date of Transfer:
 VEHICLE DETAILS

REGISTRATION NO GEARBOX NO

VEHICLE MODEL REAR AXLE NO

CHASSIS NO BATTERY NO

ENGINE NO
TYRE NO

DATE OF SALE
SOLD BY

OWNER' S DETAILS

OWNER NAME

ADDRESS

PH NO
CONTENTS

1. WARRANTY AND SERVICE ................................................................................................1

2. INSTRUMENT AND CONTROLS ....................................................................................... 32

3. PRE-DRIVING CHECKS AND ADJUSTMENTS .................................................................. 49

4. STARTING AND DRIVING ................................................................................................. 63

5. APPEARANCE AND INTERIOR CARE............................................................................... 71

6. IN CASE OF EMERGENCY ............................................................................................... 77

7. TECHNICAL INFORMATION.............................................................................................. 88

8. MAINTENANCE AND DO-IT YOURSELF .........................................................................101

9. GENERAL GUIDELINES FOR BODY BUILDING.. ............................................................. 126

 1. WARRANTY AND SERVICE

CHAPTER 11
1. WARRANTY AND SERVICE
1.1 Warranty Terms.......................................................................................................................................3
1.1.1 Terms of Warranty ..........................................................................................................................3
1.2 Warranty Exclusion List ...........................................................................................................................5
1.2.1 Exhaust Emission...........................................................................................................................7
1.2.2 Emission warranty ..........................................................................................................................7
1.2.3 Terms of Emission Warranty............................................................................................................8
1.2.4 Terms and Conditions .....................................................................................................................8
1.2.5 Annexure 1 ....................................................................................................................................11
1.2.6 Service policy.................................................................................................................................11
1.2.7 Scope of Warranty..........................................................................................................................11
1.2.8 Non-Warranty Items .......................................................................................................................11
1.3 Records of maintenance...........................................................................................................................13
1.4 Maintenance schedule ..............................................................................................................................14

1

1.1 Warranty Terms
1.1.1 Terms of Warranty
ASHOK LEYLAND LIMITED (AL)
warrants each vehicle sold by it to
be free from defects in material and
workmanship subject to the following
terms and conditions:
1. The period of warranty for
PHOENIX shall be 5 years from
date of sale or 5,00,000 Kms
which ever is earlier.
2. The warranty extends to the
registered owner of the
vehicle only or (in the absence
of registration) to the
commercial user of the vehicle.
In the event of transfer or
any alienation otherwise of
the vehicle during the period
mentioned in Clause 1 above,
the warranty shall stand
terminated unless prior written
consent of Ashok Leyland is
obtained.
3. In the event of any defect
being discovered within the
period mentioned in Clause
1 above, the vehicle being
* Conditions Apply
brought to the nearest AL
LCV Dealer workshop, within
the period of warranty as
aforesaid.
4. The obligation under warranty
shall be limited to either
repairing or replacing free of
charge such parts of the vehicle
7.
as are deemed to be defective
in the opinion of AL and shall not
extend to consequential losses.
The replaced part shall become
the property of AL.
5. For proprietary parts not
manufactured by AL such
as Fuel Injection Equipment,
Electrical Equipment,
Instruments, Batteries, Tyres
the warranty terms of the
respective supplier will be
applicable.
6. The buyer shall have no other
right except those expressly
stated herein and have in
particular no right to repudiate
the sale, or any agreement, or
to claim any reduction in the
purchase price of the vehicle
or to demand any damages
or compensation for incidental
1. WARRANTY AND SERVICE
or consequential losses such
as loss of use of vehicle,
11
loss of time, inconvenience or
damage to personal property,
commercial loss such as loss of
revenue etc., during the period
when the vehicle is undergoing
service/warranty repairs.
The customer will be
responsible for
• The cost of non-durable
materials (lubricants, fuel,
grease, etc.,), rubber
items, liners (clutch, brake),
soft trims, upholstery and
paint coatings.
• The cost of maintenance and
lubrication operations.
• The cost of repairs made
necessary by normal wear &
tear, accidents or improper
use not authorised by AL
or by improper storage or
negligence.
• The cost of on-road
repairs, towing, parking
and insurance.
• The cost of repairs, caused
by damage due to
earthquake or such
natural calamities or by civil
disturbance.
3
 1. WARRANTY AND SERVICE
1
8. The warranty shall become null
11 and void:
• If the vehicle is used in ways
not recommended by the
company, if any features of
the vehicle are if
the vehicle is repaired or
disassembled, even partially,
by persons not belonging to
AL’s authorized workshop,
if the vehicle is with
body of design, size, position
and mounting other than
what is prescribed by AL,
if the overhang is extended
in excess of the original
or if the vehicle
is loaded beyond its carrying
capacity as by AL.
• If the fuel injection
equipments calibration
are altered or the
relative seals tampered
with, if unsuitable lubricants
or fuels or coolants are
employed or non-genuine
spare parts are
• If EURO IV fuel not used.
• If the fuel used is adulterated
or contaminated.
• If the Free Services
and other recommended
services mentioned in
Owner’s manual are not
carried out.
4
• If
the recommended
maintenance practice is not
followed.
• If any unauthorized modifications
done in the vehicle.
9. When a part is replaced under
the terms of warranty the
of the warranty shall
apply to the replacement part for
the remainder of the 24 months
period or 1,00,000 KM’s and
not beyond.
10. AL reserves the right to modify
the technical and
introduce improvements to its
vehicles at any time and is under
no obligation to apply such
or improvements to
vehicles produced at an earlier
date.
11. This warranty is in lieu of
and excludes all conditions
warranties liabilities express or
implied, whether in common law
statute or otherwise in relation
to all vehicles, whether covered
by warrant or not.
12. Engine failures due to dust and
water entry, Engine over
racing, wrong gear selection are
subject to investigation and
decision of AL will be final.
 1. WARRANTY AND SERVICE
1.2 Warranty Exclusions List
11
Aggregates Major Non-Warranty Parts / Labour (Warranty Exclusion List)

Air Conditioning System AC Gas Charging

Brake System Components
Cabin & Upholstery
Electrical & ECU
Engine
Engine EATS & Sensors
Engine management System
Frame
Front Axle
Fuel System
Brake Pads, Brake Disc, Drum, Brake Shoe lining, Brake Fluid. MC or Slave Cyl. kit after 1st year
All Plastic & rubber parts and consumables
Switches, Fuses and Bulbs
Gasket & Oil Seals, All mounting, Rubber hoses & clamps and other consumables
Injector cleaning
Fuel Filter, Air filter Elements, Lube filters, Washers, Circlips
Rubber Items & packing, Rust & Paint
King Pin Bush, Wheel bearing and Hub greasing
Hoses & consumables

Gear Box Oil Seals, Mountings and consumables

Gear Shift Actuation Bushes and Rust issues

Propeller Shaft Universal Joint and consumables

Rear Axle Wheel end bearing, Seals and consequential failures

Steering Ball Joints, Rubber parts and hoses

Suspension Bushes

All kind of Lubes, Coolant, Refrigerants, Anabond, thread sealants, Gaskets, Washer, Nut, Bolts,
Consumables
Packings, glass items, Diesel, Disinfectants, Electrolyte

5
 1. WARRANTY AND SERVICE

1 11 Aggregates Major Non-Warranty Parts / Labour (Warranty Exclusion List)

Battery Charging, Gas Purging, Towing, Business losses, Monetary loss, Accident damages, Op-
Activities
erational damages. Any New modification in vehicles due to continuous improvement in Vehicle

Paint or vehicle damage due to storage, Rain, UV Sunlight, thermal effect, flood, Bird drop or
Damages & Natural Calamites damage due wind, humidity or nature, Chemical Acid or acid rain. Hydrostatic lock of Engine,
Water ingress in aggregates. Participation in Race or off-track activities

Tyre, Clutch & Pressure Plate, Fly wheel, Brake Pads & shoe lining, Hoses, Rubber Bushes,
Normal Wear & Tear items
Paint peeling, Straps & Clips

Engine Seals, Hub, Pinion, Drive, accessories belt, Timing belt, Wiper blades, window and Wind-
Seals, Rubber, Plastic & Paint items shields rubber beading. Seat cover, belt, Cushions and plastics knobs. Hoses and Nylon pipes of
all aggregates

6
 1. WARRANTY AND SERVICE

1
and adjustments as may be b. A vehicle which is not which has been changed/
11 required with the view to serviced by AL LCV Dealer tampered with, so that the
establish such compliance. as per the Maintenance actual mileage cannot be
schedule given in the readily determined.
e. Produces the “Pollution
Owner's Manual.
Under Control” (PUC) h. A vehicle which has been
c. A vehicle which has been used for competitions, races,
immediately preceding the subjected to load beyond the rallies or for the purpose of
test during which the failure approved GVW, abnormal establishing records.
is discovered, the test having use, abuse, neglect and
i. Examination by AL or AL LCV
been carried out either for improper maintenance as
Dealer of the vehicle shows
obtaining a new or may be detected by AL LCV
that any of the conditions
pursuant upon being directed Dealers or has met with an
stipulated in the Owner's
by on of as referred to accident.
Manual with regard to use
in Rule 116(3) of the Central
d. Use of replacement parts not and maintenance have been
Motor Vehicles Rules
and approved by violated.
f. Produces Owner's Manual AL.
j. A vehicle which has been
along with the Record of
e. Examination by AL LCV run on adulterated fuel or
Services Performed for
Dealer leads to a conclusion lubricant or fuel/ lubricants
of details.
that original settings in FIP other than those by
g. Produces valid has been tampered with AL in the Owner's Manual/
of insurance and RTO f. A vehicle or a part thereof, any other document given to
registration. which has been altered, the customer by AL at the
tampered, with or or time of sale of the vehicle.
12. Conditions under which
Emission Warranty will not be replaced in an unauthorised Scope and Limits
valid: manner.
1. This Emission Warranty will
a. A valid “Pollution Under g. A vehicle on which the be independent of Product
Control” (PUC) as odometer is not functioning Warranty for the vehicle as per
or the odometer has been the scope and limit described
described in Clause 11(e)
changed or the reading of in the Owner's Manual and all
above is not produced. conditions described therein

10
 PDI COUPON (Customer’s copy) PDI COUPON (Dealer’s copy)
(At the �me of new vehicle delivery) (At the �me of new vehicle delivery)

VA VA

Engine Compartment: Tyre (Pressure, Wear)

Oil (Level, Leakage) Door locks (Opera�on) Job card Number
Coolant (Level, Leakage)
Mirrors Alignment Date of Sale
Drive Belt (Tension)
Power Steering oil (Level) Func�oning of all electrical lights
Intake and Exhaust system Tools & Equipments: Date of Delivery
(Noise, Leakage)
Wheel jack and handle
Passenger Compartment: Distance Covered
Warning Triangle
Brake fluid (Level, Leakage)
Accessories:
Brake & Clutch pedal (play) Chassis Number
First Aid kit
Seat adjusters & seat belts (Check)
Second key Engine Number
Air filter indicator (Check)
Road Test:
Washer fluid (Level, Leakage) Registra� on Number
Engine performance
Steering Lock (Opera�on)
Odometer and trip meter
Under Chassis: Dealer’s Seal and Sign
Clutch and brakes opera�on
Rear axle oil (Level, Leakage)
Gear shi�ing opera�on
Fuel Leakages
AC pipes (Gas leakage)
Power steering pipes (oil Leakage)
Exterior of the vehicle:
Diesel in the fuel tank
Wheel bearing (Play)
: OK T: Tighten C: Clean R: Replace L: Lubricate A: Adjust
 Job card Number
Date of Service

Date of Delivery

Customer’s Name Distance Covered

Contact No. Chassis Number

Engine Number

Customer Signature Registr on Number

Dealer’s Seal and Sign

 1. WARRANTY AND SERVICE

1.3 Records of maintenance

11
RECORD OF MAINTENANCE

DATE NATURE OF DISTANCE JOB CARD COMPLAINT NATURE OF WORK DEALERS SEAL
SERVICE COVERED NO. REPORTED/OBSERVED CARRIED OUT AND SIGNATURE

23
 1. WARRANTY AND SERVICE
1.5 Maintenance Schedule
1 11 PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule
Maintenance Interval (In Kms)
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
Engine
Air filter element primary (Every
1 60,000 Km's or as and when red band Replace I I I I I I R I I I I I R
indication appears)
2 Engine coolant (level, Leakage) Replace I I I I I I I I R I I I I
3 Engine oil and oil filter Replace I R R R R R R R R R R R R
4 Fuel filter & Pre filter element Replace - R - R - R - R - R - R -
5 Timing belt Replace - I I I I I I I R I I I I
6 Alternator belt Inspect - I I I I I I I I I I I I
7 Power steering Inspect - I I I I I I I I I I I I
8 EGR Valve Inspect - - I - I - I - I - I - I
9 Fuel lines and connections leakage Inspect I I I I I I I I I I I I I
Intake and Exhaust system (Noise,
10 Inspect I I I I I I I I I I I I I
Leakage)
Radiator, Intercooler inspection &
11 Clean C C C C C C C C C C C C C
exterior cleaning
12 Inspect exhaust smoke level Inspect I I I I I I I I I I I I I

25
 1. WARRANTY AND SERVICE

PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule

Maintenance Interval (In Kms)
11
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
a) Oil sump bolts Tighten T T T T T T T T T T T T T
b) Fuel filter mounting brackets Tighten T T T T T T T T T T T T T
c) Air cleaner mounting Tighten T T T T T T T T T T T T T
d) Starter motor mounting Tighten T T T T T T T T T T T T T
13
e) Turbocharger mounting Tighten T T T T T T T T T T T T T
f) Exhaust manifold mounting Tighten T T T T T T T T T T T T T
g) Inlet manifold mounting Tighten T T T T T T T T T T T T T
h) Oil Pressure Adapter Tighten T T T T T T T T T T T T T
Clutch
14 Clutch pedal height & free play Inspect I I I I I I I I I I I I I
15 Clutch Pedal Greasing Lubricate L L L L L L L L L L L L L
Gear Box
16 Gear Box oil (level, leakage) - RSB Replace I R I I I I I R I I I I I
17 Vehicle Speedo sensor (mounting) Inspect I I I I I I I I I I I I I
Gear Box mounting bolt (Tighten if
18 Inspect I I I I I I I I I I I I I
necessary)
19 Gear Box breather cleaning Clean C C C C C C C C C C C C C

26
 1. WARRANTY AND SERVICE

1 11
PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule
Maintenance Interval (In Kms)
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
CSO Cables
Gear Cable Standout at Gearbox and
20 Inspect I I I I I I I I I I I I I
Cabin end
CSO cable Grommet fitment with floor
21 assembly to be checked for any tilt or Inspect I I I I I I I I I I I I I
fouling
CSO cable routing clips mounting
22 Inspect I I I I I I I I I I I I I
condition to be checked
Tilt in ball joint at Cabin end to be
23 Inspect I I I I I I I I I I I I I
checked and corrected if necessary
Suspension
Shock absorber (oil leakage, Bush
24 Inspect - - - I - - I - - I - - I
damage replace if necessary)
Condition of leaf spring (front and
rear) and spacer, bump stop, spring
25 Inspect - I I I I I I I I I I I I
seat and bushes (replace if neces-
sary)
Front "U" Bolts Torque (Tighten if
26 Inspect I I I I I I I I I I I I I
necessary)
Rear "U" Bolts Torque (Tighten if
27 Inspect I I I I I I I I I I I I I
necessary)

27
 1. WARRANTY AND SERVICE

PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule

Maintenance Interval (In Kms)
11
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
All bolts and nuts (tighten if
28 Inspect I I I I I I I I I I I I I
necessary)
Brakes
Brake fluid (level, leakage) (Every
29 Replace I I I I R I I I R I I I R
40,000 KM or 1 Year)
Front brake disc and pads for wear
30 Replace I I I I I I I I I I I I I
(Replace if necessary)
Anti - Rattle clip (During every brake
31 Replace - I I I I I I I I I I I I
pad replacement)
32 Caliper mounting bolts inspection Tighten T T T T T T T T T T T T T
Rear brake drum and shoes for wear
33 Replace I I I I I I I I I I I I I
(Replace if necessary)
34 Parking brake adjustment Inspect I I I I I I I I I I I I I
35 Caliper Minor kit Replace - - - - R - - - R - - - R
36 Caliper Major kit Replace - - - - - - - - R - - - -
37 Wheel cylinder assembly - Minor Kit Replace - - - - R - - - R - - - R
38 Wheel cylinder assembly - Major Kit Replace - - - - - - - - R - - - -
Foundation Brake and wheel cylinder
39 Tighten T T T T T T T T T T T T T
mounting bolts
40 Master Cylinder - Major Kit Replace - - - - - - R - - - - - R

28
 1. WARRANTY AND SERVICE

1 11
PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule
Maintenance Interval (In Kms)
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
41 Master Cylinder - Assembly Replace - - - - - - - - R - - - -
42 Brake pedal height & free play Inspect I I I I I I I I I I I I I
43 Brake Pedal Greasing Lubricate L L L L L L L L L L L L L
Front Axle
44 Wheel alignment Replace - R R R R R R R R R R R R
45 Greasing for kingpin Replace - R R R R R R R R R R R R
46 Kingpin play Inspect - I I I I I I I I I I I I
47 Wheel end play Inspect I I I I I I I I I I I I I
Rear axle
48 Rear axle oil (level, leakage) Replace I I I I R I I I R I I I R
49 Breather Clean Clean - C C C C C C C C C C C C
50 Wheel end play Inspect I I I I I I I I I I I I I
Wheels & Tyres
51 Tyre pressure and Wear Inspect I I I I I I I I I I I I I
52 Tyre rotation Rotate - WR WR WR WR WR WR WR WR WR WR WR WR
53 Wheels (damage) Inspect I I I I I I I I I I I I I
54 Wheel Alignment & Balancing Replace I R R R R R R R R R R R R
55 Wheel Stopper Bolt Check Inspect I I I I I I I I I I I I I

29
 1. WARRANTY AND SERVICE

11
PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule
Maintenance Interval (In Kms)
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
Power Steering
Oil in power steering container (Level,
56 Replace I I I I I I I I R I I I I
leakage)
57 Steering wheel free play Inspect I I I I I I I I I I I I I
Steering gear box mounting, pitman
58 Inspect - I I I I I I I I I I I I
drag link, tie rod (tighten if necessary)
Ball joint play and condition of castle
59 Inspect - I I I I I I I I I I I I
nut and cotter pin
60 Steering tie rods (damage and wear) Inspect I I I I I I I I I I I I I
61 Steering column greasing Lubricate L L L L L L L L L L L L L
Electricals
56 Battery electrolyte (level, leakage) Inspect I I I I I I I I I I I I I
57 Head lamp aiming and focus Inspect I I I I I I I I I I I I I
Water level in wind screen washer
58 Inspect I I I I I I I I I I I I I
container
Inspect electrical gauges for func-
59 Inspect I I I I I I I I I I I I I
tioning
60 All Wiring harness connections Inspect I I I I I I I I I I I I I
Ratings and condition of all fuses and
61 Inspect I I I I I I I I I I I I I
relays

30
 1. WARRANTY AND SERVICE

1 11
PHOENIX - EURO 4 (Ivory Coast) - Periodic Maintenance Schedule
Maintenance Interval (In Kms)
FREE SERVICE PAID SERVICE
S.No Description Activity

100000

120000
110000
10000

20000

30000

40000

50000

60000

70000

80000

90000
5000
Air Conditioner
62 Belt tension Inspect I I I I I I I I I I I I I
63 Clean condenser Clean C C C C C C C C C C C C C
64 Pipe joints for gas leakage Inspect I I I I I I I I I I I I I
65 Mounting bolts Tighten T T T T T T T T T T T T T
Mounts
66 Engine mount insulator Inspect I I I I I I I I I I I I I
67 Gear box mount insulator Inspect I I I I I I I I I I I I I
68 CAB mount insulator Inspect I I I I I I I I I I I I I
69 Engine mounting cross member Inspect I I I I I I I I I I I I I
Frame
70 Complete frame general inspection Inspect I I I I I I I I I I I I I
Frame side member general
71 Inspect - - - - - I - - - - I - -
inspection
72 All cross member general inspection Inspect - - - - - I - - - - I - -
73 All brackets general inspection Inspect - - - - - I - - - - I - -
74 All fasteners torque Inspect - - - - - I - - - - I - -

T - Tighten, I - Inspect, R - Replace, C - Clean, WR - Wheel Rotation, L - Lubricate

31
 2. INSTRUMENT AND CONTROLS

CHAPTER

2. INSTRUMENT AND CONTROLS 21

2.1 Dashboard (PHOENIX)............................................................................................................................. 34

2.2 Instrument cluster (PHOENIX)................................................................................................................... 35
2.3 Instrument gauges ................................................................................................................................ 36
2.4 Fuel gauges .......................................................................................................................................... 36
2.5 Windshield wiper switch......................................................................................................................... 40
2.6 Headlight, dimmer and turn signal switch ................................................................................................ 41
2.7 Headlight levelling switch....................................................................................................................... 41
2.8 Hazard warning switch .......................................................................................................................... 42
2.9 Horn................................................................................................................................................... 42
2.10 12V Outlet .......................................................................................................................................... 42
2.11 Interior light or cabin light ..................................................................................................................... 42
2.12 Tail lamp ............................................................................................................................................. 42
2.13 Glove box ........................................................................................................................................... 42
2.14 Bottle holder(If equipped)..................................................................................................................... 43
2.15 AC controls and operation.................................................................................................................... 44
2.15.1 Air ...................................................................................................................................... 44
2.15.2 Vent........................................................................................................................................... 45
2.15.3 Air ventilator............................................................................................................................... 45
2.15.4 Air conditioner/Cooler operation .................................................................................................. 45

32
 2. INSTRUMENT AND CONTROLS

2.1 Dashboard (PHOENIX)

Glove box with
lock and key

21
arrangement -
optional
Center ventilator
(if fitted)
Hazard Switch
Center ventilator
(if fitted)

Side ventilator Side vents

(if fitted) (if provided)

Horn
Instrument
Cluster Steering wheel Air conditioning control panel
(If fitted)

34
 2. INSTRUMENT AND CONTROLS

2.2 Instrument cluster (PHOENIX)

Speedometer High beam indicator
Low oil pressure indicator
Turn Signal hazard indicator
Service lamp
Turn Signal hazard
Charge indicator 21
indicator

rpmX100

40 F
32
24 km/h
16
8 AM E
PM
ODO TRIP A B IFE DTE
AVG
km/1

SET MODE

Fuel gauge
Parking brake/Low
brake fluid indicator High coolant
Malfunction indicator temperature Water in fuel indicator
Odometer/Tripmeter indicator
and clock

35

2.3 Instrument gauges
Speedometer
The speedometer indicates vehicle
speed in km/hr.
Odometer/Trip meter and Clock
• The odometer records the total
distance the vehicle has been
driven.
• The trip meter records the
distance of individual trips.
• Digital clock displays the time.
When the ignition switch is turned
to “ON”, the display shows any
one of the four types of indication;
odometer, trip meter A, trip meter B
and clock as shown.
36
2. INSTRUMENT AND CONTROLS
Procedure to change the MODE 4. To increase the minutes, press
1. To change from Odo to Trip A SET Button. Each key stroke will
press mode knob for less than 1 increase one Minute.
sec.
2. To change from Trip A to Trip B
press mode knob for less than 1
5. After Setting Minute, navigate to
AM / PM by pressing MODE 21
sec. Button again. Now AM / PM will
flash. Press SET button to
3. To change from Trip B to Clock
press mode knob for less than 1
change between AM / PM.
sec. 6. After setting AM / PM, press
4. To change from Clock to Odo Mode button save the set timing.
press mode knob for less than 1
sec. 2.4 Fuel Gauge
CLK/ODO
CLK/Trip B CLK/Trip A
Procedure to set the Clock The display indicates the
1. Long press MODE button to APPROXIMATE fuel level in the
select the clock screen. Now tank.
hours digit will start flashing.
2. To increase the hour, press
SET button. Each key stroke
will increase one hour.
3. After setting Hour, navigate to
Minutes by pressing the
MODE Button. Now Minutes
digits will start flashing.
 2. INSTRUMENT AND CONTROLS

This display indicates, approximate fuel level in the fuel tank.

PHOENIX - 50 Liters Capacity

Fuel segment indication Fuel quantity in liters Cluster indication

21

1. Red blinking 0-9

1. Red 10-12

2. Amber 13-22

3. Green 23-35

4. Green 36-44

5. Green 45-50

37
 2. INSTRUMENT AND CONTROLS

Low fuel warning No of Bar Colour Engine Speed in Rpm This light along with Buzzer (if
indicator–Amber light (If 1 Green 800 equipped) warns of low engine oil
equipped)
2 Green 1600 pressure. If the light comes on during
3 Green 2400 normal driving, pull off the road in a
4
5
Amber
Red
3200
4000
safe area, stop the engine 21
immediately and call AL LCV Dealer.
Note
Note
It is recommended to operate the
This light also comes on when the Whenever Ignition switch is on Low
engine at 2400 Rpm (Green band)
fuel tank is low on fuel. When you oil pressure tell tale will be on with
add fuel the light should go off. If Check Lamps continious buzzer. Once Engine is
doesn't contact your AL LCV Dealer. started tell tale and Buzzer shall go
Apply the parking brake and turn the
off
Note ignition key to "ON" without starting
Refill the fuel tank when RED bar the engine. The following lights will
starts blinking come on: WARNING

Running the engine with the Low

Tachometer
The Tachometer indicates the oil pressure indicator on could
cause serious damage to the
Engine Speed in Revolutions Per If any light fails to come on, it engine.
Minute (rpm) may indicate an open circuit in the
rpmX100 electrical system. Have the system
repaired promptly. High coolant temperature
40 indicator–Red light
All lamps should go off after starting
32 the engine. If any check lamps
24 glowing or blinking continuously,
please contact the nearest AL LCV
16 dealership.
8 Low oil pressure indicator–Red The tell tale indicates when the
light engine temperature is high, along
The Display indicates the with Buzzer(if equipped)
APPROXIMATE engine Speed
If the light indicates , stop the vehicle
as soon as safely possible. If the

38

engine is overheated, continued
operation of the vehicle may
seriously damage the engine. see “In
case of emergency” section for
immediate action required.
WARNING
Do not remove the radiator cap
while the engine is hot. Otherwise,
there is a danger of being burned
by the coolant which is likely to
erupt from the radiator.
Charge indicator–Red light
If the light comes on while the engine
is running, it may indicate that there
is something wrong with the charging
system. Turn the engine off and
check the alternator belt. If the belt is
loose, broken, missing or if the light
remains on, contact your AL LCV
Dealer immediately.
WARNING
Do not continue driving if the belt
is loose, broken or missing. This
may cause severe harden brake
pedal and continuous battery
discharging.
Parking brake/Low brake
indicator–Red light
P brake
This light functions for both the
parking brake or low brake in
the system.
The light comes along with Buzzer
(if equipped) when the parking brake
is applied and vehicle is moved or
brake level in reservoir is below Min
level.
If the light comes on along with
Buzzer while the engine is running with
the parking brake not applied, stop the
vehicle and check the brake level.
Add brake as necessary. See
"Brake level" in the "Maintenance
and Do-it-yourself” section.
WARNING
If the level is below the MINIMUM
mark on the brake reservoir,
do not drive until the brake system
has been checked at a AL LCV
Dealer.
2. INSTRUMENT AND CONTROLS
Note
Pressing the brake pedal with
the engine stopped and/or low
level could increase
your stopping distance and require
21
greater pedal effort as well as pedal
travel.
Water in fuel indicator–Yellow
light
If the light comes on while the engine
is running, it warns that you need to
drain the water from the fuel .
See "Fuel in the "Maintenance
and Do-it-yourself" section. Fail
to drain water can cause serious
damage to the engine.
Turn signal/hazard indicator
The light when the turn signal
switch lever or hazard switch is
turned on.
39

High beam indicator–Blue light
This light comes on when the
headlight high beam is on, and goes
off when the low beam is selected.
Service lamp–Red light
If the light comes on while the engine
is running, it indicates that there is
something wrong with the engine
electronic control system.
CAUTION
• If the light comes on while
driving, slow down until the
light goes out.
• If the light remains still on
contact your nearest AL LCV
Dealer.
Malfunction indicator–Amber light
40
2. INSTRUMENT AND CONTROLS
If the light comes on, it warns that
emission from vehicle are not at
acceptable levels. Contact your AL
LCV Dealer to rectify.
21
2.5 Windshield wiper switch
Note
Do not operate the wipers if
the windshield is dirty, it may
scratch/damage the glass.
2.6 Headlight, dimmer and
Windshield wiper switch with turn signal switch
washer
Lighting
Move the lever back to operate the
wiper.
Pull the lever towards you to spray
windscreen washer
WARNING
To avoid possible injury, do not
operate controls by reaching
through the steering wheel.

Turning the switch to the below
position:
The parking, tail, license plate and
instrument lights will come on.
Turning the switch to the below
position:
Headlights will come on and all the
other lights remain on.
To select the high beam, push the
lever down. Pull it back to select the
low-beam.
Flashing headlight
2. INSTRUMENT AND CONTROLS
Pulling the lever toward you will turn The projected angle of the headlights
on the headlight main beam. may change with the condition and
load. This switch is used to adjust
Turn signal-Green light
the projected angle to the proper
level. 21
Adjust the switch knob by referring to
the following examples:
Switch Loading
position condition
0 Driver
1 Driver + Load
Move the lever front and back to
2.8 Hazard warning switch
signal the turning direction. When
the turn is completed, the turn
signals cancel automatically.
Hazard
2.7 Headlight levelling switch Switch
0
1
2
Hazard warning switch
3
Push the switch on to warn other
drivers when you stop or park under
emergency conditions. All turn
signal lights wills
41

2.9 Horn
To sound the horn press the horn
button of the steering wheel. The
horn can be operated with the any
position of ignition switch.
2.10 12V Outlet
12 V outlet can be used for mobile
charging and cigarette lighter.
42
2.11 Interior light or cabin light
The switch has two position “ON or
OFF”. The light comes ON when it is
turned to ON position and vice verse.
2.12 Tail lamp
Brake light: Brake lights comes ON
when the brake pedal is pressed or
headlight is switched ON.
Reverse light: Reverse light comes
ON when gear is shifted to reverse.
2. INSTRUMENT AND CONTROLS
2.13 Glove box
21
To open the glove box press the latch
lever. To close it push the lid until it
latches securely.
The glove box also comes with an
optional lock and key arrangement.
To open the glove box, insert key
and turn clockwise and pull gently.
To close and lock, push back the
lid and turn the key in anti-clockwise
direction and withdraw the key.
 2. INSTRUMENT AND CONTROLS

WARNING

Never drive with glovebox lid

open, it could cause injury if an
21
accident occurs.

2.14 Bottle Holder (If equipped)

Bottle holders provided in both the

doors as shown in image.

43
 2. INSTRUMENT AND CONTROLS

2.15 AC controls and operation (If equipped)

2.15.1 Air flow
21
Glove box with lock and key
arrangement - optional

DEMISTING VENT (WINDSCREEN)

SIDE AIR SIDE AIR

VENT VENT

CENTER AIR VENT CENTER AIR VENT

FOOT OUTLET

44
 2. INSTRUMENT AND CONTROLS
2.15.2 Vent Air Intake Lever
Air comes out of the
Fresh air Mode centre and side air

21
Outside air is drawn into vents.
the cab.
Air from center
Recirculation Mode
vents side vents and
Interior air is recirculated foot outlet.
inside the vehicle.
Air comes out of the foot
Recirculation mode can be used in outlets.

Adjust the air direction of the 1. While driving in dusty Air comes out of the foot
ventilators as shown in the above conditions. outlets, and towards the
2. To avoid traf pollution. windscreen.
2.15.3 Air ventilator 3. To get quick cooling. Air comes out towards
the windshield.
Note 2.15.4 Air conditioner/Cooler
Whenever discomfort is felt air intake operation
lever need to be moved to fresh air
mode.

Blower speed knob

This knob turns the fan on and off,
and controls fan speed.
Air direction control knob
The knob allows you to select the air
direction.

45

Start the engine, move the blower
speed knob to the desired (1 to 4)
position and push in the A/C switch
to activate the air conditioner.
Note
The air conditioner cooling function
operates only when the engine
is running. A/C also trip off
automatically when the engine
overheats. The A/C is switched on
when the engine cools down.
Normal cooling
1. Move the air intake
lever to the position.
2. Move the air direction
control knob to the
position.
3. Move the blower speed knob to
the required position.
4. Push on the A/C switch. The
indicator light will show that A/C is
on.
46
2. INSTRUMENT AND CONTROLS
Operating tips
• Keep windows closed while the
air conditioner is in operation.
• After parking in the sun, drive
21
for two or three minutes with the
windows open to vent hot air from
the passenger compartment .
Then, close the windows. This
will allow the air conditioner to
cool the interior more quickly.
• The air conditioning system
should be operated for about ten
minutes at least once a month,
especially in winter. This could
prevent damage to the system
due to lack of lubrication.
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS

CHAPTER

3. PRE-DRIVING CHECKS AND ADJUSTMENTS

3.1 Key ...................................................................................................................................................... 51
3.2 Door locks ............................................................................................................................................ 51
3.2.1 Locking doors with key ................................................................................................................. 51
31
3.2.2 Locking the doors without key ....................................................................................................... 51
3.2.3 Fuel cap with key .................................................................................................................. 41
3.3 Seats ................................................................................................................................................... 52
3.3.1 Forward and backward ................................................................................................................. 52
3.3.2 Reclining ..................................................................................................................................... 52
3.3.3 Tilting the seats ............................................................................................................................ 53
3.4 Window ................................................................................................................................................ 53
3.5 Seat Belts............................................................................................................................................. 53
3.5.1 Seat belt maintenance .................................................................................................................. 54
3.6 3-Point type with retractor ...................................................................................................................... 54
3.6.1 Fastening the belts ....................................................................................................................... 54
3.6.2 Unfastening the belts .................................................................................................................... 55
3.6.3 Checking seat belt operation ......................................................................................................... 55
3.6.4 Convenience clip.......................................................................................................................... 55
3.7 Operating Foldable Type Parking brake lever ......................................................................................... 56
3.8 Outside rear view mirror........................................................................................................................ 47
3.9 Inside rear view mirror ........................................................................................................................ 47
3.10 Tail gate .............................................................................................................................................. 47

49

3.1 Key
Record the key number on the key
plate/metal tag and keep it in a safe
place, The vehicle comes with a pair
of identical keys. keep the spare
key in a safe place. If you lose your
keys, contact your AL LCV Dealer for
duplicates by using the key number.
CAUTION
Do not leave the ignition key
inside the vehicle when leaving
the vehicle.
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
3.2 Door locks
3.2.1 Locking doors with key
To lock the door from outside the
vehicle, insert the key and turn the
top of the key anti-clockwise.
To unlock the door from outside the
vehicle, insert the key and turn the
top of the key clockwise.
3.2.2 Locking the doors without
key
Press down the door lock button to
lock the doors and lift it upwards to
unlock the doors.
Note
The driver's door cannot be locked
from the outside without a key. 31
Use the key to lock the door. This
is to prevent the door lock from
accidentally being locked with the
key inside the vehicle.
WARNING
Before opening the door, always
look for and avoid oncoming
traf
3.2.3 Fuel cap with key
51
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS

The fuel tank is located on the left 3.3 Seats 3.3.2 Reclining
hand side of the vehicle.
Seat Adjustment
The fuel cap is located on the
top of the fuel tank. WARNING

The fuel cap can be unlocked by
using the key provided.
CAUTION
Fuel may be under pressure. Turn
the cap one-half turn and wait for
any “hissing” sound to stop, to
prevent fuel from spraying out and
possible personal injury.
Note
Use only a genuine AL fuel cap
as a replacement. It has a built-in
safety valve needed for proper
operation of the fuel system. An
incorrect cap can result in a serious
malfunction and possible injury.
Do not adjust the driver's seat
while driving. The seat may move
suddenly and could cause loss of
control of the vehicle.
Note
After adjustment, be sure that the
seat is securely locked by slightly
rocking the seat.
3.3.1 Forward and backward
Pull the lever up and hold it while you
slide the seat forward or backward
to the desired position. Release the
lever to lock the seat in position.
31
Pull the lever up and lean back until
the desired angle is obtained. To
bring the seat back forward again,
pull the lever and move your body
forward. The seat back will move
forward.
WARNING
The seat back should not be
reclined any more than needed
for comfort. Seat belts are most
effective when the passenger sits
well back and straight up in the
seat. If the seat back is reclined,
the risk of sliding under the lap belt
and being injured is increased.

52

3.3.3 Tilting the seats
Move the lever to tilt down the seat
back.
3.4 Window
Window adjustment
Raise or lower the door window by
turning the handle located on the
door panel.
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
Sliding glass window (If
WARNING
Seat belts are designed to bear
upon the bony structure of the
body, and should be worn low
across the front of the pelvis, or
the pelvis, chest and shoulders, as 31
applicable; wearing the lap section
of the belt across the abdominal
area must be avoided. Serious
injury can occur if seat belt is not
Sliding window is provided in the rear worn properly.
of the cabin for better visibility and
accessibility for the co-driver to the
cargo deck area.
3.5 Seat Belts
Precautions On Seat Belt Usage
Note
AL strongly encourages you and
your co-driver to buckle up every
time you drive. Your chances of
being injured in an accident and/or
the severity of injury may be greatly
reduced if you are wearing your seat
belt and it is properly adjusted.
53

WARNING
• No or additions
should be made by the user
which will either prevent the
seat belt adjusting devices
from operating to remove
slack, or prevent the seat belt
assembly from being adjusted
to remove slack.
• Seat belts should be adjusted
as as possible,
consistent with comfort, to
provide the protection for which
they have been designed. A
slack belt will greatly reduce
the protection afforded to the
Wearer.
Note
• Care should be taken to avoid
contamination of the webbing with
polishes, oils and chemicals, and
particularly battery acid. Cleaning
may safely be carried out using
mild soap and water. The belt
should be replaced if webbing
becomes frayed, contaminated or
damaged.
54
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
• It is essential to replace the entire
assembly after it has been worn in
a severe impact even if damage
to the assembly is not obvious.
• All seat belt assemblies including
retractors and attaching hardware
should be inspected after any
collision at your AL LCV Dealer.
AL recommends that all seat
belt assemblies in use during a
collision be replaced unless the
collision was minor and the belts
show no damage and continue
to operate properly. Seat belt
assemblies not in use during a
collision should also be inspected
and replaced if either damage or
improper operation is noted.
3.5.1 Seat belt maintenance
• To clean the seat belt
webbings, apply a mild
soap solution or any solution
recommended for cleaning
upholstery or carpets. Then
brush it, wipe with a cloth and
allow it to dry in the shade. Do
not allow the seat belts to retract
until they are completely dry.
• If dirt builds up in the shoulder belt
guide of the seat belt anchors,
the seat belts may retract slowly.
Wipe the shoulder belt guide with
a clean, dry cloth.
• Periodically check to see that
the seat belt and the metal 31
components such as buckles,
retractors, wires and
anchors work properly. If loose
parts, deterioration, cuts or other
damage on the webbing is found,
the entire belt assembly should
be replaced.
3.6 3-Point type with retractor
3.6.1 Fastening the belts
1. Adjust the seat.
2. To fasten the seat belt, sit
up straight and well back in
the seat, pull the latch plate
attached to the seat belt across

your body and press it into the
buckle until you hear a “click”
sound.
3. Position the lap belt portion low
on the hips as shown.
4. Pull the shoulder belt portion
toward the retractor to take up
extra slack.
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
question about belt operation contact
WARNING
your AL LCV Dealer.
• The seat belt should rest on the 3.6.4 Convenience clip
middle of the shoulder. It must
not rest against the neck.
• Make sure that the seat belt is
not twisted in any way. 31
3.6.2 Unfastening the belts
To unfasten the belt, push the red
“PRESS” button on the buckle and
allow the belt to retract.
3.6.3 Checking seat belt operation
Your seat belt retractors are The convenience clip is provided
designed to lock belt movement by to keep the belt in an accessible
two separate methods: position when not being used.
1. When the belt is pulled quickly Slide the convenience clip down if
from the retractor. the clip prevents the belt from being
2. When the vehicle slows down retracted into the retractor.
rapidly. Slide it away from the buckle if the
convenience clip contacts the belt
when the belt is worn.
belts, check the operation as follows:
Grasp the shoulder belt and pull
quickly forward. The retractor
should lock and restrict further belt
movement.
If the retractor does not lock during
these checks or if you have any
55

3.7 Operating Foldable type
Parking Brake Lever
Carefully read and understand the
below instructions about Foldable
type Parking brake lever before
operating.
Phoenix is equipped with Foldable
parking brake lever to provide fully
flat sleeper provision for driver when
vehicle is parked.
Normal Engaging &
Dis-Engaging Process:
Step 1 : Disengaged Position
Step 2 : To engage Hand Brake
Gently pull the lever in the direction
shown in below figure.
56
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
Step 3 : To Disengage the Hand
Brake
Push the knob as shown
Step 2: To fold the lever (In Hand 31
Brake engaged Condition)
Pull the knob in the direction shown
in figure.
And lower the lever to disengage
the hand brake. Ensure the
Handbrake warning lamp in
Dashboard is not glowing, which
indicates the complete
disengagement of hand brake.
Then lower the hand brake lever.
Now hand brake warning lamp (Red
Colour light) in dashboard and
cluster will continue to glow, which
marks the engagement of hand
Hand Brake Lever Folding
Process in brake engaged brake.
condition
Step 1 : To engage Hand Brake
Gently pull the lever in the direction
shown in below figure.
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS
Step 3: To disengage the hand
brake
Lift the hand brake lever and press
the knob as shown in the below
image.
31

Then lower the lever towards

downward position to disengage the
hand brake.

WARNING

• Ensure the warning lamp in

dashboard & speedometer is
going off before moving the
vehicle.

57
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS

3.8 Outside rear view mirror To adjust the mirror move the mirror
up, down or sideways by hand to
obtain the best view.
Outside
rear view
mirror CAUTION
Be careful when judging the size 31
or distance or other object seen in
the mirror.

3.10 Tail gate

Adjust the outside rear view mirror so To unlock and open:
that you can just see the side of your
vehicle in the mirror.
3.9 Inside rear view mirror

You can adjust the inside rear view

mirror by hand so as to see the rear
of your vehicle in the mirror.

58

The load body is locked by a locking
mechanism on both left and right
side top corner. Pull the locking
handle away from the tail gate and
the interlocking arm out of the locking
hook. Perform the same on the other
side. Take care while removing the
other side as the tail gate may drop
down all of sudden.
To lock and close:
3. PRE-DRIVING CHECKS AND ADJUSTMENTS
Push the tail gate up and place in
vertical position. Insert the locking
arm in the hook and press the locking
handle against the tail gate. After
performing the same on the other
side check the closing of 31
the tail gate by pulling the tail gate
down.
59
 3. PRE-DRIVING CHECKS AND ADJUSTMENTS

31

60
 4. STARTING AND DRIVING

CHAPTER

4. STARTING AND DRIVING

4.1 Break-In schedule ................................................................................................................................. 45
4.2 Before starting the engine...................................................................................................................... 45
4.3 Precautions when starting and driving .................................................................................................... 45
1 14 4.3.1 Exhaust gas (Carbon Monoxide) ................................................................................................... 45
4.3.2 Catalytic convertor........................................................................................................................ 46
4.3.3 To help prevent damage ............................................................................................................... 46
4.3.4 Care when driving ........................................................................................................................ 46
4.3.5 Engine cold start period ................................................................................................................ 46
4.3.6 Loading the baggage .................................................................................................................... 46
4.3.7 When the road is wet or under winter conditions............................................................................. 46
4.4 Ignition switch ....................................................................................................................................... 47
4.5 Starting the engine ................................................................................................................................ 47
4.6 Driving with manual transmission ........................................................................................................... 47
4.6.1 Driving the vehicle ........................................................................................................................ 47
4.6.2 Driving precautions....................................................................................................................... 48
4.6.3 Suggested shift-up speeds............................................................................................................ 48
4.7 Parking................................................................................................................................................. 48
4.8 Precautions when driving....................................................................................................................... 49
4.8.1 Driving uphill ................................................................................................................................ 50
4.8.2 Driving downhill............................................................................................................................ 50
4.9 Cold weather driving.............................................................................................................................. 50
4.10 Corrosion protection ............................................................................................................................ 50
63
 4. STARTING AND DRIVING
4.1 Break-In schedule • Fasten seat belts and ask 4.3 Precautions when starting
co-driver to do likewise. and driving
During the 5,000 kms, follow
these recommendations for the • Do not place hard or heavy 4.3.1 Exhaust gas (Carbon
future reliability and economy of your objects on either the front or rear Monoxide)
new vehicle. parcel shell to prevent injury in
the event of a sudden stop. WARNING
• Do not accelerate hard in top
gear. • Check the operation of warning • Do not breathe exhaust
lights when key is turned to the gases; they contain

1
• Avoid quick starts and full “ON” position.
14
colorless and odorless
acceleration. carbon monoxide. Carbon
• Avoid hard stops as much as WARNING monoxide is dangerous. It
possible. can cause unconsciousness
The driving characteristics of or death.
• Do not tow a trailer for the 2500
your vehicle can be changed
km. • If you suspect that exhaust
remarkably by any additional fumes are entering the
load. Your driving style and vehicle, drive with all
4.2 Before starting the engine speed have to be adjusted windows fully open, and
accordingly. Especially when have the vehicle inspected
• Make sure the area around the immediately.
vehicle is clear. carrying heavy loads, your
speed must be reduced • Do not run the engine in
• Check levels such as engine adequately. closed spaces such as a
oil, coolant and brake. garage.
• Check that all windows and light • Do not park the vehicle with
lenses are clean. WARNING
the engine running for any
• Visually inspect tires for their Use only EURO IV Diesel. Non extended length of time.
appearance and condition. Also compliance to the above or • It is not advisable to sit
check tire pressure for proper usage of adulterated fuel will for any length of time in
severly damage complete fuel a parked vehicle with the
system & exhaust system. engine running and A/C ON.
• Lock all doors.
• Adjust inside and outside mirrors.

65
 4. STARTING AND DRIVING
4.3.2 LNT & DPF & pSCR
A catalytic converter is an emission
control device, installed in the
exhaust system. Exhaust gases in
the converter. Harmful pollutants in
the exhaust gases are processed
and converted before getting
released to atmosphere.
1 14
CAUTION
• The exhaust gas and the
exhaust system are very hot.
While the engine is running,
keep people or
materials away from the
exhaust pipe.
• Do not stop or park the vehicle
over materials such
as dry grass, waste paper or
rags as they may burn easily.
4.3.3 To help prevent damage
CAUTION
• Keep your engine tuned
up. Malfunctions in the fuel
injection or electrical systems
can cause over rich fuel
into the engine, causing it to
overheat.
66
WARNING
Do not keep driving if the
engine or if noticeable
loss of performance or other
unusual operating conditions
are detected. Have the vehicle
inspected promptly by an
authorized AL LCV Dealer.
CAUTION
• Avoid driving with an extremely
low fuel level. Running out of
fuel could cause the vehicle
to not start due to air lock or
engine to or damage
the Exhaust System .
• Do not race the engine while
warming it up.
• Do not push or tow your vehicle
to start the engine.
4.3.4 Care when driving
Driving your vehicle to the
circumstances is essential for your
safety and comfort. As a DRIVER,
you should be the one who knows
best how to drive in the given
circumstances.
4.3.5 Engine cold start period
Due to the higher engine speeds
when the engine is cold, extra
caution must be exercised when
selecting gear during engine
warm-up period after starting the
engine.
4.3.6 Loading the baggage
Loads and their distribution and
the attachment of equipment
(coupling devices, roof baggage
carriers, etc.) will change the
driving characteristics of the vehicle
considerably. Driving style and
speed must be changed according
to the circumstances.
4.3.7 When the road is wet or
under winter conditions
• Avoid quick acceleration and
sudden braking.
• Avoid sharp turns or lane
changes.
• Suf distance to be
maintained from the vehicle in
front.
• When water covers the road
surface in puddles, small
streams, etc, REDUCE SPEED
 4. STARTING AND DRIVING
to prevent aquaplaning which will
cause skidding and loss of control
(worn tires increase this risk).
4.4 Ignition switch
1 14
The switch includes the anti-theft
steering lock device.
"LOCK" Normal parking position
The ignition key can only be removed
at this position.
To lock the steering wheel, remove
the key. To unlock the steering
wheel, insert the key and turn it
gently while rotating the steering
wheel slightly right and left.
"ACC" (Accessories) This position
activates electrical accessories such
as the radio, instrument cluster lamp
when the engine is not running.
CAUTION
Do not keep the ignition switch in
“ON” or “ACC” position for longer
time, if it is not followed leads to
complete battery drain.
"ON" Normal operating position.
This position turns on the ECU and
fuel pump.
"START" This position starts the
engine. As soon as the engine has
started, release the key immediately.
It will automatically return to the "ON"
position.
4.5 Starting the engine
1. Move the gearshift lever to "N"
(Neutral).
2. Ensure that the service lamp is
off before starting the vehicle.
3. Press the clutch pedal
4. Start the engine
5. Keep the engine idle for atleast
30 seconds. Do not accelerate
the engine immediately after
starting to avoid damage to the
turbocharger.
CAUTION
Do not crank the engine for more
than 15 seconds at a time. If
the engine does not start, wait
30 seconds and remove the key
before cranking again otherwise
the starter could be damaged.
4.6 Driving with manual
transmission
1 3 5
N
2 4 R
4.6.1 Driving the vehicle
1. Depress the clutch pedal to the
and move the gearshift
lever to the "1" or "R" position.
2. Slowly depress the accelerator
pedal, releasing the clutch pedal
at the same time.
67
 4. STARTING AND DRIVING
4.6.2 Driving precautions
To change gears, fully depress the
clutch pedal, then move the gearshift
lever. After shifting, release the
clutch slowly.
On the 5-speed transmission model,
you should not shift directly from 5th
gear into Reverse. First shift into
1
Neutral, then into Reverse.
14 If it is dif to move the shift lever
into Reverse or 1st, shift into Neutral,
then release the clutch pedal and
shift into Reverse or 1st again.
CAUTION
• Do not rest your foot on the
clutch pedal while driving. This
may cause clutch damage.
• Stop your vehicle completely
before shifting into reverse.
• When you are shifting from
one gear to another, be certain
to press the clutch pedal all
the way to the to avoid
clashing or chipping the gears.
• Do not shift directly from 5th
gear to Reverse gear during
vehicle running condition.
68
road conditions, the weather and
CAUTION individual driving habits.
• Avoid abrupt starts and
acceleration for your safety. Gear Change Km/hr
• When quick acceleration is 1st to 2nd 15
required for some reason, shift
to a lower gear and accelerate 2nd to 3rd 25
until the vehicle reaches the
maximum speed in each gear.
Do not exceed the speed
3rd to 4th 40
limit of any gear. Pay special
attention when accelerating or 4th to 5th 50
when shifting into a lower gear
on slippery surfaces. Sudden The listed refer to potential
acceleration or down shifting speed ranges for each gear. The
could cause the wheels to skid speed at which you drive, however,
and result in loss of control.
should conform to all territory laws,
• Keep the engine idle for atleast and to the condition which will permit
20 seconds before switching safe operation.
off the engine, this will allow
engine oil to lubricate the
turbocharger. 4.7 Parking
4.6.3 Suggested shift-up speeds
CAUTION
The following provides suggested
Do not park the vehicle over
speed ranges for shifting into a
materials such as dry
higher gear. These suggestions
grass, waste paper or rags, as
relate to fuel economy and vehicle
they may burn easily.
performance. Actual shift ranges
should be adjusted for
Safe parking procedures require that
the parking brake be set and the
 4. STARTING AND DRIVING
gearshift lever placed in the proper
position.
1. Firmly apply the parking brake.
2. When parking, make sure the
gear shift lever for manual
transmission vehicles is in 1st
gear or “R” (Reverse).
3. Turn the ignition key to the
1
14
"LOCK" position and remove
the key.
WARNING
Never leave the engine running
while the vehicle is unattended.
When parked on a sloping driveway.
Turn the wheels so the vehicle will
not roll into the street in case it
moves.
• HEADED DOWNHILL: 1
Turn the wheels into the curb,
allow the vehicle to move forward
until the curb side wheel gently
touches the curb. Then set the
parking brake.
• HEADED UPHILL: 2
Turn the wheels away from the
curb and allow the vehicle to
move back until the curb side
wheel gently touches the curb.
Then set the parking brake.
• HEADED UPHILL OR
DOWNHILL, NO CURB: 3
Turn the wheels toward the side of
the road so the vehicle will move
away from the center of the road
if it moves. Then set the parking
brake.
When leaving your vehicle
unoccupied:
• Always remove the ignition key -
even in your own garage.
• Close all windows completely and
lock all doors.
• Always park your vehicle where it
can be seen, at night, park in a
well lit area.
• Do not leave valuables on view to
tempt a thief. Always take your
valuables with you. If you must
leave something in your vehicle,
lock it in the glove box or hide it
out of sight.
• Do not leave the vehicle
documents in your vehicle. In the
unfortunate event of your vehicle
being stolen the documents will
only help a thief to sell the vehicle.
• Do not leave articles on a roof
rack as they are particularly
vulnerable. If possible, remove
them from the rack and lock them
in the glove box in the vehicle.
• Do not leave the spare key in the
vehicle - keep it in a safe place in
your home.
• Do not leave a note of your
vehicle key number in the vehicle.
A thief may break into the vehicle,
note the key number and return
with a key to enter and drive the
vehicle.
4.8 Precautions when driving
1. Driving with vacuum assisted
brake:
The brake booster aids braking
by using engine vacuum. If
69
 4. STARTING AND DRIVING
the engine stops or the drive
belt is broken, you can stop the
vehicle by depressing the brake
pedal. However, greater foot
pressure on the brake pedal will
be required to stop the vehicle
and the stopping distance will be
longer.
1
2. Wet brakes:
14 • When the vehicle is washed
or driven through water, the
brakes may get wet. As a
result, your braking distance
will be longer and the vehicle
may pull to one side during
braking.
• To dry brakes, drive the
vehicle at a safe speed while
lightly pressing the brake
pedal to heat-up the brakes.
Do this until the brakes return
to normal. Avoid driving the
vehicle at high speeds until
the brakes function correctly.
3. Avoid resting your foot on the
brake pedal while driving. This
will overheat the brakes, wear
out the brake linings and pads
faster and reduce mileage.
4. To help save the brakes and
to prevent the brakes from
70
overheating, before going down
a slope or long grade, reduce
speed and downshift to a lower
gear.
5. While driving on a slippery
surface, be careful when
braking, accelerating or
downshifting. Abrupt braking
actions or sudden acceleration
could cause the wheels to skid.
4.8.1 Driving uphill
When starting on a steep grade,
it is sometimes dif to operate
both the brake and clutch. Use the
parking brake to hold the vehicle.
Do not slip the clutch. When ready
to start, slowly release the parking
brake while depressing accelerator
pedal and releasing the clutch.
4.8.2 Driving downhill
The engine braking action is effective
for controlling the vehicle while
descending hills. The gearshift lever
should be placed in the lower speed
position prior to descending.
4.9 Cold weather driving
Battery
If the battery is not fully charged
during extremely cold weather
conditions, the battery may
freeze and damage the battery. To
maintain maximum ef , the
battery should be checked regularly.
For details, see "Battery" in the
“Maintenance and Do-it-yourself”
section.
4.10 Corrosion protection
Chemicals used for road surface
de-icing are extremely corrosive
and will accelerate corrosion and
the deterioration of underbody
components such as the exhaust
system, fuel and brake lines, brake
cables, pan and fenders.
Note
In winter & coastal area application,
the underbody must be cleaned
periodically. For more detailed
information concerning cleaning the
exterior to protect it from corrosion,
please refer to the "Appearance and
interior care" of this Manual.
For additional protection against
rust and corrosion, which may be
required in some areas, consult your
local AL LCV Dealer.
 5. APPEARANCE AND INTERIOR CARE

CHAPTER

5. APPEARANCE AND INTERIOR CARE

5.1 Cleaning exterior and interior ................................................................................................................. 73
5.1.1 Washing ...................................................................................................................................... 73
5.1.2 Removing spots ........................................................................................................................... 74
5.1.3 Underbody ................................................................................................................................... 74
5.1.4 Cleaning glasses.......................................................................................................................... 74
5.1.5 Cleaning interior ........................................................................................................................... 74

1 15
5.1.6 Seat belts .................................................................................................................................... 74
5.2 Protecting against corrosion................................................................................................................... 74
5.2.1 Environmental factors the rate of corrosion ...................................................................... 74
5.2.2 To protect your vehicle from corrosion............................................................................................ 75

71
 5. APPEARANCE AND INTERIOR CARE
5.1 Cleaning exterior and
interior
1 15 In order to maintain the appearance
of your vehicle, it is important to take
proper care of it.
In the following cases, please wash
your vehicle as soon as possible to
protect the paint surface.
• After driving on coastal roads.
• When things such as soot,
bird droppings, tree sap, metal
particles or insects get on the
paint surface.
• When dust or mud builds up on
the surface.
Whenever possible, store or park
your vehicle inside a garage or in a
covered area.
When it is necessary to park outside,
park in a shady area or protect the
vehicle with a body cover.
5.1.1 Washing
Wash dirt off with a wet sponge and
plenty of water. Clean the vehicle
thoroughly using a mild soap or
detergent (a special vehicle soap or
general purpose dish washing liquid)
mixed with clean, lukewarm (never
hot) water.
WARNING
• Avoid pouring water or direct high
pressure water jet on exhaust
system directly. If required wipe it
with wet cloth.
CAUTION
• Do not use strong household
soap, strong chemical
detergents, gasoline or
solvent.
• Do not wash the vehicle
in direct sunlight or while
the vehicle body is hot, as
the surface may become
water-spotted.
Rinse the vehicle thoroughly with
plenty of clean water.
Inside seams and folds
on the doors, hatches and hood
are particularly endangered by the
effects of road salt. Therefore, these
areas must be regularly cleaned.
Take care that drain holes in the
lower edge of the door are open.
Spray water under the body and in
the wheel to loosen the dirt and wash
it away.
A damp cloth can be used to dry the
vehicle to avoid water spot.
73
 5. APPEARANCE AND INTERIOR CARE
5.1.2 Removing spots
Remove tar and oil spots, industrial
dust, insects and tree sap as quickly
as possible from the surface of the
paint to avoid lasting damage or
straining. Special cleaning products
are available at your AL LCV Dealer
or any automotive accessories store.
5.1.3 Underbody
In areas where road salt is used in
winter, it is necessary to clean the
underbody regular in order to prevent
1 15 dirt and salt from building up and
causing corrosion on the underbody
and suspension.
5.1.4 Cleaning glasses
Using glasses cleaner, remove
smoke and dust from the glass
surface. It is normal for glasses to be
coated with a after the vehicle is
parked in the hot sun. Glass cleaner
and soft clothes easily remove this
When cleaning the inside of the
windows, do not use any sharp-edge
tools or abrasive cleaners or
chlorine-based disinfectant cleaners.
(These may damage the electrical
conductors or rear window defogger
elements.)
74
5.1.5 Cleaning interior
Occasionally remove loose dust
form the interior trim, plastic parts
and seat using a vacuum cleaner or
soft brush. Before using any fabric
protector, read the manufacturers
recommendations. Some fabric
protectors contains chemicals that
stain or bleach the seat material.
• Never use benzine, thinner or any
similar material.
• Never use fabric protectors
unless recommended by the
manufacturer.
5.1.6 Seat belts
The seat belts can be cleaned
by wiping them with a sponge
dampened in a mild soap solution.
Allow the belts to dry completely
before using them. Do not allow wet
belts to roll up in the reactor. NEVER
use bleach, dye or chemical solvents
since these may severely weaken
the seat belt webbing.
5.2 Protecting against
corrosion
Most common factors contributing to
vehicle corrosion:
1. The accumulation of
moisture-retaining dirt and
debris in body panel sections,
cavities, and other areas.
2. Damage to paint and other
protective coatings caused by
gravel and stone chips or minor
traf accidents.
5.2.1 Environmental factors
the rate of
corrosion
Moisture
The accumulation of sand, dirt and
water on the underside of the body
will accelerate corrosion. Floor
section which have snow and ice
trapped under the matting will
not dry.
Relative humidity
Corrosion will be accelerated in
areas of high relative humidity,
especially those areas where the
temperatures stay above freezing
and where atmospheric pollution
exists and road salt is used.
 5. APPEARANCE AND INTERIOR CARE

Temperature
A temperature increase will
accelerate the rate of corrosion
to those parts which are not well
ventilated.
Air pollution
Industrial pollution, the presence of
salt in the air in coastal areas, or
heavy road salt use will accelerate
the corrosion process. Road salt will
WARNING
Never allow water or other liquids
to come in contact with electronic
components inside the vehicle.
Chemicals used for road surface
de-icing are extremely corrosive.
They accelerate corrosion and
deterioration of underbody
CAUTION
• Do not pour water or direct high
pressure water jet on engine, Air
Intake, exhaust, electrical &
electronic systems.
• This will cause serious damages
which may affect the vehicle’s
functionality.

1 15
also accelerate the disintegration of
paint surface.
components such as the exhaust
system, fuel and brake lines, brake
WARNING

5.2.2 To protect your vehicle from
corrosion
• Wash and wax your vehicle often
to keep the vehicle clean.
• Always check for minor damage
to the paint and repair it is as soon
as possible.
• Keep drain holes at the bottom
of the doors and tailgate open to
avoid water accumulation.
• Check the underbody. If
any sand, dirt, or salt has
accumulated, wash it off with
water as soon as possible.
cables, pan and fender. • Cover Air Intake Snorkel with a
plastic cover while washing the
In winter, the underbody must be
vehicle, to prevent water entry
cleaned periodically.
into engine.
Vehicle’s Exterior & under body to be • Incase of accidental water entry,
cleaned more frequently for the DO NOT try to start the vehicle to
avoid damages to engine.
vehicles which are plying in coastal
areas. • Contact the nearby AL LCV
dealership immediately.
For additional protection against
rust and corrosion, which may be
required in some areas, consult your
local AL LCV Dealer.

75
 6. IN CASE OF EMERGENCY

CHAPTER

6. IN CASE OF EMERGENCY
6.1 Flat tire................................................................................................................................................. 79
6.1.1 Stopping the vehicle ..................................................................................................................... 79
6.1.2 Jack and Jack handle location....................................................................................................... 79
6.1.3 Spare wheel carrier ...................................................................................................................... 79
6.1.4 Blocking wheels ........................................................................................................................... 80
6.1.5 Jacking up and removing tire......................................................................................................... 80
6.1.6 Installing wheel ............................................................................................................................ 83
6.2 If engine overheats................................................................................................................................ 83
6.3 Towing.................................................................................................................................................. 84
6.3.1 Freeing vehicle from sand, snow or mud ........................................................................................ 85 61
6.4 Driving Instructions................................................................................................................................ 86

77
 6. IN CASE OF EMERGENCY

6.1 Flat tire 6.1.3 Spare wheel carrier

WARNING

Never change tires when

instructions
the vehicle is on a slope or
6.1.1 Stopping the vehicle soft uneven ground. This is
dangerous.
1. Safely move the vehicle off the
6.1.2 Jack and Jack handle
2. Turn on the hazard warning location

3. Park on a level surface and

apply the parking brake. Shift
the manual transmission into 1. Remove the split pin and loosen
reverse. the nut (1) and hanger nut (2)
by holding the T-bolt head with
4.

5.
Turn off the engine.
Place advance warning triangle
cutting plier for ease operation.
61
2. Hold the tube by hand and
Min 50m behind the vehicle. swivel the spare wheel carrier
assembly till it makes contact
with the ground.
3. Remove the spare wheel from

4.
The Jack is located in RH Side
chassis long member near battery.
Jack rod is placed behind driver-
seat.
tire.
Lift the spare wheel carrier
assembly and tighten the nut
(1) and hanger nut (2) until the
tire makes contact with spacers
provided on the frame.

79

6.1.5 Jacking up and removing
CAUTION
Be careful not to loosen the
hanger nut excessively, otherwise
the hanger will fall suddenly.
6.1.4 Blocking wheels
1.
Place suitable blocks at both
the front and back of the wheel
Note
It is recommended that the wheels
of the vehicle be chocked, and that
no person should remain inside the
vehicle that is being jacked.
80
6. IN CASE OF EMERGENCY
tire
WARNING
To help avoid personal injury,
carefully read the caution label
attached to the jack body and
the following instructions.
Place the jack directly under
the jack-up point as shown, so
that top of the jack contacts
the vehicle at the jack up point.
Having located the jack head
use the handle provided for 61
jacking up the vehicle.
Note
The jack should be used on level
6. IN CASE OF EMERGENCY

61

81
 6. IN CASE OF EMERGENCY

LIFTING POINTS -PHOENIX

Front

61

82

WARNING
Never jack up the vehicle
more than necessary.
2. Loosen each wheel nut
one or two turns by turning
counterclockwise with the wheel
nut wrench.
Note
Do not remove the wheel nuts
until the tire is off the ground.
3. Carefully raise the vehicle until
the tire clears the ground.
Remove the wheel nuts, and
then remove the tire.
Note the following points while
jacking.
• Never get under the vehicle
while it is supported only by
the jack. use a vehicle support
stand.
• Use the jack provided with your
vehicle. The jack is designed
only for lifting your vehicle
during a tire change.
• Use the correct jack up points.
never use any other part of the
vehicle for jack support.
6. IN CASE OF EMERGENCY
• Do not start or run engine while wrench, tighten the wheel nuts
vehicle is on the jack. securely in the sequence as
illustrated.
• Do not allow passengers to
stay in the vehicle while it is on • As soon as possible tighten
the jack. the wheel nuts.
• Do not raise the vehicle using a • Adjust tire pressure.
bumper jack.
Tire pressures are shown on the
6.1.6 Installing wheel
side lock pillar.
5. Securely store the spare tire
and jacking equipment in the
vehicle.
6.2 If engine overheats
61
No Loss Tank
1. Clean any mud or dirt from the
surface between the wheel and
hub.
2. Carefully put the wheel on and
tight.
3. With the wheel nut wrench,
tighten wheel nuts alternately
and evenly until they are tight.
4. Lower the vehicle slowly until
the tire touches the ground.
Then, with the wheel nut
83

WARNING
To avoid the danger of being
burned, never remove the
coolant reservoir cap and
pressure cap while the engine
is still hot.
If the high coolant temperature
indicator comes on while driving
1. Park the vehicle, apply the
parking brake and move the
gear lever to Neutral.
2. Switch off the air conditioning (if
3.
Open all the windows.
Open the engine inspection
hatch. For details, see
Engine inspection hatch in
the "Maintenance and do it
yourself" section. Do not stop
the engine (unless the belt is
broken).
4. Check whether the radiator fan
operates. The radiator hoses
and radiator should not leak
water. If coolant is leaking or
the cooling fan does not run,
stop the engine and contact the
nearest AL LCV Dealer.
84
WARNING
Be careful not to allow your
hands, hair or clothing to
come into contact with the
fan, belts, or other moving
parts.
5. If none of these faults are
detected when the engine is
running, close the inspection
hatch.
6. Switch off the ignition and wait
until the engine cools down,
check the coolant level in the
reservoir tank.
7. If the level is low, remove the
reservoir cap and add coolant to
MAX level of the reservoir tank.
Then reinstall the cap.
Note
Never water in cooling
system. It comes with premixed
solution of coolant and water.
8. Close the inspection hatch.
If, after the system,
no leaks are detected, run
the engine and check for high
6. IN CASE OF EMERGENCY
coolant temperature indicator.
If the lamp glows switch off the
engine and contact AL LCV
Dealer.
WARNING
Use only recommended coolant
grade.
6.3 Towing
CAUTION
Never try to start the vehicle by
towing it; when the engine starts,
the forward surge could cause
61
the vehicle to collide with the tow
vehicle.
1. AL recommends to use a
recovery van for towing the
vehicle.
2. Before towing, ensure that the
Front axle, Steering system,
Gear box and differential are in
good condition.
a. In case of a failure in the
Front axle or steering system,
remove the bumper and put

suitable packing cushion (E.g
old tyre) between tow chain
and cab.
b. In case of a failure in the
gearbox remove the propeller
shaft and tow the vehicle.
c. In case of a failure in the
differential/rear axle, remove
towing chain. Put suitable
packing cushion (E.g old tyre)
between tow chain and load
body.
3. Switch on hazard warning lights.
4. To avoid crash with the towing
vehicle use rigid tow bar. Do not
Release the parking brake and
5.
place the gear lever in the
neutral position before starting
to tow the vehicle.
6. In case of failure of brakes, use
parking brake to stop the vehicle
while towing.
Note
When towing the vehicle with the
front wheels on the ground, turn
the ignition key to the ACC position
and secure the steering wheel in the
straight ahead position with a rope
or similar device.
6. IN CASE OF EMERGENCY
6.3.1 Freeing vehicle from sand,
snow or mud
Tow Hook
• Use only the towing hook (where
of the vehicle, otherwise the
61
components and the bodywork
will be damaged.
• In order not to break the towing
line, tension it slowly.
• Tow hook is detachable. It can be
removed and fitted in front or rear
side based on the requirement.
• Necessary tools for removal and
re fitment are given in tools kit.
85
 6. IN CASE OF EMERGENCY

must be repaired as soon as

WARNING possible as the battery may be
drained by later engine starts.
Do not allow anyone to stand
near the towing line during this
operation.

6.4 Driving Instructions

1. If the oil pressure warning light
comes on while driving,

move the vehicle safely off

the road, apply the handbrake
and move the gear lever to N 61
(Neutral) position. Turn off the
engine. Contact the nearest AL
LCV Dealer to repair the fault.
2. Attention must also be paid to
the battery warning light when
driving.

If it lights up continuously during

driving, this means that the
alternator is not charging the
battery, in this case the fault

86
 7. TECHNICAL INFORMATION

CHAPTER

7. TECHNICAL INFORMATION
7.1 Lubrication charts.................................................................................................................................. 90
7.2 Lubrication Points ................................................................................................................................. 91
7.3 Vehicle .............................................................................................................................. 92
7.3.1 Vehicle Plate ............................................................................................................ 92
7.3.2 Engine serial number.................................................................................................................... 92
7.3.3 Clutch.......................................................................................................................................... 92
7.3.4 Gear Box ..................................................................................................................................... 92
7.3.5 Rear Axle..................................................................................................................................... 92
7.3.6 Power steering pump.................................................................................................................... 93
7.3.7 Tire placard.................................................................................................................................. 93
7.4 Technical specification PHOENIX............................................................................................................... 94

1 17

88
 7. TECHNICAL INFORMATION
7.1 Consumables Chart
RECOMMENDED OILS AND LUBRICANTS WITH FILLING CAPACITY

Aggregate Recommended Lubricants Capacity Change Interval - Phoenix

Engine oil Gulf Superfleet NxG 15W-40 4.5 Litres with filter Every 10,000 Kms or 10 months
Engine coolant Gulf Eurocool Dura NxG 50 8 Litres Every 80,000 Kilometres
2.00 Litres (With out PTO) First at 10,000 Kms then every
Gear box Oil Gulf Gear CP NxG
2.70 Litres (With PTO) 60,000 Kms. (For RSB)
Power Steering Oil Gulf Power Steering Fluid Dura Max 0.8 - 1 Litre 80000 kms
2.1 Litres (AAM) Every 40,000 Kilometers. (For
Rear axle Oil Gulf Axle NxG
1.89 Litres (DANA Spicer) AAM & DANA Spicer)
Brake oil DOT 4 830 ± 30 ml 1 Year or 40,000 Kilometers.

Front Axle King Pin Gulf MP grease Max NLGI 2 60 Grams Every 10,000 Kilometers.

1 17 Clutch Pedal, Brake

Pedal & Steering Gulf MP grease Max NLGI 2 Required Quantity Every 10,000 Kilometers.
Column Greasing

Front & Rear axle

Maintenance Free. No Greasing Required
Grease

Universal Joint (UJ Kit) Maintenance Free. No Greasing Required

Air condition Gas R134a 390 ± 10 Grams As Required

Wind shield
Water 1.5 Litres As Required
Washer Fluid

90
 7. TECHNICAL INFORMATION

7.2 Lubrication Points - PHOENIX

3
7

71
2 4
6 8

5
1

91
 7. TECHNICAL INFORMATION
The engine serial number is punched 7.3.5 Rear Axle
on the LH side rear bottom of the DANA Spicer

7.3.3 Clutch

number (VIN), Gross vehicle weight,

Gross combination weight, Axle
loads, Chassis type, Engine type,
Rear axle ratio and Engine number. d

TYPE
VIN
APPROVAL

GROSS VEHICLE GROSS COMBINATION

WEICHT(Kgs) WEICHT(Kgs)

Axle serial number is punched on

AXLE
LOADS(Kgs) 1 2
CHASSIS ENGINE
TYPE TYPE

right side of the rear axle near banjo

REAR AXLE ENGINE
RATIO NUMDER
MADE IN INDIA

Clutch identification number can be housing cover.

located in clutch disc & cover assembly.
American Axle
7.3.4 Gear Box
1 17
7.3.2 Engine serial number

The number is punched on the LH Axle serial number is punched on the

mid portion of front casing. banjo housing cover of rear axle.

92
 7. TECHNICAL INFORMATION
7.3.6 Power steering pump PHOENIX
215/75 R15 LT Inflation
Tyre Size
(Tubeless) Pressure (PSI)

UnLaden 35
Front
Laden 40

xx
x UnLaden 35
xx Rear
Laden 65

Power steering pump number is

located in the body of the pump at
the rear side.
7.3.7 Tire placard
The cold tire pressures is shown on
the tire placard.
71

93
 7. TECHNICAL INFORMATION
7.4 Technical Specifications - PHOENIX

PHOENIX
ENGINE
Model AL P15 EURO 4
Type 3 Cylinder 4 stroke common rail turbo charged with intercooler Diesel Engine
Cylinder arrangement 3 Inline
Bore x Stroke (mm 80 mm x 98 mm
Firing order 1-2-3
Capacity 1478 cc
Maximum Engine output 80 HP@ 3300 rpm
Maximum Torque 190 NM@ 1600-2400 rpm
Engine Oil Capacity 4.5 litres with filter
Compression Ratio 16.5:1

1 17 Air Filter
Oil Filter
Dry Type
Spin on type
Fuel Injection Pump Unit pump with IMV
Coolant 50 : 50 Coolant Water mixture (Premixed)
CLUTCH
Type Single, Diaphragm push type, Cable operated
Diameter 240 mm
Type of Actuation Mechanical Cable operated

94
 7. TECHNICAL INFORMATION

PHOENIX
GEAR BOX
a. RSB
Fully synchronised 5 speed manual gear box - Reverse constant mesh (With PTO
Type
Provision)
Gear Shifting Cable operated
Gear Ratios 1st - 4.722; 2nd - 2.778; 3rd - 1.609; 4th - 1; 5th - 0.798; Rev - 4.487
2.00 Liters(Without PTO)
Oil Capacity
2.70 Liters (With PTO)
AXLES
Front Reverse Elliot Type, Rigid tubular axle, Forged ends with Unitised Bearing
Rear Semi floating, Banjo type
Make AAM
Rear Axle ratio 4.56:1
Oil capacity 2.1 Liters 71
Make DANA Spicer
Rear Axle Ratio 4.56:1
Oil Capacity 1.89 Liters
STEERING
Type Recirculating Ball Type
Ratio 18.8:1
Steering wheel dia 400 mm

95
 7. TECHNICAL INFORMATION

PHOENIX
Turning circle diameter (TCD) 11 m
BRAKES
Service Brakes Vacuum assisted hydraulic brake with LSPV
Front Brakes Disc
Rear Brakes Drum - 282 mm x 50.8 mm
FRAME
Frame Ladder type, Joggled and drooped – Variable Open “C” Section Frame
SUSPENSION
FRONT
Suspension Description Parabolic Leaf suspension with double acting Shock absorber

1 17
Number of Leaf
REAR
3 Leaf

Leaf Spring Type Semi elliptic Leaf suspension with double acting Shock absorber
Number of Leaf 3 Main + 3 Helper Leaf’s
FUEL TANK
Capacity 50 Litres
ELECTRICAL SYSTEMS
System voltage 12 V

96
 7. TECHNICAL INFORMATION

PHOENIX
Alternator capacity (Non AC/AC) 90 Amps (Non A/c)
Battery 12V 50Ah
Wind Screen wiper Two speed wiper
PERFORMANCE
Maximum Speed 85 kmph (ECU Limited)
Maximum Gradeability at rated GVW
28.32% Restart Gradeablity
(Estimated)
WHEELS & TYRES
Front/Rear Single
No.of wheels 4+1
Tyre size 215/75 R15 LT (Tubeless)
Rim 5.5 J X 15
TYRE PRESSURE
UN LADEN 71
Front 35 PSI
Rear 35 PSI
AT RATED PAY LOAD
Front 40 PSI
Rear 65 PSI

97
 7. TECHNICAL INFORMATION
Weights & Dimensions - PHOENIX

Vehicle Type Cab Chassis Fixed Side Deck (FSD) Drop Side Deck (DSD)
PHOENIX PHOENIX PHOENIX PHOENIX PHOENIX PHOENIX
Variants Unit
LS LX LS LX LS LX
Unladen Front Axle Weight kg 946 963 972 989 974 974
Unladen Rear Axle Weight kg 477 477 625 625 627 627
Unladen Gross Vehicle Weight kg 1423 1440 1597 1614 1601 1601
Front Axle Weight kg 1476 1491 1476 1491 1476 1491
Rear Axle Weight kg 2014 1999 2014 1999 2014 1999
WEIGHTS Gross Vehicle Weight kg 3490 3490 3490 3490 3490 3490
Rated Payload (in kg) kg 1893 1876 1893 1876 1889 1889
Overload Front Axle Weight kg 1653 1668 1653 1668 1653 1668
Overload Rear Axle Weight kg 3047 3032 3047 3032 3047 3032
Overload Gross Vehicle Weight kg 4700 4700 4700 4700 4700 4700

1 17
Overload Payload (in kg)
Wheel base
kg
mm
3277 3260 3103
2590
3086 3099 3099

Overall Length mm 4850 5025

Overall Height (Unladen) mm *2039 *2037
Overall Width (With Fender) mm 1842
OVER ALL Front Track mm 1580
DIMENSIONS
Rear Track mm 1495
Turning circle Diameter Curb to
m ≤11m
Curb (TCD)
Min. Ground Clearance mm 185 (@ FA Tie rod Clamp), 202 (@FA Beam)
Front Overhang (With Bumper) mm 1297

98
 7. TECHNICAL INFORMATION

Vehicle Type Cab Chassis Fixed Side Deck (FSD) Drop Side Deck (DSD)
PHOENIX PHOENIX PHOENIX PHOENIX PHOENIX PHOENIX
Variants Unit
LS LX LS LX LS LX
Rear Overhang mm #963 1138
OVER ALL Angle of Approach Deg. 19.4⁰
DIMENSIONS Angle of Departure Deg. 21.9⁰
Ramp Over Angle Deg. 26.9⁰
Load Body Length (Outer / Inner) mm 2950 / 2879
Load Body Width (Outer / Inner) mm 1750 / 1678

LOAD BODY Load Body Side Deck

NA
DIMENSIONS Height(Outer mm 490 / 415
/ Inner)
Loading Platform Height mm
~920*
(Un-Laden)

71

99
 8. MAINTENANCE AND DO-IT YOURSELF

CHAPTER

8. MAINTENANCE AND DO-IT YOURSELF

8.1 Maintenance Requirements ...................................................................................................................103
8.2 Maintenance Precautions ......................................................................................................................103
8.3 General Maintenance ............................................................................................................................104
8.4 Check locations ....................................................................................................................................105
8.5 Engine oil .............................................................................................................................................106
8.5.1 Checking engine oil level ..............................................................................................................106
107
8.6 Engine cooling system...........................................................................................................................108
8.6.1 Checking coolant level ..................................................................................................................109
8.6.2 Changing engine coolant ..............................................................................................................109
110
8.7.1 Draining water..............................................................................................................................110
110
8.7.3 Bleeding the fuel system ............................................................................................................... 110
111
8.9 Emission control system ........................................................................................................................111
8.9.1 Exhaust emission control system...................................................................................................112 81
8.9.2 Maintenance recommendation ......................................................................................................112
8.10 Drive belt ............................................................................................................................................112
113
113
8.13 Wiper blades.......................................................................................................................................113
114

101
 8. MAINTENANCE AND DO-IT YOURSELF

8.15 Brake conditions ................................................................................................................................. 115

8.16 Battery................................................................................................................................................ 115
8.17 Battery cover (If ......................................................................................................................... 117
8.18 Fuses ................................................................................................................................................. 117
8.18.1 Cabin fuse box ........................................................................................................................... 118
8.18.2 Chassis fuse box ........................................................................................................................ 119
8.18.3 Maxi fuse ........... ........................................................................................................................ 120
8.19 Lights bulbs ........................................................................................................................................ 121
8.19.1 Headlights.................................................................................................................................. 121
8.19.2 Front side light or turn signal light ................................................................................................ 121
8.19.3 Side turn light (If ................................................................................................................ 121
8.19.4 Rear combination light ................................................................................................................ 122
8.19.5 Interior lights .............................................................................................................................. 122
8.20 Bulbs.................................................................................................................................................. 122
8.20.1 Replacement procedures ............................................................................................................ 123
8.21 Wheels and tyres ................................................................................................................................ 123

1 18

102

8.1 Maintenance
Requirements
Your AL vehicle has been designed
to have minimum maintenance
requirements with longer service
intervals to save your time and
money.
However, some day - to - day and
regular maintenance is essential
to maintain good mechanical
conditions as well as its emission
and engine performance.
It is the owner’s responsibility
maintenance, as well as general
maintenance, is performed. As the
vehicle owner, you are the only one
who can ensure that your vehicle
receives the proper maintenance
care. You are a vital link in the
maintenance chain.
Scheduled maintenance
For your convenience, the required
scheduled maintenance items are
described and listed in a separate
section Warranty and service. You
must refer to that section to ensure
that necessary maintenance is
8. MAINTENANCE AND DO-IT YOURSELF
performed on your AL vehicle at
regular intervals.
General maintenance
General maintenance includes those
items which should be checked
during normal day-to-day operation
of the vehicle. They are essential if
your vehicle is to continue to operate
properly. It is your responsibility to
perform these procedures regularly
as prescribed. These checks or
inspections can be done by yourself
and your AL LCV Dealer.
Where to go for service
If service is required or your
vehicle appears to malfunction,
have the systems checked and
tuned by AL LCV Dealer. AL LCV
Dealer technicians are well-trained
specialists and are kept up to date
with the latest service information
through technical bulletins, service
tips, and in-dealers training
work on your vehicle. You can be
performs the best job to meet the
maintenance requirements on your
vehicle – in a reliable and economic
way. Refer to the list of Authorized
service centres at the end of the
manual.
8.2 Maintenance Precautions
Follow these precautions before
carrying out any inspection or
maintenance work on the vehicle.
Failure to follow these
recommendations could lead to
personal injuries or damage to the
vehicle.
• Park the vehicle on a level
surface, apply the parking brake
and block the wheels to prevent
any accidental movement of the
vehicle. Put the gearshift level in
N (neutral) position.
• Be sure to turn the ignition key
to the LOCK position when
performing any replacement or
81
repair and also disconnect battery
–ve terminal
• Do not work in the engine
compartment while the engine is
hot. Wait for the engine to cools
down.
103
 8. MAINTENANCE AND DO-IT YOURSELF
8.1 Maintenance
Requirements
Your AL vehicle has been designed
to have minimum maintenance
requirements with longer service
intervals to save your time and
money.
However, some day - to - day and
regular maintenance is essential
to maintain good mechanical
conditions as well as its emission
and engine performance.
It is the owner’s responsibility
maintenance, as well as general
maintenance, is performed. As the
vehicle owner, you are the only one
who can ensure that your vehicle
receives the proper maintenance
care. You are a vital link in the
1 18 maintenance chain.
Scheduled maintenance
For your convenience, the required
scheduled maintenance items are
described and listed in a separate
section Warranty and service. You
must refer to that section to ensure
that necessary maintenance is
performed on your AL vehicle at
regular intervals.
General maintenance
General maintenance includes those
items which should be checked
during normal day-to-day operation
of the vehicle. They are essential if
your vehicle is to continue to operate
properly. It is your responsibility to
perform these procedures regularly
as prescribed. These checks or
inspections can be done by yourself
and your AL LCV Dealer.
Where to go for service
If service is required or your
vehicle appears to malfunction,
have the systems checked and
tuned by AL LCV Dealer. AL LCV
Dealer technicians are well-trained
specialists and are kept up to date
with the latest service information
through technical bulletins, service
tips, and in-dealers training
work on your vehicle. You can be
performs the best job to meet the
maintenance requirements on your
vehicle – in a reliable and economic
way. Refer to the list of Authorized
service centres at the end of the
manual.
8.2 Maintenance Precautions
Follow these precautions before
carrying out any inspection or
maintenance work on the vehicle.
Failure to follow these
recommendations could lead to
personal injuries or damage to the
vehicle.
• Park the vehicle on a level
surface, apply the parking brake
and block the wheels to prevent
any accidental movement of the
vehicle. Put the gearshift level in
N (neutral) position.
• Be sure to turn the ignition key
to the LOCK position when
performing any replacement or
repair and also disconnect battery
–ve terminal
• Do not work in the engine
compartment while the engine is
hot. Wait for the engine to cools
down.
103

• If it is necessary to work with
the engine running, keep hands,
clothes, hair and tools away
from the fan, belts and any other
moving parts.
• It is not recommended to work
while wearing loose clothing.
Remove any personal objects
such as rings, watch, etc. before
starting work on the vehicle.
• If the engine must be left running
in an enclosed space, it is
necessary to ensure that there is
adequate ventilation to facilitate
the escape of exhaust fumes.
• Never get under the vehicle while
it is only supported by the jack. If
it is necessary to work under the
vehicle, always use safety stands.
• coverage. In case of doubt about
from the battery, fuel tank and
engine compartment.
• Additional electronic equipment
may negatively affect the
correct operation of the vehicle’s
electronic components. It is
therefore forbidden to use such
equipment provision in fuse box
for any addition connections. AL
does not accept responsibility for
the consequences of failing to
comply with this point.
104
8. MAINTENANCE AND DO-IT YOURSELF
• to check for the cause or contact
be serviced by a AL LCV Dealer.
The fuel lines are subjected to
very high pressures, even when
the engine is not running.
•
in the vehicle can damage the
local regulations for disposal of
• Avoid direct contact with used
engine oil.
CAUTION
The owner should be aware that
incomplete or improper servicing
could cause incorrect operation,
which could affect the warranty
any servicing, contact AL LCV
Dealer.
8.3 General Maintenance
During the normal day-to-day
operation of the vehicle, general
maintenance should be performed
regularly as prescribed in this
section. If you detect any unusual
sounds, vibrations or smell, be sure
your AL LCV Dealer. In addition, you
should notify your AL LCV Dealer if
you think that repairs are required.
When performing any checks or
maintenance work, closely observe
the Maintenance precautions as
described later in this section.
Note
Additional information on the
following items with “*” is found
later in this section.
Exterior of vehicle
Lights*
Ensure that the headlights, brake
lights, side indicator lights and
reverse lights are functioning well.
Spare wheel 81
Ensure that the spare wheel is
secured correctly in its proper
location.
Tyres*
Check the tyres pressure
(including the spare wheel) as
 8. MAINTENANCE AND DO-IT YOURSELF
necessary. Check for cuts or Steering wheel
excessive wear. applicable)*
Check for free play, stiffness or
Doors strange noises. Check that the level is between the
“MAX” and “MIN” marks with the
Check that all the doors open and
engine cold.
close correctly. Lubricate the locks,
equipped)
hinges, etc, if necessary. Seat belts
Check the level in the reservoir.
Note
If you drive in industrial areas or Engine coolant* retractors and adjustment devices
on roads covered with salt or other function and are correctly installed.
Check the coolant level when the Check that they are not cut or worn,
corrosive materials, lubricate these
engine is cold. etc.
points frequently.
Engine oil*
8.4 Check locations
Windscreen wiper blades* P15

when the engine is hot (with off

Check for breaks or wear and
condition).
whether areas of the windscreen
remain dirty when the wipers are
used.
Check that the level is between

1
Battery*
18 Check that the level of electrolyte in
the “MAX” and “MIN” marks on the
reservoir.
each cell and add distilled water if
Engine inspection hatch*
required.
Check for oil leaks from the following
Interior of vehicle Check that the hinges and clips locations:
function correctly. Lubricate the
Instrument panel 1. Engine oil dipstick (1)
hinges, etc, if necessary.
2.
Ensure that the gauges and audio (if
3.

105
 8. MAINTENANCE AND DO-IT YOURSELF

4. Open the engine inspection

WARNING
5
Always check that the engine
compartment inspection hatch is
closed and locked securely.
4 in the engine compartment
inspection hatch.
hatch.
5. Remove the dipstick and wipe it
clean. Reinsert it all the way.
6. Remove the dipstick again
and check the oil level. It
should be between the MIN and
MAX range. If the oil level is

1. Check for fuel leaks around the cap and pour recommended
fuel tank area (4). 8.5 Engine oil oil through the opening until
reaches (MAX).
2. Check the battery condition (5). 8.5.1 Checking engine oil level
7. Recheck the oil level with the
Engine compartment inspection dipstick.
hatch 8. Close and lock the inspection
The engine compartment inspection hatch.
hatch provides easy access to the
engine compartment.
To open the engine compartment
inspection hatch:
1.
and apply parking brake.
1. Park the vehicle on a level
81
2. Unlock the two latches surface and apply the
3. Open the engine compartment handbrake.
inspection hatch and attach
2. Run the engine until it reaches
the strap, located behind the
operating temperature.
codriver seat, to the hook.
3. Turn off the engine. Wait a few
To lock reverse the order as minutes for the oil to drain
instructed for opening. back into the sump.

106
 8. MAINTENANCE AND DO-IT YOURSELF
Note
It is normal to add some engine oil
between oil maintenance intervals
depending on the severity of
operating conditions or depending
on the property of the engine
oil used. More engine oil is
consumed by frequent acceleration
/ deceleration especially when the
engine rpm is high.
Consumption is likely to be higher
when the engine is new.
CAUTION
Oil level should be checked
amount of oil can damage the
engine, and such damage is not
1
covered by the warranty.
18
8.5.2 Changing engine oil and oil
WARNING
• Used oil must not be poured
into the ground, canals, rivers,
etc. It should be disposed of
at a rubbish tip having proper
facilities. We recommend
having your oil changed by AL
LCV Dealer. 5. Place a container under the
1. Park the vehicle on a horizontal
surface and apply the parking 6. Remove the drain plug with a
brake. wrench and completely drain the
2. Allow the engine to run
until it reaches its operating
temperature, then turn the
engine off.
3. Open the engine inspection
hatch. (For details, see Engine
inspection hatch in this section.)
4.
Drain Plug
107
 8. MAINTENANCE AND DO-IT YOURSELF

13. Close the engine inspection

hatch.

WARNING

• Prolonged and repeated

contact with used engine oil

skin cancer, dermatitis, etc.

7. Clean and re-install the drain 10.
plug. Securely tighten the drain oil (add 4.4 ltr of engine oil
plug with a wrench. Do not use
excessive force. and install the cap. See the
“Technical Information” section
8.
for engine oil capacity.
with engine oil.
WARNING
When adding oil, pull out the
dipstick until the seal is free
of its housing to allow air to
escape from the sump.
11. Start the engine. Check for
leakage around the drain plug
• Try to avoid any contact
with the used engine oil. If
skin contact is made, wash
thoroughly with soap or hand
cleaner as soon as possible.
• Keep (used) engine oil out of
reach of children.
Protection of the environment
It is illegal to pollute drains, water
courses or soil. Use authorized
waste collection facilities and
garages providing facilities for
disposal of used oil and used oil 81
Authority for advice on disposal.

8.6 Engine cooling system

9.
hand until a slight resistance is
felt, and then tighten additionally
3/4th turn.
12. Turn the engine off and wait
several minutes. Check the oil
level with the dipstick and add
engine oil, if necessary.
at the factory with a high-quality, and
extended life engine coolant. The
high quality engine coolant contains

108
 8. MAINTENANCE AND DO-IT YOURSELF
the anti-corrosion and the antifreeze
function. Therefore, additional
cooling system additives are not
necessary.
Never add water to the radiator.
Use only recommended pre-mixed
ethylene glycol base anti-freeze.
Never use any other types of
engine coolant since it could
damage the cooling system.
WARNING
Engine coolant is poisonous.
Therefore it should be kept in a
properly marked container and
out of reach of children.
1 18
8.6.1 Checking coolant level
Check the coolant level in the
reservoir tank daily when the engine
is cold.
No Loss Tank
Open the inspection hatch. For
details, see “Engine compartment
inspection hatch” in this section.
And check, if the coolant level is
below the MIN mark, add coolant
recommended by AL until it reaches
checking, close the inspection hatch.
CAUTION
If the cooling system frequently
requires to add the coolant, have
it checked by AL LCV Dealer.
8.6.2 Changing engine coolant
Note
Major engine cooling system repairs
should be performed by AL LCV
Dealer. The service procedures
can be found in the appropriate AL
Service Manual. Improper servicing
can result in engine overheating.
WARNING
To avoid the danger of being burnt,
never change the coolant when
the engine is hot.
Drain
Plug
Drain
Plug
1. Loose the reservoir cap and
remove the drain plug from
radiator and drain the coolant.
109
 8. MAINTENANCE AND DO-IT YOURSELF

2. Flush the cooling system by 4. Bleed the air from the fuel
running clean water (without 8.7.1 Draining water system.
foreign particles).
For additional information, see
3. Install the drain plug to the Bleeding the fuel system in this
radiator. section.
4. See the “Technical information”
section for cooling system
capacity. Fill the reservoir tank 1. Disconnect fuel lines from the
up to the MAX mark by slowly
pouring coolant to allow the air
to escape out of the system. CAUTION
5. Install the reservoir cap, start Plug the pipe to prevent fuel
the engine and let it run for from draining.
several minutes.
when the water in fuel indicator
6. Stop the engine. After it 2.
comes on in the dashboard.
completely cools down, check
the coolant level and add Follow the procedure as described chassis frame.
coolant in the reservoir tank up below.
3.
to the MAX mark. 1. Place an appropriate container the bowl by unscrewing the 4
7. Check for any sign of leaks. bolts on the top cover plate.
2. Loosen the drain plug (2) a 4.
couple of turns. To avoid and assemble back the top
dropping it, do not loosen the
drain plug too much.
cover plate.
81
5.
3. After draining the water 8.7.3 Bleeding the fuel system
completely, screw the drain plug
back in place. If air enters the fuel circuit on any

proceed as follows:

110
 8. MAINTENANCE AND DO-IT YOURSELF
1.
fuel in the tank.
2. Open the engine inspection
hatch (For details, see “Engine
compartment inspection hatch”
in this section.)
3. Loosen the air vent screw (1) on
the Unit pump (2).
4. Switch ON the ignition (do not
crank) until bubble free fuel
comes out of the air vent screw.
1
18 5. Tighten the air vent screw.
6. Start the engine and make sure
that there are no leaks in the
connector or any other element
that has been handled.
7. Close and lock the engine
inspection hatch.
5. Reset the indicator by pressing
it on the top again after
element.
appearance of a red band in the
WARNING
housing.
• Do not run the engine without
the air-cleaner as it also
8.9 Emission control system
The control of automotive air
pollution largely depends upon the
development of effective emission
1. Remove the hose clip and unclip control systems. To meet this
demand, AL been making consistent
2. and continuous efforts towards the
further development of such devices.
3. Replace with new and genuine
Your AL vehicle is equipped with
the components.
Note
emission control devices which
are designed and built to provide
Place the hose back with arrow emission performance levels
required by Indian design rules. In
some States owners may be subject
made to the emission control
systems after delivery,
111

With this emission control system
built into AL, the discharge of
pollutants has been reduced
substantially.
These pollutants are primarily
hydrocarbons, nitrogen oxide, parti-
culate matter and carbon monoxides.
Hydrocarbons and nitrogen
oxides when exposed to sunlight
under certain conditions produce
photochemical smog.
Carbon monoxide is toxic when
highly concentrated in the air.
8.9.1 Exhaust emission control
system
EGR + OC
Exhaust gas recirculation (EGR)
system
The purpose of the EGR system is
to direct burnt gas into the intake
manifold so that it re-enters the
engine combustion chambers.
This system controls the engine
combustion temperature, thus
reducing NOx emissions.
112
8. MAINTENANCE AND DO-IT YOURSELF
Oxidation catalytic converter (OC) 8.10 Drive belt
The oxidation catalytic converter
oxidizes and reduces hydrocarbons
(HC) and carbon monoxide (CO)
emissions.
8.9.2 Maintenance
recommendation
Please make your contribution
to clean air in our environment
by operating the vehicle within
the prescribed load limits and by WARNING
maintaining the emission control
Be sure the ignition key is in the
system in accordance with our
LOCK position.
recommendations.
To maintain the original quality built
into the emission control system
we recommend that the system
be maintained by your AL LCV
Dealer who uses only Genuine AL
Replacement Parts, The use of
other parts which may be inferior 81
to genuine AL parts could lead to a
reduction in the effect of the system,
 8. MAINTENANCE AND DO-IT YOURSELF

Visually inspect each belt for signs 3. 8.13 Wiper blades

of unusual wear, cuts, fraying or lowest mark (MIN), add power
Wiper blades replacement
looseness. If the belt is in poor
condition or loose, have it replaced
mark (MAX).
or adjusted by AL LCV Dealer.
Note
Note
When checking the power steering
Have the belts checked regularly for
condition and tension in accordance entering the reservoir.
with the maintenance schedule.
The power steering will not operate

equipped)
only recommended power steering 1. Pull the wiper arm up.
be checked when the engine is cold.
recommended oil and lubricants” in 2. Push the lock pin, then remove
1. Open the engine inspection the “Technical Information” section. the wiper blade.
hatch. For details, see “Engine
3. Insert the new wiper blade to the
compartment inspection hatch”
wiper arm.
in this section.
reservoir (If equipped) 4. Return the wiper arm to its
2. Check that the level is between
original position.
the MAX and MIN marks

1 18 Max
In the winter season, add
windscreen washer anti-freeze.
a
If the windscreen is not clear after
using the windscreen washer, or
if the wiper blade chatters when
running, wax or other material may
MAX

MIN
CAUTION be on the blade or windscreen.
Min Do not substitute engine • Clean the outside of the
antifreeze coolant for windscreen windscreen with a washer
washer solution. This may solution or a mild detergent. The
damage the paint. windscreen is clean if beads do

113

not form when rinsing with clear
water.
• Clean the blade by wiping it with a
cloth soaked in a washer solution
or a mild detergent. Then rinse
the blade with clear water. If the
windscreen is still not clear after
cleaning the blades and using the
wiper, replace the blades.
WARNING
1.
When waxing the front panel of
the vehicle, be careful not to
let wax get into the windscreen
washer nozzles which could
2.
cause them to clog or create
improper windscreen washer
operation.
CAUTION
Make sure the wiper blade
contacts the glass otherwise the
arm may be damaged because of
wind pressure.
8. MAINTENANCE AND DO-IT YOURSELF
•
•
in the reservoir from opening
located on the right side of the
dashboard.
The level must be between the
MAX and MIN marks on the
reservoir. If it is below the MIN
indicator comes on, add brake
the MAX mark.
CAUTION
frequently, the system must be
checked by AL LCV Dealer.
surfaces since it will damage the
paintwork. Wash immediately
with water if this happens.
CAUTION
makes it ineffective in operation.
Don’t leave it uncapped for a long
time.
WARNING
therefore always be kept in its
original container and stored out of
reach of children.
81

in the brake.

•
brakes and reduce braking

114
 8. MAINTENANCE AND DO-IT YOURSELF

8.15 Brake conditions Brake pedal

Parking brake 5 2
3
LSPV
4 1

Front Rear

2. Place the other end of the

Periodically check the retention
capacity of the hand brake by
parking the vehicle on a steep hill
and braking the vehicle with the
parking brake only. If it does not hold
satisfactorily, visit AL LCV Dealer.
Brake bleeding procedure
tube in a bleeder bottle,
to submerge the end of the tube.
3. Start the engine and depress the
brake pedal 3 to 4 times with an
interval of 3 to 4 seconds.
4. Hold the pedal in depressed
condition and open the bleed
screw by 1/2 to 3/4 of a turn.
5. Repeat the action until bubbles
If the brake pedal suddenly goes
down further than normal, the pedal
feels “spongy” or the vehicle seems
to take longer to stop, visit AL LCV
Dealer immediately.
8.16 Battery
• Keep the battery surface clean
and dry. Any corrosion should
be washed off with a solution of

1 18 Whenever air bubbles present in the

brake lines, it is essential to bleed the 6.
of air comes out of the system.
Close the bleed screw
baking soda and water.
• Make sure that the terminal
system. immediately. connections are cleaned and
securely tightened.
1. Attach bleed tube to the
bleed screw (As per bleeding • Check that the battery is secured.
• Clean and apply neutral Vaseline
on battery terminal.
• If the vehicle is not to be used
for 30 days or longer, disconnect

115
 8. MAINTENANCE AND DO-IT YOURSELF

the “-” negative battery terminal and MIN lines. If electrolyte level is
WARNING
cable to prevent the battery from below MIN mark, add only distilled
discharging. water to bring the level to the MAX
• Do not expose the battery to
mark in each cell.
Hydrogen gas generated by
battery action is explosive.
• Do not allow electrolyte to
contact your skin, eyes,
fabrics, or painted surfaces on
the car.
• Do not touch or rub your eyes
after touching a battery or
battery cap. Thoroughly wash
your hands. If the acid contacts
your eyes, skin or clothing, 1. Remove the cell plugs using a
suitable tool.
at least 15 minutes and seek
medical attention. 2. Add distilled water up to the
MAX level.
• Keep the battery out of the
reach of children. 3. Check the level by looking
directly above the cell, as
Maintenance free illustrated.
This battery needs no regular 4. Tighten the cell plugs. 81
checking of the electrolyte level or
the addition of distilled water.
CAUTION
However, to prevent possible
damage, the level should be
Excessive electrolyte may leak
checked at least once a month.
out of the battery during charging,
Check the electrolyte level in each and may cause paint damage.
cell. It should be between the MAX

116
 8. MAINTENANCE AND DO-IT YOURSELF

checked and repaired by AL

LCV Dealer.

CAUTION
Never use a fuse of lower or higher

on the fuse box cover.

The Battery cover is provided for the

safety of the battery as shown in the

8.18 Fuses
If the electrical equipment does not
operate, check for a blown out fuse.

The affected circuits are shown on

1
the back of the fuse box lid.
18 1. Be sure the ignition key in the
“LOCK” position.
2. Open the fuse box cover and
remove the fuse
3. If the fuse is open, replace it with
a new fuse.
4. If a new fuse blows out again,
have the electrical system

117
 8. MAINTENANCE AND DO-IT YOURSELF

8.18.1 Cabin fuse box:

Cabin fuse box is located at the lower part of the dashboard,

FB-1 FB-2
1

10
2

8
9
1. PARK HAZARD HORN - 10A 3
2. HL LOW BEAM - 15A
4
3. HL HIGH BEAM - 15A AC
5
4. IGN BRAKE - 10A COMP
5. ACCESSORIES - 10A 6 RELAY
6. TURN & WIPER - 15A 7
7. BODY LOAD - 10A
Fuse Box

8. AC IGNITION - 10A HL LOW

9. COMPRESSOR - 10A & HIGH
FLASHER
10. BLOWER - 10A BEAM
RELAY

81

BLOWER

118
 8. MAINTENANCE AND DO-IT YOURSELF
8.18.2 Chassis fuse box:
Chassis fuse box is located at Right hand side of the chassis just behind front RH wheel arch.

IGN LOAD COOL FAN

15A 10A
STARTER
10A
ECU IGN
10A
FEED PUMP
15A

1 18
ECU 20A

SPARE FUSES
RADIATOR FAN
RELAY LOW

SPARE FUSES
ECU RELAY
PULLER

FEED PUMP
RELAY STARTER RELAY

119
 8. MAINTENANCE AND DO-IT YOURSELF

8.18.3 MAXI fuse:

It is located in battery Positive terminal.

RAD ALT
60A 80A

81

120
 8. MAINTENANCE AND DO-IT YOURSELF

8.19 Lights bulbs 8.19.2 Front side light or turn

8.19.1 Headlights CAUTION signal light

• Do not touch the glass of a

Replacing bulbs
1. Disconnect the battery.
2. Remove the side panel.
3. Disconnect the connector (1).
4. Remove the rubber cover (2).
5. Remove the bulb by pressing on
its retainer spring.
6. Fit the new bulb into the head
1 18 lamp, ensuring that the retainer
7. Fit the rubber cover (2) so that
its tongue faces upward.
8. Connect the connector (1).
9.
10. Connect the battery.
halogen bulb with your hands
or with dirty gloves; use a
clean cloth. If it is accidentally
touched, clean it with cotton
soaked in alcohol.
• Ensure that the lip of the rubber F og lamp
cover is in contact with the P rovis ion
headlights unit body.
• Always use bulbs of the 1. Disconnect the battery.
2. Remove the side panel.
• It is not necessary to adjust
the height of the head lamp 3. Takeout the side light and
remove it from its housing.
after replacing bulbs. When an
adjustment needs to be made, 4.
visit AL LCV Dealer. the new one in the reverse order
of the removal procedure.
• Do not leave the headlights unit
without its glass and its rubber
protector for a long time.
• Dust, damp, smoke, etc, may
affect its operation.
• Remove the bulb just before

121
 8. MAINTENANCE AND DO-IT YOURSELF

1. Disconnect the battery. 4. To install, reverse the removal 8.20 Bulbs

procedure, ensuring that the
2. Remove the side panel.
Power
3. Disconnect the connector (1) ITEM
8.19.5 Interior lights (W)
and takeout the blown out bulb.
Head lamp
4. Fit the new bulb in the reverse
order of the removal procedure. Low beam 55
8.19.4 Rear combination light High beam 60
Front side lights

Parking light 5
Turn signal light 21
Rear combination lights
1. Disconnect the battery. Side turn light 5
2. Remove the bulb-holder. Turn signal light 21
3. Remove the blown bulb and Side/brake light 5/21
1. Disconnect the battery. removal procedure. Reverse light 21
2. Remove the bolts (1).
Interior lights
3. Replace the blown bulb.
Front 10 81
The location of the different
bulbs in the rear combination
light assembly is:
– Turn signal light (2)
– Brake light (3)
– Reverse light (4).

122
 8. MAINTENANCE AND DO-IT YOURSELF
8.20.1 Replacement procedures 8.21 Wheels and tyres in the “In case of emergency”section
for tyre replacing procedures.
of emergency” section.

d
Periodically check the tyre pressure
A (including spare). COLD tyre
pressures are shown on the tyre
TWI

centre pillar or for details, see

B “Wheels and tyres” in the “Technical
information” section.
Incorrect tyre pressure may • After rotating the tyres, adjust the
adversely affect tyre life and vehicle tyre PRESSURE.
C
•
lead to an overheating of the tyre
care or maintenance can affect
Remove
Remove and subsequent internal damage. the vehicle’s safety with risk of
At high speeds, this could result in accident and injury. If any doubt,
Fit
Fit
tread separation and even bursting consult your AL LCV Dealer or
of the tyre. the tyre manufacturer.

1
All other lights are either type A, B, C
18 CAUTION Tyre wear and damage
or D.
When changing or replacing tyres, Tyres should be periodically
be sure all four tyres are of the inspected for wear, cracking,
the lens and/or cover.
same type (i.e., summer, all bulging, or objects caught in the
season or snow) and construction. tread. If excessive wear, cracks,
bulging, or deep cuts are found, the
Tyre rotation tyre should be replaced.
AL recommends that tyres be rotated
for every 10,000 km. See “Flat tyre”

123

TWI
The original tyres have a built-in
tread wear indicator. When the wear
indicator is visible, the tyre should
be replaced.
Changing tyres and wheels
Note
When replacing a tyre, use the same
size, speed rating and load carrying
capacity as originally equipped.
Recommended types and sizes are
shown in “Wheels and tyres” in the
“Technical information” section.
If the wheels are changed for
any reason, always replace with
wheels which have the same offset
dimension.
124
8. MAINTENANCE AND DO-IT YOURSELF
Wheels of a different offset
could cause early tyre wear,
possibly degraded vehicle handling
characteristics and/or interference
with the brake discs/drums. Such
interference can lead to decreased
pad/shoe wear.
WARNING
Do not install a deformed wheel or
tyre even if it has been repaired.
Such wheels or tyres could have
structural damage and could fail
without warning.
Wheel balance
Unbalanced wheels may affect
vehicle handling and tyre life. Even
with regular use, wheels can become
unbalanced. Therefore, they should 81
be balanced as required. Wheel
balance service should be performed
with the wheels off the vehicle. Spin
balancing the rear wheels on the
vehicle could lead to transmission
damage.
 8. MAINTENANCE AND DO-IT YOURSELF

Wheel alignment

Incorrect wheel alignment affects vehicle handling and tyre life. Whenever uneven tyre wear is noticed contact the
nearest AL LCV Dealer.

PHOENIX Wheel alignment parameters

Description PHOENIX
Toe In 2 ± 1 mm
Camber angle 0.5° ± 30'

Caster angle (With Load body) 10.4° (+ 1° / - 2.5°)

Kingpin inclination 10° ± 15’

Wheel lock angle - Inner/Outer 41° ± 1 / 28 + 4 / -2°

Care of wheels

• Wash the wheels when washing the vehicle to maintain their appearance.
1 18
• Clean the inner side of the wheels when the wheel is changed or the underside of the vehicle is washed.

• Do not use abrasive cleaners when washing the wheels.

• Inspect wheel rims regularly for dents or corrosion. This may cause loss of pressure or damage the tyre bead.

125
 9. GENERAL GUIDELINES FOR BODY BUILDING

C H A P T E R__________

9. GENERAL GUIDELINES FOR BODY BUILDING PHOENIX

9.1 Installation of Lighting & Signaling Devices ..................................................................................................127

Tape ....................................................................................................................... 130
9.3 General Guidelines For Body Building - PHOENIX ..................................................................................... 132
9.4 3.49T Vehicle Dimensions and Weight ........................................................................................................ 132
9.5 Load Body Mounting Points ......................................................................................................................... 137

91

126
 9. GENERAL GUIDELINES FOR BODY BUILDING
9.1 Installation of Lighting & Signaling Devices - PHOENIX
Furnished below are the requirements for Lighting and Signaling Devices

WIDTH FROM DISTANCE BULB

HEIGHT FROM
LAMP NUMBER OUTER EDGE BETWEEN LAMPS POSITION DESIGNATION AS
GROUND (mm)
(mm) (mm) PER AIS 034

Rear
Not More Than
Direction 2 350-1500 Max-1800 Rear P21W
400
Indicator
- Not Less Than 600 P21/5W
Stop Lamp 2 350-1500 Rear

Rear
Registration 1 To Illuminate The Rear Registration Plate Rear P21/5W
Plate Lamp
Rear Position Not More Than Not Less Than 600 Rear P21/5W
2 350-1500
Lamp 400
Rear Not More Than
2 250-900 Not Less Than 600 Rear RED
400

I.

II. For Installation Details refer following Figure. All Lamp Devices shall comply to AIS 012 - 2004 and Installation shall be

1
III. Position and Installation of Head Lamp Main Beam & Dipped Beam, Front Position Lamp & Front Indicator Lamp shall
19 be unaltered and complies to standards as mentioned above.
IV. Initial Aiming position of HLLD Switch must be Re-Adjusted after body building in Unladen Condition.

127
 9. GENERAL GUIDELINES FOR BODY BUILDING

H
G
F
E

REVERSE LAMP
POSITION & STOP LAMP
REFLEX REFLECTOR
REGISTRATION PLATE LAMP
REAR DIRECTION INDICATOR
A

C
D
B

91
J

OVERALL WIDTH

128
 9. GENERAL GUIDELINES FOR BODY BUILDING

S.NO MODEL OVERALL WIDTH A B C D E F G H I J K L

1 PHOENIX 1842 650 623 591 564 105 200 280 380 1635 1470 1260 1090

1 19

129
 9. GENERAL GUIDELINES FOR BODY BUILDING

9.2 Installation of Reflective Tape

208.6
B 1350

C Reflective Tape Fixing On Load Body

91

130
 9. GENERAL GUIDELINES FOR BODY BUILDING

Installation of Reflective Tape (PHOENIX)

Corner Support

Unladen Condition
1066 - B
20

240
196

Rear Member

Ground Plane

1 19 1600

C - 1750

131
 9. GENERAL GUIDELINES FOR BODY BUILDING

9.3 General Guidelines for Body Building - PHOENIX

1600 ± 2 #1 RED REFLECTIVE TAPE
As per AIS 090
AGGRESIVE PRESSURE
TYPE SENSITIVE

0.8 THK
ACRYLIC ADHESIVE

20 ± 1
B

All Dimensions are in mm

± 3 mm Tolerance is applicable for all Dimensions of the Table above.
9.4 3.49T Vehicle Dimensions & Weights:
I. Vehicle overall Length shall not exceed 5025mm.
II. Vehicle overall Width shall not exceed 1842mm.

III. Vehicle overall Height shall not exceed 2061mm

IV. The super structure (or) built body weight on cab-chassis shall be minimum of 170 Kg.
V. After Body building the payload shall be such that the following GVW values are never exceeded in service.

MODEL NAME GVW in Kg

i4 - LS 3490 91
i4 - LX 3490

132
 9. GENERAL GUIDELINES FOR BODY BUILDING

9.5 Mounting of Load Body

Load body has to be built on the points shown in the following Figure

1 19

133
 9. GENERAL GUIDELINES FOR BODY BUILDING

9.5 Load Body Mounting Points

Installation Guidance:
Do’s
I. Provided Torque to be used110~150Nm
II. Load carrier mounting points tobe used as shown in Fig..
III. Balata package to be used between frame & Load body
Dont’s
I. Do not weld or drill on the chassisframe
II. Do not extend chassis frame to mount the load carrier, as this can lead to permanent failure
III. Do not load the vehicle more than rated GVW.
IV. Do not reinforce the chassis frame to carry the load carrier.
91
V. Do not change the mounting points of the load carrier.
134
 No.1, Sardar Patel Road
Guindy, Chennai 600 032.
Email: lcvccc@ashokleyland.com

Publication No: OM PNX 3.49 LHD E4 IC / 03-2022

Version : V001