tata spacio withgold+ manual

8/8/2019 Tata Spacio WithGold+ Manual

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Do you know ?

While taking delivery of your New TATA Spacio (Soft Top)

vehicle

you are privileged to have the following :

1. Owners Manual & Service Book

2. Battery warranty Card

3. First Aid Kit4. Advance Warning Triangle

5. Jack and Handle

6. Spare Headlamps Bulbs - 2 Nos.

7. Spare Fuses - (Provided in fuse box)

8. Pre - delivery inspection and service.

9. Complimentary diesel in the fuel tank.

10. Tool Kit

a. Wheel Spanner

b. Screw Driver

c. Ring Spanner (8-9)

d. Socket Handle (Part no. 2654 5890 35 24)

You are also entitled for :

Free Services as per details given in your Owners manualand service book, at any Tata Motors Dealership orTata Motors Authorised Service Centre ( TASC )or Tata Motors Authorised Service Point (TASP).

On the spot settlement of warranty as per terms andconditions given in this book.

We welcome your suggestions for better service.

Should you require any assistance, please contact Works

Manager of Tata Motors Dealership or TASC.

EXCELLENT CUSTOMER SUPPORT FOR TOTAL

SATISFACTION

OUR TOLL FREE NO. 1800 209 6688


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FOREWORD

Thank you for selectingTATA SPACIOvehicle of your choice.

We welcome you to the world of advanced automotive engineeringin a form especially suited to our operating conditions.

This book gives you all the information necessary for making your

ownership of the vehicle, a thoroughly satisfying experience.

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

Should you need any special assistance, please call on our Authorised

Dealer.Please note that by adhering to the correct operating proceduresand by availing the scheduled maintenance services at ourauthorised service centres, you can obtain the maximumperformance from your vehicle.

We request you to go through the book and drive many miles ofmotoring pleasure.

We provide safe, high quality, high performance vehicles.In order to maintain the level of performance and reliabilityin the vehicle, it is important that only Tata Motorsgenuine accessories are to be fit ted. Any accessory thatis fitted or modification that is carried out withoutauthorisation can hamper the safety and performanceof the vehicle besides depriving you of your warrantybenefits.

Use of genuine parts, designed and manufactured to our exactingstandards, are the best way to maintain your vehiclein peak operating condition. Please do not use substitutes.

They always prove costlier in the long run.Failure to use genuine parts can invalidate any futurewarranty claims.

Edition : RVP/C-2005/RP/15001-17000

The information and specification given in this book

are valid as on the date of printing. Tata Motors

reserves the right to make changes in design andspecifications and / or to make additions to orimprovements in this product without obligation toinstall them on products previously sold.


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Contents

Foreword iii

Environmental Protection 1

Warranty Terms & Conditions 3

Dos 5

Donts 7

Aggregate Numbering 8

Handling

Key 9

Locking & unlocking doors 9Sun Visors 10

Rear View Mirror 10

Seats 11

Seat Belt 14

Vehicle Jack & Tools 15Instrument Cluster 16

Gauges 17

Indicators 17

Ignition Switch 18

Combination Switch 19

Turn Signals 19

Lights 19

Front Windshield wiper/washer 20

Hazard Warning 21

Headlamp leveling switch 21

Roof Lamp & Courtsy lamp 22

Cigarette lighter & Ash Tray 22

Bonnet Opening & Closing 23

Engine compartment lamp 23

Driving Controls 24

Gear Shift Lever 25

Parking Brake 25

Spare Wheel 26

Air conditioning (if fitted) 27

EGR system (if fitted) 29

Catalytic converter (if fitted) 30

Preparing the vehicle for the drive 31

Driving Instruction

Before Driving 34

Gear Shifting Speeds 35

Driving Instructions 35

Braking 35

Stopping the engine 36Fuel Economy 36

Towing the Vehicle 37

Driving Safety 38

Vehicle MaintenanceEngine Compartment 40

Engine Oil Change 41

Engine Oil Filter Change 41

Air Filter 42

Fuel System Bleeding 43Fan Belt Tension Adjustment 43

Clutch System Bleeding 44

Cooling System 45

Brake System 46


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Contents

Brake System Bleeding 47

Brake Adjustment 48

Parking Brake Adjustment 49

Power Steering 49A

Power Steering belt Adjustment 49B

Wheels & Tyres 50

Wheel Change 50

Wheel Alignment 50

Tyre pressure 50

Wheel Balancing 51

Tyre Rotation 52

Headlamps 52

Headlamp Adjustment 52

Headlamp Bulb replacement 54

Fuse Box 54

Bulb Specifications 55

Care & Cleaning of the vehicle 56

Fuel 58

Lubricants 58

Coolants 59

Recommended oils, lubricants

and filling capacities 60

Technical specifications 61

Special Instructions 64

Service Schedule 66

Record of Service Performed 69

Abbrevations 73

Tata Motors sales andservice set-ups A-1

Tata MotorsDealers Network B-1

Free service coupons


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Environmental Protection

TATA MOTORS is committed to

produce vehicles using environmentallysustainable technology. A number offeatures have been incorporated in TataMotors Passenger Car Vehicles whichhave been designed to ensureenvironmental compatibility

throughout the life cycle of the vehicle.We would like to inform you that yourvehicle meets Emission norms and this

is being regularly validated at the stageof manufacturing.

As a user, you too can protect theenvironment by operating your vehiclein a pro-active manner. A lot dependson your driving style and the way youmaintain your vehicle. We are givingbelow a few tips for your guidance.

Drivingl Avoid frequent and violent

accelerations.

l Do not carry any unnecessaryweight on the vehicle as itoverloads the engine. Avoid using

devices requiring high power

consumption during slow trafficcondition.

l Monitor the cars fuel consumption

regularly and if it shows a rising trend,get the car immediately attended atour Authorised Service Centre.

l Switch off the engine during longstops at traffic jams or signals. If thesituation demands that engine be keptrunning, avoid frequent revving up ofthe engine. Also avoid frequentstopping and restarting, if uncalled for.

l It is not necessary to rev up theengine before turning it off as itunnecessarily burns the fuel.

l Shift to higher gears as soon as

possible. Use each gear upto 2/3rd of

its maximum engine speed. A chartindicating gear shifting speed isgiven in this book.

Maintenance of the vehicle

l Ensure that recommended

maintenance is carried out on the

vehicle regularly at our AuthorisedService Outlets.

l As soon as you see any leakages ofoil or fuel in the car, get it attendedimmediately.

l

Use only recommended brands andgrades of lubricants and cleanuncontaminated fuels.

l Get your vehicle checked for emission

periodically by authorised dealer andregularly renew the P.U.C. certificate.

l Ensure that fuel filter, oil filter andbreathers are periodically checkedand if required, replace the same byonly genuine Tata Motorsrecommended brands.

l Do not pour used oils or coolants into

the sewage drains, garden soil or openstreams. Dispose the used filters andbatteries in compliance with thecurrent legislation.

l Do not allow any unauthorisedperson to tamper with engine


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settings or to carry modifications on

the vehicle.

l Never allow the vehicle to run out offuel.

l Parts like brake liners, clutch discshould be vacuum cleaned. Do not

use the compressed air for cleaningthese parts which may spread thedust in the atmosphere.

While carrying out the servicingor repairs on your vehicle, you

should pay keen attention to someof the important aggregates, whichgreatly affect emission. Thesecomponents are :-

1. Fuel injection pump, Injectors/Nozzles

2. Air intake & Exhaust systemespecially for leakages

3. Cylinder head for valve leakage

4. All filters such as air, oil and fuelfilters (check periodically)

Environmental ProtectionEnvironmental Protection

5. Turbocharger and intercooler (if

fitted)

6. Catalytic converter

7. EGR

This Owners Manual contains further

information on driving precautions andmaintenance care leading toenvironment protection. Pleasefamiliarise yourself with these aspectsbefore driving.


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Terms and conditionsWarranty

of the vehicle or any damage due to

negligent or improper operation orstorage of the vehicle. This warrantyshall not apply to normalmaintenance services viz. oils & fluidchanges, head lamps focussing,fastener retightening, wheelbalancing, tyre rotation, adjustment

of valve clearance, fuel timing,ignit ion t iming and consumables likebulbs, fuel filters and oil filters etc. Thiswarranty shall not apply to anydamage or deterioration causedby environmental pollution or birddroppings. This warranty shall notapply to V-belts, hoses and gasleaks in case of air conditionedvehicle. Slight ir regulari t ies notrecognised as affecting thefunction or quality of the vehicle orparts, such as slight noise or

vibration, defects appearing onlyunder particular are irregularoperations or i t ems consideredcharacterist ic of the vehicle.

7. This warranty shall be null and voidif the vehicle is subjected toabnormal use such as rallying,

racing or participat ion in any other

competitive sports. This warrantyshall not apply to any repairs orreplacement as a result of accidentor collision.

8. This warranty is expressly in lieu ofall warranties, whether by law or

otherwise, expressed or implied,and all other obligations orliabil it ies on our part and weneither assume nor authorise anyperson to assume on our behalf,any other liabilit y arising from thesale of the vehicle or any

agreement in relation thereto.9. The buyer shal l have no other

rights except those set out aboveand have, particular, no right torepudiate the sale, or anyagreement or to claim anyreduction in the purchase price of

the vehicle, or to demand anydamages or compensation forlosses, incidental or indirect, orinconvenience or consequentialdamages, loss of vehicle, or loss oftime, otherwise, incurred oraccrued.

10. Any claim ar ising f rom th is

warranty shall be recognised onlyif it is notified in writ ing to us or toour concerned dealer without anydelay soon after such defect ascovered and ascertained under thiswarranty.

11. This warrant y shall st andterminated if the vehicle istransferred or otherwise alienatedby the buyer without our priorwrit ten consent.

12. We reserve our rights to make anychange or modif ication in the

design of t he vehicle or i ts parts orto introduce any improvementtherein or to incorporate in thevehicle any additional part oraccessory at any time withoutincurring any obligation toincorporate the same in the

vehicles previously sold.


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Dos

1. Use recommended oils and

lubricants only.

2. Change oil in engine, gear box,transfer case, steering system, frontlive axle and rear axle at prescribedintervals.

3. Use only genuine oil filter and fuelfilter elements. Replace them atregular intervals.

4. Clean air filter element regularly.Replace filter element when serviceindicator shows red band even aftercleaning the filter element or, at 40,000

km in clean condition or 25,000 km industy condition.

5. Ensure periodic servicing as permaintenance schedule.

6. Insist on use of genuine spare parts.

7. Ensure that caps of auxiliary tankand genuine radiator are firmlyfitted to keep the cooling systempressurised and to maintain coolantlevel.Always use radiator cap onlyof 1.0 kg/cm2 (14 PSI), forreplacement.

8. Check tyres for damage from time to

time and remove any foreign bodiesembedded in treads.

In case of tyre replacement or repairsdue to puncture have the wheelbalanced. Keep grease, oil and fuelaway from the tyres. In case of

uneven tyre wear get the vehicleattended to by any of our authorisedservice set-ups.

9. Maintain correct tyre pressure.

10. Check battery every week and top upelectrolyte level. Keep batteryterminals clean and cable joints tight.Apply vaseline / petroleum jelly onterminals. Use distilled water only fortopping up.

11. Observe correct polarity whenconnecting battery terminals.

12. Disconnect alternator terminalswhile carrying out any welding onthe vehicle.

13. Avoid panic braking. Use lower gearswhile descending gradients.

Friendly notes Dos


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14. Start the vehicle always in the 1st

gear to avoid premature clutch wear.

15. Keep both foot and parking brakesproperly adjusted.

16 Before engaging reverse gear,ensure that vehicle has come to astop, declutch, wait for a few seconds

and shift into reverse gear.

17. When parking on slopes, use wheelchocks, apply parking brake and keepvehicle in low gear.

18. In case of emergency parking orbreakdown on road, pull the hazard

warning switch to flash all the blinkerlights to warn other road users.

19. Release parking brake beforedriving off.

20. Release the ignition key as soon asengine starts.

21. Retighten wheel mounting nuts after100 km of every wheel change.Tightening Torque : 12 -15 mkg.

22. Use only recommended FUSES andalways keep spare fuses in the box.

23. In case of engine not starting first

check the fuse of fuel injectionpump solenoid.

24. Inspect the engine timing belt atevery 16,000 km. and replace, if foundtorn, cracked, worn or soaked in oil.

25. Ensure doors are properly closed.

Where Air conditioning system isinstalled

1. After parking in the sun, drive withwindows rolled down for a fewminutes to blow off hot air beforeswitching on AC.

2. Keep all window rolled-up when ACsystem is working.

3. During stop and go city driving uselower gears to obtain efficient cooling.

4. If you feel irritation in the eyes due tosmoke or during long drive, stop ACand ventilate for half a minute by

opening doors.

5. Before stopping the engine first switchoff AC and then the blower.

6. During off-season operate the airconditioner a few times every monthto lubricate components.

Dos

Friendly notes Dos


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Donts

1. Do not start the vehicle if Brake Fail

indicator is ON.

2. Do not use Clutch Pedal as FootRest. This will reduce clutch life.

3. Do not Coast vehicle in Neutral andengine switched-off position. This is a

safety hazard.

4. Do not run engine without RadiatorCap. Use genuine Cap only, to keepsystem pressurised.

5. Do not overtighten engine oil filter.

6. Front and rear suspension shockabsorbers fitted on this vehicle havein-built rebound stopper. There is noseparate rebound stopper fitted onthe vehicle. Hence, do not drive thevehicle either without shock absorbersOR with non-genuine shock absorbers,otherwise suspension is likely to bedamaged.

7. If your vehicle has a turbochargedengine, do not stop the engine atonce, allow it to run at idling speed

Friendly notes Donts

for atleast 1 minute. Also do not

accelerate engine till the engine oilpressure has built up.

8. Do not cause heating of AC pipe(where fit ted), while welding/brazingin its viscinity.

9. Do not disturb the fast idiling controldevice actuator setting, where fitted.

10. Do not open any hose/pipe points ofAC system (where fitted).

11. Do not put your hand inside the

condenser fan when the grille isremoved. Disconnect power supply tofan and switch off engine before anymaintenance work, where applicable.


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Location of chassis and aggregate serial numbers

Chassis number plate Chassis number on frame

Gear box number

Handling

Rear axle number (Spicer) Body shell number plate

FIP number (MICO)

Engine number

Rear Axle number (Tata Motors)


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Handling Key & Central Door Locking

KeyA key has been provided for operationof steering lock cum ignit ion switch, forlocking and unlocking of drivers sidedoor, glove box and rear door.

Locking and Unlocking of DoorsFrom outside :To unlock the door turnkey antilockwise and swing handle (1)upwards. To lock the door turn keyclockwise.

Where the central locking system isprovided, if you lock/unlock driver doorwith the key, the remaining three doorsget locked/unlocked at a time. The tailgate door is not part of the centrallocking system.

From inside : Pull knob (2) and thenonlypull handle (3) in the door panel tounlock the door. To lock the door pressknob (2)

In case knob (2) is pressed with dooropen, it will get releasedautomotically when door is closed.The co-drivers side door and middledoors can be opened from outside isfrom inside by pressing knob 2. The rear

door can be opened and locked frominside.

Window glasses

For operating window glasses usehandle (4).

3

2

4


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Handling Sun Visors & Rear View Mirror

Sun visorTwo adjustable sun visors are providedinside the cab to prevent sun glare.

Lower the sun visors to protect the eyesfrom bright sunlight. The sun visors also

moves sideways towards the door.A Vanity mirror has been provided onthe co-drivers sun visor.

Rear View Mirror - Outside

Rear view mirrorRear view mirror is fitted on drivers andco-drivers side door. It can be adjustedto the desired positions by hand. Themirror can be folded backwards forconvenience when the vehicle is to be

driven through narrow passages.

The additional adjustable anti-glare rear

view mirror is fitted inside the cab. It canbe adjusted in following two positionsby using knob provided on the mirror.

Vanity Mirror

SunvisorsMirror

Rear View Mirror - Inside

1. Normal posit ion2. Anti-glare position

Use anti-glare position only ifnecessary as it reduces the rear viewclarity considerably.


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Seat Adjustment lever

2

1

Seats

Drivers seat

Adjustable type seat is provided fordriver. The seat is fitted with lever andhandle, to adjust the seat.

The seat can be adjusted in forward andbackward directions. To achieve correctposition for proper driving, lift handle(1) and slide the seat either forward orbackward. Once the desired posit ion is

achieved push down the handle to lock

the seat.

Turn the lever (2) to adjust backrest todesired position. Release the lever tolock it.

Do not adjust seat while driving.

Lumber Support

The lumber support is adjusted by using thelever provided at the side of the seatbackrest for both drivers and co-driversseats.

Co-driver seat

Soft cushioned comfortable bench seat isprovided at front by the side of driver fortwo passengers.

In some versions soft cushioned adjustabletype seat is provided for co-driver.

Middle seatsA cushion bench seat has been provided forthe middle passengers. In few versions, acushion bench 60:40 split seat has beenprovided for the middle passengers. Anyone of the split can be folded by releasingthe latch, on the backrest simultaneously.For more luggage space or to access frontfacing third row seat, the folded middle seatcan be somersaulted further.

For fixing the rear seat back upright, justpush back the seat in position. It will getlocked by itself.

Middle Seat

Handling Seats


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Handling Seats

4 5 6

Rear jump seat Total luggage space where front facing seat is removed & middle seat folded

Luggage space where rearjump seats are folded

32

Slide the knob and fold the seat Press the knob and pull the seat to its position

Front facing rear seat

1


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Handling Seats at rear

For folding back, pull the strapas shown in figure

Lift the lever and fold the seat furtherto get maximum luggage space

For detaching seat, operate two leversprovided on wheel house area and pull it out

1 2 3

Seats at rear

Two seater folding bench seat each on rightand left hand side at tail end are provided.These seats can be folded for carryingbulkier baggages as per procedure givenbelow:

1. Lift the seat squab and hold againstbackrest.

2. Engage strap with the hook on seatsquab.

3. Fold the seat stand.

To open the seats follow the reverse order.Ensure stand is fully opened and vertical tothe floor.

To open the seats follow the reverse order.Ensure stand is fully opened and vertical to

the floor.Front facing third row seat (Optional)

The foldable and detachable type softcushioned comfortable bench seat hasbeen provided at the rear. (fig. 3 on previouspage)

For folding back, a seat pull strap has beenprovided behind seat back. (fig. 1)

For detaching seat, operate two leversprovided over wheel house area. (fig. 3)


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Handling Seat belts

SEAT-BELT ARRANGEMENT ON VARIOUS FRONT SEATS

Seat-Belt Arrangement on Bucket Seat

1. Anchor

2. Webbing

3. tongue

4. Buckle

3

2

Seat-Belt Arrangement on Bench Seat

1

SEAT BELTThe vehicle has been fitted with three pointbelt for extra safety for driver, co-driver andpassengers on middle seat.

Fastening the belt

Insert belt tongue into buckle, a positive

locking click indicates correct and safeassembly.

Releasing the belt

Press the release button, the tongue will beejected clear of the locking mechanismwithin the buckle.

Belt adjustmentWhen the vehicle is at rest, adjust the lengthof the belt to suit convenience. Insert belttongue in buckle. A positive click indicatescorrect assembly.

Adjust length of the belt to suit you andfasten. The lap section should becomfortably t ight, the diagonal sectionsshould be adjusted so that a flat hand willpass between the chest and the strap.

To tighten (shorten) the belt.

Pull free end of webbing through adjusteruntil required adjustment is achieved.

To loosen (lengthen) the belt.Tilt the adjuster by means of the grip andslide it along the strap until suitably adjusted.

Lap belt for middle passengers of frontbench seat. (Where applicable)

Middle passenger is provide with lap belt.

Adjust length of belt to suit convenience.Insert belt tongue in buckle. A positive clickindicate correct assembly. To release, pressthe release button. The tongue will beejected from the buckle.


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CAUTIONl The belt is designed for use of only one person.

l It is not intended for children under 10 years.

l The belt should at all time be adjusted and used in accordance with theinstructions and no excessive slackness in the belt should be evident.

l Avoid twisting the straps during use.

l Webbing must not be allowed to chafe against sharp edges on seat orbodywork.

l Do not make any alterations or additions to the belt. If in doubt consultthe authorised service outlet

l The belt that have been cut, frayed, damaged or have been stressedthrough impact, should be replaced.

l To clean and occasional wipe with warm soapy water will maintain thewebbing in a clean condition. Do not use bleach or dye under anycircumstances.

l Periodic inspection of the installation will ensure safe and reliableservice of the seat belt.

Vehicle Tools & Jack

Vehicle tool bag is kept in lockable box below co-driver seat. Jack and handleare kept below rear right seat. Jack is mounted on floor over studs by wingnuts screwed on them.

Lift the rear right seat squab to have access jack and handle.

Handling Vehicle Tools & Jack

Jack


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Handling Instrument cluster

Instrument cluster

1

2

34 5 6 7 8

10

9

1. Fuel Gauge

2. High Beam Indicator

3. Battery Charging Indicator

4. Turn signal indicator left

5. Speedometer

6. Odometer

7. Turn signal indicator right

8. Oil Pressure indicator light

9. Parking brake cum brake fluidlevel indicator

10. Coolant temperature gauge

11. Trip meter

12. Reset knob for t ripmeter

12 11


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1. Fuel gauge

It indicates the approximate level of fuel in tank.

FILL UP THE TANK WITH RECOMMENDED DIESEL FUEL WELLIN ADVANCE, BEFORE THE NEEDLE TOUCHES E MARK ONTHE GAUGE.

2. High beam indicator

(Blue)3. Battery charging

indicator light. (Red)

It comes on when ignition key is turned to position ON andmust go off when the engine starts running.

4. Turn signal indicator

(Left) (Green)

5. SpeedometerIt indicates vehicle speed in km/h.

6. Odometer registers total distance covered by the vehicle inkm.

7. Turn signal indicator(Right) (Green)

Handling Gauges & Indicators

8. Oil pressure

indicator light (Red)

It comes on when ignition key is turned to position ON andgoes off as soon as the required oil pressure has developed afterthe engine has started. If the light continues to glow when theengine is running, it indicates low oil level in engine oil sump,or a fault in the lubrication or electrical system.

Continued running of the engine when the oil pressureindicator light is on, may damage the engine.

9. Parking brake indicator cum Brake fluid levelindicator (Red)

a. This lamp comes ON when parking brake is applied andgoes OFF when it is released.

b. It also comes on when ignition key is turned to positionON and must go off when the engine starts running. Ifthe light continues to glow when the engine is running,it indicates low level of brake fluid in the container.

In case of such an event, get your vehicle checked at

authorised service centre for leakages in brake system.

10. Coolant temperature gauge

(0C) Red band of this gauge indicates engine overheating.i.e. temperature is > 120o C.


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Handling

Ignition switch :

Ignition switch is fit ted on steering column of the vehiclel to start the engine.

l to switch on and off the electrical system other than listed below.Horn, parking lamps and hazard warning indicators are not connectedthrough this switch and operate independently.

l to switch on and off the accessories only.

The switch is located on the steering column support and has the

following key positions:LOCKKey can be inserted or taken out in this position. Steering gets locked onlyafter the key is withdrawn from the switch.After withdrawing the key from the switch ensure that steering is locked byturning steering wheel clockwise and anticlockwise. To unlock the steering,insert the key into the switch and turn it clockwise. If any difficulty arises in

unlocking turn the steering wheel a little clockwise or anticlockwise whileturning the key.

ACCBy turning the key to ACC posit ion power supply to accessories is switched on.

ONBy turning the key to this position all remaining electrical systems becomeoperative and lamps of battery charging indicator, low oil pressure and brakefluid level cum parking brake indicator will come on.

STARTTurn the key further clockwise to start position (spring loaded) to operate startermotor. As soon as the engine starts release the ignition key, so that key can comeback to ON position and starter motor disengages. Vehicle is driven in this positionby turning the ignit ion key from ON posit ion to ACC or LOCK posit ion.

Ignition Switch

Ignition switch

Ignition switch key positions

LOCK


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Combination Switch

The combination switch is mounted on steering column. Its right side leveroperates turn signals, headlamps and parking lights and number plate lights.

Turn Signals

Moving the combination switch lever in sideways direction operates the turnsignals:

Position 4 - Turn signal left

Position 5 - Turn signal right

The lever returns to neutral position automatically when the steeringwheel is returned to straight ahead position.

Lights

Lights are operated by turning the knob of combination switch as indicated

below:

First notch (P L position)

Parking lights, number plate lights and controls backlights are switched ON.

Second notch ( H L position)

Head lights are also switched ON, in addition to parking lights, number platelights and controls backlights.

Handling Combination Switch

Combination switch

Combination switch (RH side)

3

4

5

2

1


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Wiper motor operating lever

Handling Combination Switch and Wiper / Washer

OFF - Position

The combination switch lever can be operated up and down to select theheadlight beam as follows :

Position 1 - High beam

2 - Low beam

3 - High beam flash

High beam flash (No. 3 position)

High beam flash will be ON as long as lever is held in posit ion 3 irrespectiveof the knob position. This is spring loaded position and can be used in daytime also for giving signal to the on coming traffic.

Front Windshield wiper / washer

The combination switch lever mounted on the left side operates thewindshield wipers and washers :

Position

OFF - Wiper motor switched OFF

INT - Wiper sweeps intermittently

LO - Low speed of wiper motorHI - High speed of wiper motor

To operate windshield washer, lift the lever. The windshield washer will remainin operation as long as the lever is held in this posit ion.


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Headlamp leveling Switch

Hazard warning switch

To operate the system, pull the switch located behind the steering wheel. Allturn signal lights will flash simultaneously to warn other road users about thehazardous condition of the vehicle.

Headlamp leveling switch : (if provided)

A motorised headlamp leveling arrangement with the setting knob providedon the dash board.

As and when required, head lamp leveling setting is done by rotating theknob to select one of the levels marked in the switch depending upon theloading conditions of the vehicle.

Sr. No. Loading conditions Switch position/Marks assigned

1. Unladen + one person in driver seat 0

2. Driver + co-driver 0

3. Driver + co-driver + all the seats farthest torear occupied 0

4. All the seats occupied 1

5. Laden (all the seats occupied + luggagein boot space to achive permissible load on

the rear axle.) 26. Driver + evently distributed load in the boot

to obtain permissible load on corresponding axle 3

Handling Hazard Warning Switchand Headlamp Leveling Switch

Hazard warning switch

* Since the leveling switch takes care of headlamp focus pattern under differentload conditions, it is advisable to select the correct position before starting a trip(depending on load).


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Roof lamps and courtesy lampA roof lamp is mounted in the middle of thecompartment.

The roof lamp switch has 3 positions:

1. OFF

2. ON

3. Door open

Courtsy lamp

Handling Roof Lamp, Courtsy Lamp and Cigarette lighter & Ash Tray

Cigarette lighter

2

3

1

1. Lamp off

2. Lamp on

3. Door

Roof lamp

Courtsy lampA courtsy lamp is provided above the rearview mirror inside the cab.

The roof lamp switch has 2 positions:

1. OFF

2. ON

Cigarette lighter and Ash Tray :With ignition switch in ACC posit ion, pressthe cigarette lighter fully in when heated tospecified temperature it pops out. Take thelighter out and light your cigarette. After useplace lighter in its position. Do not insert anyother part or assesory in the cigarettelighter. It may damage cigarette lighter.

Ash tray is provided on the console. To openash tray push it gently.


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Bonnet opening lever

Bonnet opening and closing

To open pull lever as shown in figure. This will release the bonnet lock. To open fully, lift theadditional lock lever located on the bonnet centre with the help of finger. Use the bonnet stayrod to keep the bonnet open.

For closing the bonnet, disengage the stay rod, clamp it properly and press down the bonnettill it is fully shut.

Ensure that the bonnet is fully locked before driving off.

In case of failure of cable attached to lever, bonnet lock can be opened by inserting a screwdriver from the top centre position of grill through a slot provided behind it on the sheetmetal and by pressing the lock plate towards your left. Push upward the additional lock leverat your right and lift the bonnet while the lock plate is kept pressed with the help of screwdriver.

Engine Compartment lamp : (if fitted)

To operate engine compartment lamp light pull switch (2)

Handling Bonnet Opening & Closing and Engine Compartment Lamp

1. Engine compartment light2. Engine compartment light switch

1

2


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Handling Driving Controls

Driving Controls - Spacio Gold+

1. Steering Wheel*

2. Horn

3. Instrument Cluster

4. Combination Switch

5. Headlamp Leveling Switch (if fitted)

6. Steering Lock cum Ignition Switch

7. Bonnet Opening Lever

8. Clutch Pedal

9. Brake Pedal

10. Accelerator Pedal

11. Parking Brake

12. Gear Shifting Lever

13. Glove Box

* Two spoke steering wheel for vehicleswith Mechanical steering (other thanSpacio Gold+)


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Gear Shifting Pattern

Handling Gear shift lever and Parking Brake

Gear shift lever

The different gear positions are marked on the knob. The 5th gear (anoverdrive) has been provided to obtain better fuel economy while driving onhighways.

Parking brake (Floor moutned)

The parking brake is mounted on floor between RH door and drivers seat.

To apply the parking brake, pull lever full up. To release it, pull the lever upslightly, press the release button and push the lever down.

Ensure parking brake is released before driving the vehicle.

Parking Brake


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Spare Wheel

Handling Spare wheel

Spare Wheel

Spare wheel is mounted on tubular structure at tail gate.

Wheel spanner provided with the vehicle can be used to loosen and t ightenthe bolts of the spare wheel mount ing.

The spare wheel mounting pin has a hole to lock the spare wheel with a pad lock.


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AC Control Switch

Assy. cooling unit

Air conditioning (If fitted)

The vehicle has been fitted with anefficient air conditioning system forair cooling.The bolwer can be run at threedifferent speeds i.e. low. medium andhigh.

The clockwise movement of the ACcontrol notch gives graduallyminimum to maximum cooling effect.

Precaution while using the carcooler during long distance driving

When long distance driving is doneat high speeds, the compressor rpmis high and thus the cooling becomeshigh. Additionally if thermostat is setto maximum cool position, icing mayoccur on the evaporator due to

overcooling. This icing reduces airflow and the cooling becomes poor.Thus it is recommeded to have suchdriving at maximum air flow and lowtemerature setting of the themostat.

Handling Air conditioning & Ventilation (if fitted)

}

Air conditioning system comprises

the following equipment andaccessories

Compressor

Condenser with fan

Receiver dryer

Pressure safety switch

Expansion valve

Evaporator

Bolwer

Engine fast idling control device

Assembly thermo control

(Thermister, thermo amplifierPotentiometer)

AC Control Switch location


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Handling Air conditioning & Ventilation (if fitted)

Cleaning the condenser

Condenser and radiator must be kept free of dust and foreign matters.They must be cleaned. Direct the tap water on the condenser installedat the front of the radiator to wash off any dirt or mud stuck to thecondenser. If there is excessive dirt, use a soft haired brush whileapplying water.A hard haired brush may damage or bend the fins.Straighten any crushed fins carefully.

Check for any abnormal noise from compressor

In case of noise tighten compressor mounting bracket bolts. If noiseis not rectifiable then contact authorised service outlet.

Check and rectify belt tension as per procedure for fan belt.

NOTEThis vehicle is provided with an over temperature cut-off systemto switch-off AC in the event of engine temperature crossing 1130C.The AC will start operating again as soon as the engine temperaturedrops by 20C to 40C.

Air vents

Four air vents having provision to adjust air flow in the desireddirection, are provided on the dashboard.

CAUTION

Exercise caution that refrigerant does not enter the eyes orcome into contact with skin. It is harmful to the eyes and skin.


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Handling Taking care of the environment

CATALYTIC CONVERTER :

Tata Spacio is fitted with Oxidation Catalytic Converter to reduceexhaust pollution. The two way Catalytic Converter has coating ofprecious metals which enables conversion of pollutants.

Care of the Catalytic Converter :

The Catalytic Converter does not require any special maintenance

however, following precaution should be taken for the effectivefunctioning of the converter and to avoid damage to the Converter.

It is mandatory to use Diesel fuel with sulphur content less than0.035%. Use of any other diesel fuel can increase the pollutants.

Parking Warning :

Avoid parking the vehicle over inflammable materials, such as dryleaves, grass etc., as the exhaust system is hot enough to initiateFIRE.

H dli P i th hi l f th d i


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Check the following regularly, particularly before starting on along journey.

1. Fuel level in tank

Top up if required with correct diesel fuel, secure cap and lockthe flap.

2. Engine oil level

Check engine oil level before start ing the engine or at least 20minutes after stopping the engine. Top up if oil level is less thanmidway between upper and lower marks on the dipstick.

The oil level should not exceed the MAX mark.

USE ONLY THE GENUINE CO-BRANDED OILS.

Handling Preparing the vehicle for the drive

Fuel Filling Cap

3. Coolant level

With the engine cool, check the coolant in the auxiliary tank.The level should be between the FULL and MIN mark, top upwith the recommended coolant. Bring the level upto the FULLmark. The level must not exceed the FULL mark. If the coolantlevel drops within a short time after replenishing, there may bea leak in the system. Rectify the leakage and

top up radiator also.USE GENUINE CO-BRANDED COOLANT

If no leak can be found inspection should be carried out at anauthorised service outlet.

1. Engine Oil Filler Cap 2. Dip Stick Engine Coolant Container



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Brake Fluid Container Clutch Fluid Container


jelly / vaseline on terminals for protection against corrosion.Secure covers provided over terminals.

6. Check all lights, horn, gauges, switches and wiper forproper functioning.

7. Check condition and tensionof fan belt. Adjust tension ifnecessary.

8. Check leakages of coolant, fuel and oil at all joints of hosesand pipes and rectify, if any.

9. Check level of brake fluid in plastic container. Top up if necessary.

Do not overfill. Use only co-branded brake fluid.

Checking Belt Tension

NOTICE

Always use genuine radiator cap only of 1.0 kg / cm2 (14 psi), ifrequired to be replaced.

4. Check power steering oil level.

Use only the genuine co-branded oils. If required, to up uptoMAX mark level.

5. Ensure battery electrolyte level is 10-12 mm above top ofbattery plates. Top up with distilled water if required (NOT ACID).

Keep battery terminals clean and tight. Apply petroleum



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Windshield washer water reservoir


10. Check level of clutch fluidin plastic container. Top up ifnecessary. Do not overfill as this would result in spillage duringclutch operation.

Use only GENUINE CO-BRANDED clutch fluid.

11. Check level of waterin Windshield washer reservoir. Top up

with clean water if required.Use good quality cleaning solvent available in the market inthe ratio as specified by its manufacturer.

12. Level of gear box oil : Periodic check gear box oil level.

13. Level of rear:Periodically check rear axle oil level.

14. Check condition of wiper blades, replace if rubber profile isdamaged.

15. Check level of oil in steering gear box.

16. Check and correct tyre inflation pressure(with cold tyres).

Gear box oil filler/level plug1. Filler plug / Level plug 2. Drain plug

1

2

Rear axle oil filler / level plug

Driving instruction Driving and Gear Shifting


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Driving instruction

Start the engine and observe that :

l Low oil pressure indicator light goesOFF

l Battery charging indicator light goesOFF

l ENSURE THAT PARKING BRAKE ISRELEASED (INDICATOR LAMP OFF)

l VEHICLE IS NOW READY FOR ADRIVE.

l DO NOT ALLOW VEHICLE TO ROLLBACK ON GRADIENTS.

During running - in period :

i.e. first 2,000 km of operation :Do not exceed the following vehiclespeeds:

Speed in km/hr.

Gear Min Max

First - 20Second 15 35

Thrird 25 55

Fourth 35 75

Fifth 45 Max speed

l Avoid rapid acceleration andprolonged high speed running of theengine.

l Avoid sudden braking.

l Retighten wheel nuts to 12-15 mkg.torque after first 100 km of running of

a new vehicle and after every wheelchange.

Driving and Gear Shifting

BEFORE DRIVING

Check

l Fuel level

l Coolant level

l Engine oil level

l Tyre pressure

l Brake and clutch fluid levell Door flaps are firmly closed

Adjust

l Driver seat

l Rear view mirrors

Ensure

l Gear shift lever is in neutral posit ion.

l All switches and lamps are working.

l Brake fail indicator is OFFl Fuel level indicated on fuel gauge

is above reserve mark

Driving instruction Driving instructionsand braking


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Driving instruction Driving instructions and braking

Driving Instructions

DRIVE SAFELY AND JUDICIOUSLY. REMEMBERSAFETY FIRST.

l Depress clutch pedal fully before shifting gears. This will ensurelonger synchro cone life.

l For smooth start ing of vehicle without jerks, synchronise releaseof clutch pedal with pressing of accelerator pedal.

l Start the vehicle in first gear only.

l Change gear at appropriate speed and do not lug the engineby too early shifting to higher gear at low speeds.

Recommended speeds for gear changes :

Gear Speed in km/hr.

1st to 2nd 20

2nd to 3rd 35

3rd to 4th 60

4th to 5th 80

l Engage reverse gear, only when vehicle is stationary.

l Depress clutch pedal fully before engaging the reverse gear.Wait for a few seconds then engage the gear. If gear shiftingdoes not occur, then release the clutch pedal, once again pressthe clutch pedal and engage the reverse gear.

Braking

l While braking on turns apply brakes gently.

l Before driving down a long steep gradient, reduce vehicle speedby changing to lower gear.

l Do not ride the brakes as they may overheat and theirperformance may be impaired.

l Do not use half engaged clutch to hold the vehicle on upgradient as this will result in premature clutch failure.

l After driving through pockets of water, apply the brake a fewtimesat low speed to get rid of moisture inside thebrake drums.

l When it beings to rain, reduce vehicle speed and avoidsudden braking.

Driving instruction Stopping the engine and Fuel Economy


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Driving instruction Stopping the engine and Fuel Economy

Stopping the engine

a. Park the vehicle in safe place. Apply parking brake.

b. Release the accelerator pedal.

c. Stop the engine by turning ignition key to OFF position.

Fuel Economy

a. Drive smoothly, accelerate gradually and anticipate stops.

b. Best fuel consumption is obtained at low engine speeds in the highestpossible gear without labouring the engine.

c. Driving with accelerator pedal fully depressed means using excessivefuel.

d. Do not allow the engine labour by too early high gear changes. Changeto lower gear when engine no longer runs smoothly.

e. Do not ride the clutch. Do not use clutch pedal as foot rest.

f. Depending on traffic conditions, a constant speed should bemaintained.

The vehicle uses more fuel, every t ime you speed up or slow down.

g. Hard braking, abrupt cornering and rapid acceleration use more fuel.Avoid these.

Ignition switch

Ignition switch key positions

LOCK

Towing the vehicleDriving instruction


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Towing the Vehicle

For towing the vehicle, the best way is to use a recovery van. Alternatively use a rigid tow bar. Avoid using flexible cable or rope as your vehicle may crash into

towing vehicle when it stops suddenly.

Switch ON Hazard warning switch to warn the other road users.

Keep the engine in idling so that power steering assistance isavailable. This will also built the vacuum for the brakes. In case of brake failure, use parking brake to control the vehicle.

Towing the vehicleDriving instruction

Driving instruction Driving Safety


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Mobile phones

Avoid using mobile phones whiledriving. This could divert yourattention from the road and result inan accident.

Fatigue 'Rest Revive survive'

Do not attempt driving when you feel

tired, sleepy long distance driving cantire you very much and fatigue can dullyour reflexes and judgment. Take a breakand get refreshed at intervals.

SAFETY CHECKS

Windshield wiper/windshield washer

Always keep windshield glass clean toavoid any distraction in visibility. Ensure

proper working of wipers and conditionof wiper blade. Ensure that windshieldwasher reservoir is full. Do not operatewiper alone when the windshield glassis dry this would damage the windshield.

Headlights

Keep headlight lenses clean. Check foroperation of headlamp in both high/low beam condit ion. Check for correctfocusing of headlamps. Use onlyrecommended type of bulbs. Do notuse the high beam unless it is inevitable.

Its dazzle may glare the driver of theoncoming car thus causing an accident.

DRIVING SAFETY

Seat-Belt

Seat-belts are life saving equipment, useof seat-belt reduces the chance of injuryand severity of injury in case of anaccident. It is strongly recommendedthat all the car occupants should alwayswear seat-belt while car is in motion.

Influence of Alcohol

Avoid driving under the influence ofalcohol or drugs. Alcohol and drugs

will severely impair your control ofthe vehicle and increase the risk ofinjury to yourself and others.

g g y

Driving SafetyDriving instruction


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Side indicators / Hazard warning

Ensure that all side indicators/hazardwarning lights are always in workingcondit ion and they are used when required.

Horn

Ensure the horn is working properly. Hornprovides safety to other road users by

alerting your presence.

Brakes

Ensure brakes are in working condition.Check brake fluid level in reservoir. Do notdrive the car when brake warning lamp is'ON'.

Tyres

Check the condition of tyres for anyabnormalities. Maintain correct tyrepressure, it is very important particularlywhen subjected to extreme condit ion, such

as high speed, high load and high outsidetemperature. Do not use worn or bald tyreson the front wheels.

First Aid Kit

First aid kit is provided in your vehicle. Thisis for use in case of minor injuries. It is to beregularly checked for any disintegration andshould be updated regularly.

Advance Warning Triangle

There is an advance warning triangleprovided along with your vehicle. In casethere is a breakdown and the vehicle isparked at the side of road, then the triangleis to be kept as per instructions given

below :Remove advance warning triangle fromcase and assemble.

Place the triangle on the road behind thevehicle when it stranded on the road. Thetriangle must be at least 50 meters behindthe vehicle in the same lane of traffic.

Increase the distance to 150 meters on ahighway or if a bend/hill top obscures theview.

g yg

Vehicle maintenance Engine Compartment


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ENGINE COMPARTMENT

Brake fluid container Clutch fluid containerWindshield washer fluid container

Engine oil filling cap

Battery

Radiator Cap

Dip stick

Power steering fluidcontainer (if fitted)

Auxilliary reservoir(Coolant Tank)

Air filter

Service indicator

Vehicle maintenance Changing engine oil & oil filter


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Changing engine oil

The engine oil should be drained while it is still hot.a. Unscrew sump drain plug and allow the oil to drain out for 20 minutes.

b. Unscrew centre bolt and remove oil filter bowl.Discard oil filter cartidge.The filter cartidge should be cleaned or reused.

c. Check O ring and seals for any damage. replace if found damaged.

d. Clean the bowl thoroughly and insert a new genuine full flow fi lter

cartidge into the bowl.

e. During reassembly fill the filter bowl first with one litre of engine oil.Reassemble the filter to the top cover. This is done so that when the engineis started, the oil can immediately flow to the bearings and the timerequired by the toil to attain the correct pressure is minimised. If thisinstruction is ignored the bearings may get damaged. The oil filter must

be kept clean as far as possible to protect the engine components fromrapid and excessive wear and tear due to abrasion. Tighten the centrebolt to 4 mkg. torque.

f. Clean the drain plug of the engine oil sumps and refit with a new sealingwasher, if necessary. Tighten to 4 to 6 mkg. torque.

g. Fill in recommended quantity of engine oil into the sump.

h. Start engine and allow it to runfor a few minutes and stop the engine.i. After 20 minutes check oil level indicated on the dipstick. It should be at

the upper mark, if not, top up.

Caution :

Make sure that only genuine oil filter cartidge is used. Inspection of non-genuine cart idge available in the market at low prices have revealed. Oil filter cartridge

1. Engine Oil Sump 2. Drain plug3. Engine Oil Filter

2

3

1

Vehicle maintenance Air Filter & Fuel Tank


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1. Air Filter 2. Service Indicator

i. Use of inferior filtering material which cannot properly filter the engine

oil.ii. Improper dimensions which cannot prevent unfiltered oil gett ing mixed

with filtered oil. Since it is extremely difficult to distinguish betweengenuine and non-genuine filter elements.

Obtain these only from an Authorised Service Outlet.

Engine Air Filter

Periodically clean air filter element and replace it with a new one when aircleaner service indicator shows red band, even after cleaning.

Always use genuine air filter element.

Remove the cover and the filter element. Clean it gently by tapping and rollingon a table. Clean the cover and air ducting.

Check the element for puncture and pin holes by a light source. If found okay

refit the filter element and the cover.

Reset service indicator by pressing rubber cap, red band will disappear fromservice indicator.

On starting the engine, if service indicator continues to show red band, replacethe paper filter element with new one and reset the service indicator.

Replace the air filter element when service indicator shows red band evenafter cleaning the filter element or, at 40,000 kms. in clean conditions, or at25,000kms. in dusty conditions.

Air filter service indicator

Vehicle maintenance Fuel filter and Fuel system


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Fuel System Bleeding

If the performance of the engine is affected due to presenceof air in fuel system(commonly known as air lock) the defect can be removed by bleeding thefuel system as follows :

a. Loosen bleeding screw on primary fuel filter.

b. Unscrew lift pump plunger knob and prime till diesel oil coming out ofthe bleeding screw of the primary fuel filter is free from any air bubble.Tighten the bleeding screw.

c. Repeat the same bleeding process on secondary fuel filter and thereafteron F.I.P. gallery.

d. If the air bubbles continue coming out of the bleeding screw, either thereis less diesel in the tank or there is an air leak in the suction pipe.Check and rectify.

e. Tighten the plunger knob.

Fan belt tension adjustment

The fan belt tension should regularly be checked and if necessary adjusted.The belt tension is correct, if it can be depressed by 20 mm with the thumbpressure applied in the middle of its length. If belt is loose, i.e. it getsdepressed by more than 20 mm, adjust the belt tension.

Belt tension adjusting procedure :

a. Loosen bottom mounting bolt of the alternator.

b. Loosen bolt holding upper mounting of alternator to the clampingpiece.

c. Loosen the lock nut.

1. Bleeding screw 2. Primary fuel filter3. Secondary fuel filter4. Drain plug

1

2

4

3

1. Lock nut 2. Adjusting nut 3. Clamping bolt 4. Clamping piece

3

1

2

4

Vehicle maintenance Bleeding clutch system


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Bleeding clutch slave cylinder

Clutch Fluid Container

d. Adjust the adjusting nut i.e. by turning the alternator away from theengine.

e. Tighten lock nut and the bolt holding the clamping piece to alternator.

f. Tighten bottom mounting bolt.

g. Recheck belt tension.

Clutch system bleeding

A dry friction, single disc, diaphragm type clutch has been fitted which isactuated hydraulically.

The procedure for bleeding the system is as follows :

a. Ensure that fluid level in clutch fluid container is upto maximum level.

b. Remove dust cap from slave cylinder bleed screw and clean the screwthoroughly. Attach bleeding tube to bleed screw and place other end of

tube in a clean glass jar containing sufficient clutch fluid to submergetube end.

c. Pump clutch pedal twice or thrice slowly throughout its stroke and byholding clutch pedal in depressed condit ion, loosen bleed screw on slavecylinder, Watch for air bubbles in glass jar.

d. Retighten bleed screw on slave cylinder and repeat the process until airbubbles cease to appear at the end of tube in glass jar, allowing onlyfluid to flow.

e. After completing bleeding operation, ensure that bleed screw on slavecylinder is fully t ightened. Replace dust cap on the bleed screw.

During bleeding process keep a watch on fluid level in container andtop-up.

Vehicle maintenance Cooling system


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Cooling system :

If engine overheating occurs, there could be a fault in the cooling systemwhich may be on account of :1. Less coolant in the system or dirt/ scale having accumulated inside

coolant passages, especially in the radiator core.

2. Chocking of radiator passages due to foreign material or damages.

3. Defective/stuck thermostat.

4. Loose fan drive belt.

5. Coolant leakage from system.

Always use genuine radiator cap of 1.0 kg/cm2 (14 psi), if required to bereplaced. A proper radiator cap firmly fit ted maintains pressure in the coolingsystem.

Prevention of rust formation :

Use genuine co-branded premixed coolant in the cooling system to preventrust formation and freezing of coolant inside the crankcase passages.

The total capacity of the cooling system is approx. 12 lit res.Fill the radiatorauxiliary tank upto FULL mark.

Changing of coolant in the cooling system :

(At every 80000 km or 2 years whichever is earlier)

a. Drain the cooling system and flush it with clean water.b. Pour the genuine co-branded coolant into the radiator until it is full.

c. Start the engine. Top up the radiator with coolant.

d. Fill the auxiliary tank upto FULL mark.

e. Ensure no leakage in the system.

Engine Coolant Container

Vehicle maintenance Brakes


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Brake system

The dual circuit service brake system operated through the tandem mastercylinder is designed such that one circuit will continue to provide brakingaction if the other circuit fails. This vehicle is fitted with disc brakes at frontand drum brakes at rear.

Stopping the vehicle after loss of the brake fluid in one circuit will requiremore pedal pressure and pedal travel than normal. Also stopping distancewill be longer.

Service brakes are vacuum assisted. In case of failure of vacuum, the vehiclecan still be stooped, however with a higher effort.

Brake system bleeding

If the brake pedal becomes spongy, this may be due to air in the hydraulicbrake system.

Whenever any repair / overhaul or disconnecting of any brake pipe is done,or level of brake fluid has fallen so low that air has been drawn into mastercylinder, it is necessary to bleed the system to remove the trapped air.

Proceed as follows for bleeding the brake system :

a. Clean all dirt from around the fluid container. Remove cap and top-upfluid upto the maximum level.

b. Remove dust cap at each bleed screw and clean the area around it.c. Attach the bleed tube to the front left calliper bleed screw and placethe other end in a clean jar containing sufficient fluid to submerge theend of the tube.

d. Pump the brake pedal 3-4 times slowly throughout its stroke and byholding the pedal depressed, loosen the bleed screw and watch for airbubbles in the glass jar.

Bleeding front wheel cylinder



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e. Re-tighten the bleed screw and release the brake pedal. Repeat theprocess until air bubbles cease to appear at the end of bleed tube,allowing only fluid to flow.

f. Replace the dust cap on bleed screw.

Repeat the same procedure ( steps a to f ) on the front right calliper, rear leftwheel cylinder followed by rear right wheel cylinder. After completion ofbleeding, apply the brake several times and check for any leakages at jointsand bleed screws.

During the bleeding process keep the following points in mind :1. Ensure that the fluid level in the fluid container does not fall low enough

to cause air to be drawn into the hydraulic system.

2. Maintain absolute cleanliness. The brake system must be kept entirelyfree from petrol, kerosene or any form of mineral oil, as mineralcontamination spreads rapidly in the hydraulic system, causingdangerous deterioration of the rubber seals.

3. Never, under any circumstances, use the fluid which has been bled outfrom the system to top-up the container. It may be aerated, have toomuch moisture content and/or is contaminated.

4. Always use recommended brand of brake fluid.

5. As brake fluid absorbs moisture from the atmosphere, we recommendchanging of brake fluid in the system annually.

6. Take care to see that the brake fluid is not spilled on the paint work.

Bleeding rear wheel cylinder

Brake Fluid Container



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Brake adjustment

The front wheels are fitted with disc brakes. These are self adjusting, thereforeneed no adjustment. The rear wheel brakes can, however be adjusted. Due towear on the brake shoe linings the clearance between rear brake shoe liningsand the brake drum increases. This must be adjusted after every 5,000 km ifrequired :

After installing new rear brake shoes or linings, check and adjust brakesafter 500 km run.

For adjusting rear wheel brake shoes proceed as follows :

1. Put chocks on front wheels.

2. Jack up rear axle. Release parking brake. Ensure that parking brake cableis slack. Place the gear shift lever in neutral position.

3. Loosen the adjusting screws of both brake shoes so that the wheel isabsolutely free to rotate.

4. Now turn the adjusting screw of one of the brake shoes till brake beginsto bind - i.e. the brake shoe touches the brake drum. Now turn theadjusting screw in the opposite direction just upto the point when wheelcan be rotated freely. Adjust the other brake shoe of the same wheel inthe manner described above.

5. Adjust both brake shoes of the other wheel as described above.

6. Operate brake pedal twice/thrice, simultaneously rotating both rearwheel, for checking proper application and release of brakes.

7. Check and readjust parking brake, if necessary.

8. Remove front wheel chocks.

9. Test drive vehicle for proper brake function.

Adjusting the rear brakes

1. Adjustment Screw

2 & 3. To increase or reduce theclearance between brake shoeand drum.

Vehicle maintenance Parking brake


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Adjustment of parking brake :

Ensure that all four rear brake shoes have been properly adjusted.1. Put chocks on front wheels.

2. Jack up the rear axle.

3. Loosen check nut (2). Pull parking brake lever upto secondnotch.

4. Tighten the parking brake adjustment nut (1) till rear wheels

start jamming and cannot be rotated.5. Release the parking brake and ensure that wheels are rotating

freely., then tighten check nut (2). Operate parking brake a fewtimes to ensure proper operation.

ENSURE THAT ON RELEASING THE PARKING BRAKEBOTH REAR WHEELS ARE FREE .

6. Lower down the rear axle.

7. Remove chocks from front wheels.

1. Parking Brake Adjustment Nut

2. Check Nut

2

1



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POWER STEERING(When provided)

Power steering is fitted for lighter steering effort and easymanoeuvrability. The system consists of steering gear box,hydraulic pump and hydraulic reservoir suitably mounted andconnected by piping. Pump drive is through belt from engine.Power assistance is available during normal functioning of thepower steering system.

In case of any failure in hydraulic system, the steering

can be operated mechanically with increased steering

effort for bringing the vehicle to a repair station.

Procedure for oil filling and bleeding the power steeringsystem. (Ensure that the reservoir is totally cleaned before

starting the work.)1. Fill the reservoir nearly full. Crank the engine for 10 seconds

without, if possible, allowing it to start. If the engine doesstart, shut off immediately. Check and refill the reservoir.Repeat atleast three times, each time checking and refillingthe reservoir.

2. Check for any leakage in the system and if noticed takecorrective action.

3. Start the engine and steer the vehicle from full left to fullright turn 3-4 times. Add fluid if necessary to maintain the

level up to the filter top.

4. With the engine at steady speed check for bubble/foamingin the fluid. If present it ndicatesthat air is gett ing suckedinto the system.

Check the sustion line / fittings and correct if necessary.

5. Once the system is bled properly and free from foaming,there should not be appreciable change in fluid level in thereservoir, when the engine is started / stop repeatedly. Topup or remove excess fluid so that the final level is at Hmark ondipstick.

6. Now the system is ready for driving.

CAUTION

Do not allow the fluid level to drop significantly or run out ofthe reservoir during the above operation. This may induce airinto the system.

Do not start the engine without fluid in the power steeringsystem. This will result in serious damage to the pump.

NOTICE

Always use recommended brand of fluid from closed containers.Any dirty fluid poured in the system will result in damage topump/gear.



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Power steering pump belt tension check

Check the condit ions of belts on the engine. Examine the edgeof the belt for cracks or fraying.

Check the tension of the belt by pushing on it with your thumbAlternator / Power Steering belt as shown in schematic diagram.

The belts should have deflection of 8 to 10 mm.

If the belt tension is not proper, get if attended at the nearestAuthorised service outlet.

Vehicle maintenance Wheels and tyres


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Wheels and tyres

Always use only recommended size wheel rims and tyres. Use ofrims and tyres not recommended by us may have adverse effect onvehicle safety and further more could infringe on motor vehicleregulations.

Wheel change

When changing wheels use the jack provided with the vehicle.

Jack should be placed below chassis long member behind frontwheel for changing front tyres and before rear wheel as shown.

Wheel alignment

If uneven tyre wear is noticed, get the vehicle examined and attendedby Tata Motors authorised workshop. Periodically check and maintain

correct tyre pressure to obtain longer tyre life.

Recommended tyre pressures :

( with cold tyres )

At Unladen Laden

(Rated GVW)

Front 38 psi 38 psi

(2.6 bar) (2.6 bar)Rear 38 psi 47 psi

(2.6 bar) (3.3 bar)

Jack location at front Jack location at rear Tightening wheel nuts

Vehicle maintenance Wheels and tyres


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Check tyres for damage from time to time and remove any foreignbodies (nails/stones, metal chips etc.) embedded in treads.

While fitting wheels on the vehicle make sure that wheel bolts arefree from dust, scratches, dirt , dents, etc.

Do not oil wheel bolts and nuts. Wipe off any adhering oilon bolts/nuts

Tightening torque of wheel nuts :12-15 mkg. Retighten wheelnuts after 100 km of every wheel change.

New tyres do not give maximum grip straightway and shouldtherefore be run-in at moderate speed for the first 100 km. Thiswill help to make the tyres last long.

To avoid damage to tyres and wheels, drive slowly over speedbreakers / bumps / rough roads.

Wheel balancing

Wheels of your vehicle are balanced. The same should be maintainedwhen repairing a tyre or tube and replacing the tyre or rim.

Repairing a tyre / tube

Mark suitably the tyre position (If original colour dot mark is not

visible) with respect to valve stem hole to ensure that tyre is refittedin original location. Ensure that the balancing weights are notdisturbed during removal of tyres. Check the balance weight priorto removal of tyre, if found loose, mark its location on the rim andrefit properly.

Replacing a tyre / rim.

When the tyre or rim is changed the wheel should be properlybalanced on a machine after inflating to the specified value as perthe following norms.

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

2. Permissible balance weight for tyre with rim = 140 gm max.

3. Relocate the tyre if the weight required to balance is more than140 gm.

4. Do not use more than one balance weight on side.

Vehicle maintenance Wheels and tyres, Electrical system


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Tyre rotation

Tyre rotation is recommended for achieving identical wear on eachtyre. It is also advisable to change rotating direction to relieve tyresof continual one way rotation. Regular rotation of tyres also willprevent abnormal wear. The sketch indicates a suggested sequenceof tyre rotation. Rotate tyres first at specified intervalsor earlier depending on operation.

Headlamps

The head lamp provides two types of light beams; a high beamto give maximum light well ahead of vehicle, and a low beamwhich is shorter and lower so that it will not dazzle the oncomingdrivers and can be use in low visibility area.

The head lamp also incorporates a parking lights.

The head lamps must be properly aligned in order to obtainmaximum road safety, proper road illumination and reduced glareto oncoming traffic.

It is recommended to check alignment of headlamp beamsperiodically and whenever headlamp bulbs are replaced, by meansof a headlamp aligner or with the help of a screen as shown in figureon the following page.

Adjusting head lamps focus with the help of screen

The vehicle should be parked 10 meters away from screen with itscentre in line with central vertical line on screen, and screen at rightangle to longitudinal axis of the vehicle. The vehicle should be inunloaded condition with no sag in suspension springs and all tyresequally inflated.

On the marked up screen as shown in figure, area above horizontal

and inclined lines (shaded) is called Dark zone and the area below itis called The illuminated zone.

Each headlamp is aligned individually by masking the otherheadlamp. Headlamp is first adjusted for proper height of low beamby adjusting knob at its top. Light from low beam should fall belowhorizontal and inclined lines.

SCHEMATIC DIAGRAM - TYRE ROTATION

RADIAL PLY TYRES

DIAGONAL PLY TYRES

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3FRONT

REAR

S

PAREWHEEL

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3

1 2 3FRONT

REAR

SPARE

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No light should fall above these lines i.e. in Dark zone. Thereafterlateral adjustment is done by adjusting knob at bottom of headlampso that contour of low beam coincides with contour formed byhorizontal and inclined lines below Dark zone.

When properly adjusted, most brightly illuminated area will be just

below the intersection point A of these two lines.

The Second head lamp is adjusted in a similar manner withoutdisturbing the position of the vehicle and the screen.

Now switch ON high beam. They will be symmetrical above points.

A and B of intersection of vehicle lines and horizontal lines. It ispossible that high beams may not be exactly symmetrical butfor this reason headlamps should not be realigned.

Preferably, the alignment should be done in the dark.

No masking of headlamps with black paint is required. If done,

this will reduce the intensity of lights.(For adjustment on vehicle fitted with headlamp leveling switch,please refer to page 21)

* Head lamp focusing should be carried out in the level O positionof the switch only (where headlamp leveling switch is provided).

Headlamp alignment on BS - II vehicle

1470 530 530 1470

746

H d l b lb l t



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Head lamp bulb replacement

Raise the bonnet of the vehicle. Remove the rear protective cover.Pull out cable socket from bulb. Remove lock ring holding the bulband remove the bulb.

Install new bulb, properly locating it in the housing. Fit back lockingring, cable socket and protective cover.

Realign headlamp beam after replacing bulb

Do not clean the reflector as it will cause damage to mirror - finishedsurface. Do not replace bulb with dirty or oily hands, since oil willevaporate due to bulb heat and stain the reflector.

Fuse Box

In order to protect the cable harness and other equipments from

damage in case of short circuit and overloads, fuse links are providedin the fuse box.

In case of a fault in the electrical system check the respective fuse.The part iculars of the consumers served by each fuse and amperageare printed on the fuse box cover. The fuse link can be identified foramperage by color codes :

1. Fuse link - Red -10 Amps2. Fuse link - light brown -5 Amps3. Fuse link - Yellow -20 AmpsWhile fit ting fuse box cover ensure that cover knob rests in the slotprovided inside the fuse box.

Spare fuse links are provided inside the fuse box.

Always use fuses of correct rating. Do not use wire in place offuse.

Flasher with short circuit protection

If flasher circuit is short circuited or overloaded (more than 110 W)flasher will shut off. It can be reset by momentarily centering the

indicator arm of combi switch. If flasher is shutting off or fuse isblowing off repeatedly the flasher circuit should be checked for shortcircuit. Check the flasher separately for its functioning.

Fuse Box


B lb ifi ti


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Bulb specifications

Description Location Type Specifications Qty.

Headlights Headlamp Halogen 12V 55 / 60 W 2

Turn indicator light Front D 12 /1 12V 21 W 2

Tail lamp D 12 /1 12V 21 W 2

Side Indicators Side 5 W 5 12V 5W 2

Stop lights Tail lamp D 12 /1 12V 21 W 2Parking lights Head lamp M 12 /4 12 V 4W 2

Tail Lamp M 12 /6 12 V 10W 2

Registration number plate lights Rear number plate light M 12 /6 12 V 10W 2

Reverse indicator lights Tail lamp D 12 /1 12 V 21W 2

Warning and illumination lamps Instrument Cluster

Head light (Main beam) W 12 V 2W 1

Turn indicators W 12 V 2W 2

Battery charging indicator W 12 V 2W 1

Low oil pressure indicator W 12 V 2W 1

Brake fail/Parking brake indicator W 12 V 2W 1

Gauge illumination lights W 12 V 2W 4Roof lamp Cab roof K 12 V 10 W 1

Front roof lamp (if fitted) Near inner rear view mirror K 12 V 10 W 1

Engine compartment lamp (if fitted) Engine compartment BA 155 12 V 21 W 1

Vehicle maintenance Care and cleaning of vehicle

= Carpets (if fitted)Care and cleaning of the vehicle


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= Carpets (if fitted)

Remove dirt as much as possible by using a vacuum cleaner. Rubthe stained area with clean cloth made damp with soap to absorbthe stain and remove the soap. Repeat unt il the stain is removed.

You can use commercially available carpet cleaner. In this case,carefully follow the manufacturers instructions and precautions.

Cleaning exterior of the vehicle

Dirt or any other foreign material on the painted surface may resultin :

= Faded paint.

= Rust on body due to deteriorated paint film.

= Rust due to scratches.

= Body rust due to contact with damp dirt trapped in the body.

Therefore it is important that your vehicle is always kept clean andfree from dirt in order to maintain the paint in a good condition andto protect the entire body against corrosion.

Washing

When washing the vehicle, follow the instructions given below.

= Flush underside of body and wheel housing with pressurisedwater to remove mud and debris. Use plenty of water to loosenand remove dirt.

Care and cleaning of the vehicle

Caution

When cleaning the interior / exterior of the vehicle, NEVER USEvolatile solvents such as thinner, petrol or any other cleaningmaterials such as bleaches or strong household detergents. Thesematerials may be poisonous or flammable and their improper usemay cause personal injury or damage to the vehicle.

Cleaning of vehicle interior

= Floor mat (provided)

Dirt can be removed from the mat with water and mild soap.Use a brush to help loosen dirt. After dirt is loosened, wash themat thoroughly with water and dry it in the shade.

= Seat belt

Clean the seat belts with a mild soap and water only. No bleachor dye should be used as this may weaken the belt fabric. Thebelts should be allowed to dry in the shade.

= Upholstery

Prepare a solut ion of soap or neutral detergent mixed with warmwater. Apply solution with a sponge or soft cloth and let it soakfor a few minutes to loosen dirt. Wipe the surface with a clean,damp cloth to remove dirt and soap solution. If some dirt stillremains on the surface, repeat the procedure.

Vehicle maintenance Care and cleaning of vehicle

Protection against corrosion := Remove dirt and mud from body exterior with running water


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Protection against corrosion :

The following cause corrosion := Moisture trapped in body cavities.

= Dirt and salts collected in hollows on the underside of the vehicle.

= Removal of paint and protective coatings from the exterior andunderside of the vehicle.

Corrosion preventive measures have been incorporated in your

vehicle. You can avoid corrosion of your vehicle by performing somesimple periodic maintenance :

= Repair chips and scratches in the paint as soon as youdiscover them.

= Inspect and clean the drain holes in the bottom of the doorsand body.

= Check the floor coverings for dampness. Carpets and floor matsremain damp for a long time, especially in winter. This caneventually cause the floor panels to corrode.

= Use a high pressure spray to clean the underside of your vehicle.This is especially important in areas near chemical and otherindustries.

=

Have corrosion preventive coatings done on the underside ofyour vehicle using Tata Motors co-branded anti-corrosivetreatment.

= Remove dirt and mud from body exterior with running water.Use a soft sponge, brush with water. Do not use hard material

which can scratch the paint.= Wash the exterior with water, light ly rubbing with sponge or soft

cloth. The sponge or cloth should frequently soaked in water.

Caution

When using commercial wash products precautions specified bythe manufacturer should be observed. Do not use stronghousehold detergents or soaps.

= Once dirt has been completely removed, wash off with runninghose water.

= After rinsing, wipe the body lightly with wet chamois or clothand allow the body to dry it in the shade.

WarningAfter washing, check that the brakes are dry. If brakes are not dry, drythem by gently, repeatedly applying while driving at low speeds.

Waxing the vehicle exterior

After washing the vehicle, waxing and polishing are recommendedto protect and beautify the paint.

= Use only good quality waxes and polishes.

= When using waxes and polishes, the precautions specified by themanufacturers should be observed.

= Chrome plated parts should also be waxed.

Fuel Care should be taken that diesel and supplementary fuel are

Fuel, lubricants, coolants Fuel, lubricants


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Fuel

High speed diesel conforming to IS 1460 or DIN 51601 or equivalentis recommended to be used as fuel.

At very low temperature fluidity of diesel may become insufficientdue to paraffin separation. It is therefore, necessary to mixsupplementary fuel with summer or winter grade diesel. Thesupplementary fuel to be used is kerosene or aviation turbine fuel.

Ratios for mixing of supplementary fuel and diesel are shown in table:

Ambient Percentage

temperature upto Summer Supplementary0C grade diesel fuel

upto 0 100 0

0 to -10 70 30-10 to -15 50 50

Ambient Percentage

temperature upto Winter Supplementary0C grade diesel fuel

upto -15 100 0

-15 to -20 70 30

-20 and below 50 50

Care should be taken that diesel and supplementary fuel are

thoroughly mixed before filling.

* Use only BS - III fuel on BS - III vehicles.

Lubricants

Recommended lubricants conform to the following specifications:

1. SAE 15W40 to API CF4+ - Engine oil

2. ATF Type A - Gearbox oils

3. APIGL 5 - Rear axle and

mechanical steeringgear box oils

Please use only recommended brands for good performance.

The oil change periods recommended in maintenance scheduleshould be adhered to.

Use of reclaimed oil is not recommended.

Engine oil

Recommended grades of engine oil conforming to SAE API CF4+specifications and range of ambient temperature at which these

can be used are given below :

Ambient temperature 0C Engine oil grade

-10 and above SAE 15W/40

-20 TO 0 SAE 10W/30

-10 and below SAE 5W/20

Fuel, lubricants, coolants Lubricants

Running In oil Lubrication of steering spindle and sleeve


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Running In oil

In first 2000 km of operation of a new or recommended engine, anyone of the running in oils listed below should be used :

Autolub 30 : HP

Gear box oil

Use recommended gear oil conforming to ATF Type A specifications.

Rear axle and mechanical steering gear box oil (Not applicablefor power steering)

Use oils conforming to APIGL 5 specification. SAE 90 oil shouldbe used upto -90C and SAE 75 between - 90C and -400C.

Hub bearing grease (Spicer axles)

Use Lithium base multipurpose grease.

Quantity 92 gms per hub (Front)25 gms per hub. (Rear)

Brake and clutch fluid

Brake fluid conforming to IS : 8654/DOT 3 is recommended.

Spicer propeller shaft ( where applicable )Lubricate slip joint with multipurpose grease - 2.

Lubrication of steering spindle and sleeve

Lubricate steering spindle and sleeve with Molykote - BR2 grease orMobiltac NC grease, at specified intervals.

Coolants

Presence of dirt in coolant chokes up passages in radiator, cylinderhead and crankcase, thereby causing overheating of engine.

To prevent rust formation and freezing of coolant inside the passagesof radiator, crankcase and cylinder head use only branded premixedcoolant.

Coolant should be drained and fresh premixed coolant filled atspecified intervals.

IMPORTANT INFORMATION Co-branded Fuel, Coolants & Lubricants

PLEASEUSEONLY GENUINE OILS COOLANTS LUBRICANTS ANTI- RUST & SOUND DEADENING


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PLEASE USE ONLY GENUINE OILS, COOLANTS , LUBRICANTS , ANTI RUST & SOUND DEADENING

COATS, WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORSFOR OPTIMUM PERFORMANCE OF YOURTATA SPACIO

ITEM COMPANY BRAND QTY

ENGINE OIL CASTROL Castrol GTD 15W/40 5.5 LitresHPCL HP Milcy 15W/40

COOLANT SUNSTAR Golden Cruiser 1400 M

ANCHEMCO Frostox SFD 12 12 Litres Approx.HPCL HP Thanda Raja P

GEAR BOX (G-76) HPCL HP ATF 1.5 LitresCASTROL Castrol Transpower TQ

REAR AXLE HPCL HP Gear oil XP 85W140 GLS 1.9 Litres for RearCASTROL Castrol Extreme Pressure 85 W 140

STEERING OIL (Power Steering) HPCL HP ATF 0.5 Litres (Mechanical)CASTROL Castrol Transpower TQ

BRAKE / CLUTCH FLUID HPCL HP Super Duty Brake Fluid DOT - 3 As requiredCASTROL Castrol Universal Brake

tata spacio withgold+ manual

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