tata xenon manual

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TA TA TA TA TATA XENON XENON XENON XENON XENON Owner's Manual & Service Book Q Mumbai Q Pune Q This owner’s manual should be considered as a permanent part of the vehicle and must remain with the vehicle. Edition :

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TATA XENON

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Page 1: Tata Xenon Manual

TATATATATATTTTTAAAAA XENONXENONXENONXENONXENONOwner's Manual & Service Book

Mumbai Pune

This owner’s manual should be considered as a permanent part of the vehicle and must remain with the vehicle.

Edition :

Page 2: Tata Xenon Manual

2

This Owner’s Manual should be kept in the vehicle at all times.

This book will help you to understand the vehicle better, maximise uptime of the vehicle & obtainbetter performance at optimum cost.

The recommended routine maintenance servicing along with any running repairs that may be required,should be entrusted to a TATA MOTORS Authorised Workshop to ensure that only latest methods andgenuine TATA MOTORS replacement parts are used for the continued reliability, safety and performance ofthe vehicle.

Some of the items / accessories / features shown / given in this book may not be fitted on your vehicle, butthey are applicable for other versions of XENON.

(C) Copyright 2004 TATA MOTORS

All rights reserved. The material in this manual may not be reproduced or copied, in whole or in part, in anyform without written permission from TATA MOTORS.

The information and specifications given in this book are valid as on the date of printing. TATA MOTORSLimited reserves the right to make changes in design and specifications and/or to make additions to orimprovements in this product without obligation to install them on products previously sold.

In the event of the Vehicle being sold, please ensure that this manual is left in the vehicle for the reference ofthe new owner.

A Note

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DEAR CUSTOMER,

We are pleased to hand over to you a TATA XENON vehicle manufactured by TATA MOTORSwhere quality is the watchword and major attention is paid even to minor details at all stagesof manufacture.

Please carefully read this book, it helps you to know your vehicle better, to ensure your vehicleis ready for operation at all times and to obtain better performance at optimum operating costs.

All service and maintenance tasks should be carried out at the specified service intervals.

Some of the items / accessories / features shown / given in this book may not be applicablefor your vehicle, but may apply to other versions of this model.

For any further assistance, kindly contact the nearest TATA MOTORS authorised workshopdealership or our offices.

We wish you good luck and prosperity.

Foreword

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Contents

Getting StartedKey & Door Lock 50

Child Lock 51

Seats, Seat Adjustments & Seat Belts 52

Steering Wheel Adjustment 56

DrivingChecks Before Driving 57

Safety Checks 58

Fuel Saving Tips 59

Starting & Stopping The Engine 61

Gear Shifting 62

Braking 66

Driving In Adverse Conditions 67

Incase Of EmergencyJack Location / Warning Triangle 69

Flat Tyres Replacement 69

Spare Wheel 71

Limp Home Mode 72

Starting The Engine With Jump Leads 73

Know your Xenon 6

Warranty - Terms & Condition 8Environmental Care 10

Xenon At A GlanceDriving Controls 12Instrument Cluster 13Steering Lock and Ignition Switch 20Combi Switch 21Head Lamp Levelling 24Transfer Case Switch 25Music System, Analog Clock & Antenna 26Heating, Ventilation & Air Conditioning 27Grab Handle & Cigarette Lighter 32Lamps 33Sun Visor & Mirrors 36Rear View Mirror 37Glove Box, Cup Holder & Utility Pockets 38Window Glass Operations 39Fuel Flap Opening 40Gear Shift Lever & Parking Brake 41Anti Theft / Immobiliser System 42

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Contents

Windshield Washer & Tyre 98

Repair of Tyre / Tube 99

Tyre Rotation 100

Wheel Alignment, Balancing & CatalyticConverter Maintenance 101

Battery 102

Important Technical InformationFuel, Lubricants & Coolants 103

Oil Filling & Drain Points 106

Technical Specification 107

Information At a Glance (Dimensions) 110

Vehicle Identification

Location of Aggregate Number 111

PDI Service 113

Service Schedule 117

Service Maintenance Schedule 119

Record of Services Performed 124

Record of Repairs Carried Out 126

Towing The Vehicle 72

Routine Service 73

Preliminary Trouble Shooting 74

Electrical MaintenanceFuses & Relays 82

Bulb Specification 84

Bulb Replacement 85

Vehicle CareWashing & Cleaning 87

General Precautions 89

MaintenanceOpening & Closing The Bonnet 90

Engine Compartment 91

Air Filter, Engine, & Engine Oil Level 92

Engine Coolant & Brake Fluid Level 93

Power Steering Fluid Level 94

Load Conscious Pressure Reducing Valve 95

Clutch Fluid & Sedimenter 96

Fuel Filter & Priming Pump 97

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TATA XENON is a versatile vehicle. It incorporateswell known and proven features of Tata Motors precisionand advanced technology. Easy maneuverability andeconomic life cycle cost make this vehicle ideal forurban and rural areas for operation as pick-up truck,delivery van, service van, etc.

TATA XENON comes equipped with a TATA DICORengine with BS-III compliant norms and having a 5speed full synchromesh gearbox with overdrive 5th forexcellent fuel efficiency and tough road gripping tyresfor added traction.

Know Your Xenon

The DICOR Engine has a sophisticated common railfuel system. It consists of ECU, sensors and actuators.The electronic control unit (ECU) is a 32 bitmicroprocessor which controls engine fuel injectionparameters and other vehicle related parameters. TheECU receives input from various sensors fitted to theengine and on the vehicle to decide fuel injectionquantity, fuel timing and number of injections bestsuited for the engine to work with maximum fuelefficiency and safety.

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Know Your Xenon

Other features like vacuum assisted independenthydraulic brakes on front and rear wheels throughtandem master cylinder and tandem booster. Alsoventilated front brake discs with twin port calipersprovides better braking efficiency and greater safety.Telescopic shock absorbers and an antiroll bar makeup the front independent suspension set-up. Parabolicsprings coupled at the rear ensure good road holdingand stability.

An ergonomically designed cabin with added featuressuch as adjustable steering column, central locking,headlamp leveling, power windows, rotary HVACcontrols, electronic cluster, internally adjusted ORVMfor good all-round visibility. Easy access to areas ofdaily maintenance are some of the other user-friendlyfeatures.

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Know Your XenonWARRANTY - TERMS & CONDITIONSWE WARRANT each TATA XENONvehicles & parts thereof manufacturedby us to be free from defect in materialand workmanship, subject to thefollowing terms & conditions :

1. This warranty shall be for 24months OR 75000 kms, whicheveris earlier from the date of sale ofthe vehicle, However, for thevehicles used for commercialapplications (including those usedfor hire or reward viz those operatingwith a yellow number plate), thewarranty shall be limited to 24months or 50,000 kms, whicheveroccurs earlier.

2. Our obligation under this warrantyshall be limited to repairing orreplacing, free of charge, such partsof the vehicle which, in our opinion,are defective, on the vehicle beingbrought to us or to our dealers withinthe warranty period. The parts sorepaired or replaced shall also bewarranted for quality andworkmanship but such warranty

shall be co-terminus with thisoriginal warranty.

3. Any part which is found to bedefective and is replaced by usunder the warranty shall be ourproperty.

4. As for such parts as tyres,batteries, transfer case, rubberparts, electrical equipment and fuelinjection equipment, power steeringequipment, A.C. equipment notmanufactured by us but supplied byother parties, this warranty shall notapply, but buyers of the vehicle shallbe entitled to, so far as permissible

by law, all such rights as we mayhave against such parties undertheir warranties in respect of suchparts. Our Dealers/TASC’s willassist the purchaser in taking upthe complaint with the respectivemanufacturers and their decision onthe warranty will be final.

5. This warranty shall not apply if thevehicle or any part thereof isrepaired or altered otherwise than

in accordance with our standardrepair procedure, or by any personother than our sales or serviceestablishments, our authoriseddealers or service centres orservice points in any way so as, inour judgement which shall be finaland binding, to effect its reliability,nor shall it apply if, in our opinionwhich shall be final and binding thevehicle is subjected to misuse,negligence, improper or inadequatemaintenance or accident or loadingin excess of such carrying capacityas certified by us, or such servicesas prescribed in our Owner’sManual and Service Book are notcarried out by the buyer through oursales or service establishments,our authorised dealers or servicecentres or service points.

6. This warranty shall not cover normalwear and tear or any inherent normaldeterioration of the vehicle or any ofits parts arising from the actual useof the vehicle or any damage due tonegligent or improper operation or

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Know Your XenonWARRANTY - TERMS & CONDITIONS

storage of the vehicle. This warrantyshall not apply to normalmaintenance services viz. oils &fluid changes, head lampsfocussing, fastener retightening,wheel balancing, tyre rotation,adjustment of valve clearance, fueltiming, ignition timing andconsumables like bulbs, fuel filtersand oil filters etc. This warranty shallnot apply to any damage ordeterioration caused byenvironmental pollution or birddroppings. This warranty shall notapply to V-belts, hoses and gasleaks in case of air conditionedvehicle. Slight irregularities notrecognised as affecting the functionor quality of the vehicle or parts suchas slight noise or vibration anddefects appearing only underparticular or irregular operations oritems considered characteristic ofthe vehicle.

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

racing or participation in any othercompetitive 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 orotherwise, expressed or implied,and all other obligations or liabilitieson our part and we neither assumenor authorise any person to assumeon our behalf, any other liabilityarising from the sale of the vehicleor any agreement in relation thereto.

9. The buyer shall have no other rightsexcept those set out above andhave, particular, no right to repudiatethe sale, or any agreement or toclaim any reduction in the purchaseprice of the vehicle, or to demandany damages or compensation forlosses, incidental or indirect, orinconvenience or consequentialdamages, loss of vehicle, or loss oftime, otherwise, incurred oraccrued.

10. Any claim arising from this warrantyshall be recognised only if it isnotified in writing to us or to ourconcerned dealer without any delaysoon after such defect as coveredand ascertained under this warranty.

11. This warranty shall stand terminatedif the vehicle is transferred orotherwise alienated by the buyerwithout our prior written consent.

12. We reserve our rights to make anychange or modification in the designof the vehicle or its parts or tointroduce any improvement thereinor to incorporate in the vehicle anyadditional part or accessory at anytime without incurring any obligationto incorporate the same in thevehicles previously sold.

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Know Your XenonENVIRONMENTAL CARETATA MOTORS is committed toproducing vehicles usingenvironmentally sustainabletechnologies. A number offeatures have been incorporatedin TATA Vehicles which have beendesigned to ensure environmentalcompatibility throughout their lifecycle. We would like to inform youthat your vehicle meetsappropriate environmental normsand this is being regularlyvalidated at all stages ofmanufacturing.As a user, you too can protect theenvironment by operating yourvehicle in a proactive manner. Alot depends on you driving styleand the way you maintain yourvehicle. The following points areprovided for your guidance.

Driving• Avoid frequent and rapid

acceleration.• Do not carry any unnecessary

weight on your vehicle as itoverloads the engine.

• Avoid using devices requiringhigh power consumption duringslow traffic condition.

• It is not advisable to warm upthe engine during first start ofthe day by idling, as coldtemperatures within enginecould cause rise in theemissions such as CO & HCparticulate.

• Monitor fuel consumptionregularly and if it shows a risingtrend, get the vehicleimmediately attended by anauthorised Tata dealer.

• Switch off engine during longstops at traffic jams or signals.If situation demands that enginebe kept running, avoid frequent

revving of the engine. Also avoidfrequent stopping andrestarting, if uncalled for.

• It is not necessary to rev theengine before turning it off.

• Shift to higher gears as soonas possible . Use each gear upto 2/3rd of its maximum enginespeed. Recommended gearshift speed are furnished in thismanual.

Maintenance• Ensure that periodical services

are carried out regularly by anauthorised Tata dealer.

• As soon as you see anyleakages of oil, fuel, air orcoolant, get it attended toimmediately.

• Use only recommended brandsand grades of lubricants andclean/uncontaminated fuels.

• Get your vehicle checked foremission periodically by anauthorised Tata dealer.

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Know Your XenonENVIRONMENTAL CARE

• Ensure that fuel filters, oil filteretc. are replaced atrecommended intervals.

• Do not pour used oils orcoolants into sewage drains,garden soil or open streams.Dispose used filters andbatteries in compliance withlocal laws.

• It is not recommended thatunauthorised workshopstamper with the engine settingsor to carry out modifications onthe vehicle.

• Avoid running the vehicle outof fuel, as it can result in enginemisfire.

• Please adhere torecommended fuelspecifications while filling uptop.

While carrying out servicing orrepairs, you should pay keenattention to components givenbelow which affect emission.1. Fuel injection pump,

injectors.2. Air intake and Exhaust

system.3. Cylinder head for valve

leakage.4. All filters such as air, oil and

fuel filters.5. Turbocharger and intercooler

(if fitted.)6. EGR system components &

Electrical connections.7. Glow plug timer.8. Catalytic convertor.

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Xenon At a Glance DRIVING CONTROLS

1. Air Vents2. Instrument Cluster3. Steering Wheel4. Side Air Vents5. Horn Pad6. Accelerator Pedal7. Brake Pedal8. Clutch Pedal9. Music System10. Ash Tray11. Parking Brake12. Power Window Switches13. Cup Holder14. Gear Shift Lever15. Cigarette Lighter16. A.C. Controls17. Analog Clock18. Hazard Warning Switch19. Glove Box

DRIVING CONTROLS

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INSTRUMENT CLUSTERXenon At a Glance

1

2

3

4

5

6

7

8

10

11121115 14 13

16

18

1727 21

9

2524

INSTRUMENT CLUSTER

20 19 22 26

23

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INSTRUMENT CLUSTER1. Front Fog Lamp Indicator (Green)

2. ‘Check Engine’ Indicator (Red)

3. Door Open Indicator (Red)

4. High Water Level Indicator in Sedimenter (Amber)

5. 4WD Low (For 4x4 Vehicles Only) (Green)

6. 4WD High (For 4x4 Vehicles Only) (Green)

7. Rear Fog Lamp Indicator (Amber)

8. MIL Indicator (Amber) If fitted

9. Anti - Theft Indicator (Red)

10. Glow Plug “ON” Indicator (Amber) - If fitted

11. Direction Indicator (Green)

12. Head Lamp Main Beam Indicator (Blue)

13. Engine Low Oil Pressure Indicator (Red)

14. Battery Charging Indicator (Red)

15. Brake Fluid Level Check/Parking Brake Indicator(Red)

16. Seat Belt Indicator (Red)

17. Trip Odometer

18. Cumulative Odometer

19. Mode Selector Knob (Odometer)

20. Set Knob (Odometer)

21. High Temperature Warning

22. Low Fuel warning

23. Over Speed Indicator

24. Speedo Meter

25. RPM Meter

26. Fuel Gauge

27. Temperature Gauge

Xenon At a Glance

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INSTRUMENT CLUSTERFront Fog LampIndicator (Provision):This symbol (Green coloured) lightsup when the front fog lamps areswitched ‘ON’

Check EngineIndicator:

This indicates engine condition,when a malfunctioning occurs in theEngine or EMS (EngineManagement System) . It Remains“OFF” in “IGN” position ORRemains “ON” in running position.

CAUTIONCAUTIONCAUTIONCAUTIONCAUTIONWhen Engine Check Indicatorcomes ON, get the problemattended immediately, at theearliest, at an Authorisedservice outlet.

Xenon At a Glance

switch in 2H mode both 4H and 4Lindicator light on instrument panelshould glow for a few seconds onlyand go ‘OFF’. Continuousillumination indicates an electricalfault. Do not run the vehicle if both4H and 4L indicator are ON. The4H or 4L indicator light will glowonly when the transfer case iseither in 4H or 4L mode.

Rear Fog LampIndicator (Provision):This symbol (Amber coloured)lights up when the rear fog lampsare switched ‘ON’.

Turn Signal:Turn signal lamps can be operatedonly when the ignition supply is‘ON’ and by using the turn indicatorswitch on the combi switch. Thedirection indicator arrow (LHS)and (RHS) on the instrument

Door Open Warning:

Prior to driving ensure that all thedoors are properly closed. If any oneof the doors is partially open, thedoor open indicator will come on.In addition to this, if driver’s sidedoor is not properly closed an audiobeep will sound for a few seconds,when the key is inserted.

Water in fuel sedimenterindicator:This light comes on when there isexcess water in the fuel sedimenter.In this case it is recommended totake your vehicle to nearestservice outlet or drain the waterfrom the sedimenter yourself.Please refer to fuel filter and fuelsystem in maintenance section.

4H, 4L Indicator:(* For 4WD model only)With ignition ‘ON’ and transfer case

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CAUTIONCAUTIONCAUTIONCAUTIONCAUTION

INSTRUMENT CLUSTERXenon At a Glance

cluster flashes along with externalindicator lights as selected.

High Beam Indicator:

Symbol lights up when theheadlamp high beam is ‘ON’.

Low Oil PressureIndicator:When the ignition key is turned tothe ‘IGN’ position, symbol lights upand goes off as soon as the requiredengine oil pressure is reached afterstarting the engine.

If the low oil pressure indicator doesnot glow or remains ‘ON’ with the‘IGN’ on and engine is running, itindicates a fault in the electricalcircuit/lubrication system. Check &get the problem attended to at anAuthorised Service outlet.

Battery Indicator:

Symbol lights up when the ‘IGN’ isturned ‘ON’ and should go ‘OFF’after the engine starts.

If it remains ‘ON’ while theengine is running. It indicatesthat the alternator is notfunctioning. Switch off allunnecessary electricalequipment and get the problemattended to at an AuthorisedService outlet.

It also lights up when brake fluidlevel is low.

When ignition key is turned to“IGN” position, this indicatorlights up and goes off whenengine starts.

Seat Belt Indicator:

This indicator comes ON withignition and goes OFF wheneverthe drivers seat belt is fastened.

Odometer and Trip meter(on LCD):The odometer records the totaldistance the car has been driven.The trip meter can be used tomeasure the distance traveled oneach trip or between fuel fillings.Keep track of the odometer reading& follow the maintenance scheduleregularly for meeting servicerequirements.

Parking Brake Indicatorand Low Brake FluidWarning Light:

This indicator has multiple functionsas follows - It lights up when the parking

brake is applied and goes offwhen parking brake is released.

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INSTRUMENT CLUSTERXenon At a Glance

Odometer, Trip meter andIllumination intensity control oninstrument panel (LCD):The instrument panel has an LCDto display the following :Main Odometer (Non- resettable)- Counts up to 999999 kms Trip meter A (Resettable) -

Counts up to 1999.9 kms Trip meter B (Resettable) -

Counts up to 1999.9 kms Intensity level of instrument

panel illumination – selectionamong preset levels.

LCD has two line display. The firstline displays the Odometer count.The second line displays either ofTrip meter A, Trip meter B,Intensity level of panel illumination.The selection and control offunctions are done through ‘MODE’and ‘SET’ push buttons (knobs)provided on either side of the LCD.

The ‘MODE’ knob is used to selectone of the Trip meter A, Trip meterB OR Intensity level of panelillumination. Switching among theabove three functions can be doneby pressing the knob.

The panel illumination intensityvaries among preset levels asfollows:

= Min

= = = = Max

This display returns to Trip meterA after a few seconds of intensitylevel selection, if left in this mode.

The ‘SET’ knob is used to controlthe chosen function. Pressing theknob for a few seconds resets thechosen trip meter and varies theintensity level of instrument panelillumination.

Intensity Level Indicator

NOTICEMain Odometer and TripMeter - A indication will remainon display even if the ignitionkey is removed.

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INSTRUMENT CLUSTERXenon At a Glance

Hazard Warning:

This can be operated withoutignition ‘ON’. Press the hazardwarning switch (red knob) on thecentre of the dash board, all turnindicator lights will f lashsimultaneously to warn the otherroad users about any hazardouscondition of the car. Press the knobagain to switch ‘OFF’ the hazardfunction.

NOTICEIf lights do not blink or blinkrapidly, it is an indication ofproblem in the blinker electricalsystem or the indicator bulb atfront or rear has fused. Get itrectified immediately.

Lock Indicator WarningLight:If it blinks on the dashboard,vehicle cannot be driven withoutpressing UNLOCK button on theUser remote.

Over Speed Indicator:It will Indicates when the vehiclespeed exceeds 120 km/hrs.

Low Fuel Indicator:(Amber/Orange) :

It comes on when fuel level reaches10 liters (approx) in tank alertingthe user to fill fuel.

Over SpeedIndicator

Low FuelIndicator

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INSTRUMENT CLUSTER

RPM Meter:

The meter indicates engine speed in revolutions perminute (rpm) Change gears at appropriate engine rpmand vehicle speed to get optimum fuel economy. Thepermitted engine rpm upper limit is the start of RedZone on the dial.

Fuel Gauge:

The fuel gauge indicates the approximate fuel level inthe tank. Refill the fuel tank at the earliest, before theneedle touches the red band on the gauge. At thispoint, approx.10 liters of fuel is remaining in tank andit is advised to get fuel filled immediately

Temperature Gauge:The gauge indicates the temperature of the enginecoolant. The red zone at ‘H’ indicates temperaturehigher than the normal. Avoid driving, when the pointeris in the red zone. It indicates engine overheating,which may be due to insufficient coolant in the radiatoror due to any other defect. At this stage take the carto the nearest Tata Authorised Service outlet fornecessary attention.Never remove the cap from the coolant reservoirwhen the engine is hot. Do not restart the engineuntil the problem has been duly attended.The speedometer: The speedometer indicates thecar speed in km/hr.

TemperatureGauge

HighTemperature

Warning

Speedo Meter

Xenon At a Glance

Fuel Gauge

Low FuelIndicator

RPM Meter

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NOTICELOCK:You can insert or remove the keyonly in this position. The steeringcolumn is locked when the key isremoved.

WARNINGDo not remove the key whiledriving. It will lock the steeringand can cause loss of control.Remove the key only when thevehicle is parked.

ACC:By turning key to ACC positionpower supply to accessories isswitched ON.

START:Turn the key further clockwise tothe START position (spring loaded)to start the engine. As soon as theengine starts release the ignitionkey to ON position.

Do not crank the engine morethan 10 secs. continuously.If the engine does not start waitfor 30 secs. before cranking itagain. Release the keyimmediately after starting theengine otherwise starter motor/flywheel ring may getdamaged.

STOP:By turning the ignition key from ONposition to ACC or LOCK position,engine can be stopped.

STEERING LOCK AND IGNITION SWITCHXenon At a Glance

Steering Lock and IgnitionSwitch:Key of ignition switch is commonfor the door lock, steering lock andglove box lock.The ignition switch is on the rightside of the steering column. It hasfour positions. Turn the keyclockwise for further functions.

LOCK - Steering LockedACC - Accessories ‘ON’ON - All electricals ‘ON’START - Engine crank

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COMBI SWITCHXenon At a Glance

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COMBI SWITCHXenon At a Glance

WIPER CONTROL SWITCH LEVER - LEFT

The selector Knob is used for the Operation ofFront & Rear Fog Lamp.

LIGHTS CONTROL SWITCH LEVER - RIGHT

Rotate selector knob to set delay timing forintermittent wipeAfter wash function is activated then there will be threewipes of wiper. There will be one more wipe after5 sec. to clean traces of water on wind screen.

Selector Selector

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FRONT FOG LAMP SELECTORSWITCH:

Rotate the Selector switch clockwise to switch on the front for lamp.Front fog lamps are operative onlywhen the head lights are switchedON. Rotate the Selector switch tosame direction to switch OFF thefront fog lamp.

REAR FOG LAMP SELECTORSWITCH:

Rotate the switch anti-clock wiseto switch on the rear fog lamp. Rearfog lamps are operative only whenthe head lights or front fog lampsare switched ON. Rotate the switchto same direction to switch OFFthe rear fog lamp.

CAUTIONIf the lights do not blink or blinkrapidly, it is an indication of aproblem in the blinker electricalsystem or the indicator bulb atthe front or rear has fused. Getit rectified immediately.

COMBI SWITCHXenon At a Glance

Selector Selector

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Head Lamp Leveling Switch:

A motorized head lamp levelingarrangement with the setting knobat the dash board is provided onthe centre console. As and whenrequired, head lamp leveling.Setting is done by rotating theknob to select one of the 3 levelsmarked on the knob dependingupon the loading of the vehicle.

HEAD LAMP LEVELING SWITCHXenon At a Glance

1. Head Lamp Leveling Switch2. Electrical Demisting Switch

Head Lamp Leveling Switch

1 2

NOTICESince the leveling switch takescare of headlamp focus patternunder different load conditions; itis advisable to select the correctposition before starting a trip(depending on load).

Loading SwitchCondition positionUnladen / Driver /Driver + Co-driver 0Driver + Co-driver+ All seats occupied 1Laden + All seatsoccupied 2Laden + All seatsoccupied + permissible 3luggage load

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TRANSFER CASE SWITCHXenon At a Glance

Transfer Case Electric Shift Switch

Location Transfer Case Electric ShiftSwitch

Electrical DemistingSwitch (If fitted) :

Rear window & Outer Rear viewMirrors are provided with electricaldemisting switch for better vision.

Transfer Case Electric ShiftSwitch (for 4x4 vehicle only) :

It is electrically operated andmounted on dashboard below theinstrument cluster. It is a gearselector switch. It has 3 differentgear positions 2H, 4H and 4L.They indicate- 2H - 4 x 2

4H - 4 x 4 High4L - 4 x 4 Low

Shifting from 2H to 4H or 4H to2H:

Shifting can be done up to speeds65 kmph (40mph).

Shifting from 4H to 4L or 4L to4H :

Shifting to be done only whenvehicle is stationary.

Important:

Do not march the vehicle till 4H/4Lindicator light stops blinking.

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Xenon At a GlanceMUSIC SYSTEM, CLOCK & ANTENNA

Speaker Location on Front Door

Antenna: The antenna is locatedover the roof.

Music System (If fitted) :A provision has been made on allmodels for fitment of a musicsystem on the facia & for theinstallation of speakers is made onall doors.

Analog Clock:The vehicle is fitted with analogclock on the centre console. It hasa knob at the bottom of the dial forresetting the time.

1. Analog Clock2. Provision for Music System

Analog Clock:

Setting Knob

12

Speaker Location on Rear Door

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HEATING, VENTILATION & AIR CONDITIONING (HVAC)Xenon At a Glance

AIR FLOW PATTERN

Central Air vents ( Towards Face)

Towards foot Board

Side Airvents

Towards foot Board

Side Airvents

Demisting vents(Towards Windscreen)

Demisting vents(Towards Windscreen)

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A. Temperature-Control Knob :

The air temperature in the vehiclecan be controlled by operating thetemperature control knob (A) at theleft-hand side of the control panel.The temperature can be increasedby rotating the knob towards thered segment and decreased byrotating it towards the bluesegment.

regulated to any one of thefollowing speeds by operating theblower knob (B) centre of thecontrol panel.

HEATING, VENTILATION & AIR CONDITIONING (HVAC)Xenon At a Glance

C. Air Direction Control Knob :

The air flow can be changed byturning the knob (C) to the desireddirection.

B. Blower Speed RegulationKnob :

The HVAC system has a four speedblower. The blower speeds can be

Off

Low

MediumHigh

VeryHigh

Cool

Hot

D E

A B C

Towards face

Towards face and feet

Towards feet

Towards feet and windshield(Recommended for clearingmist on windshield)

Air demist/defrost windshield(Recommended for clearingheavy fog or snow

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HEATING, VENTILATION & AIR CONDITIONING (HVAC)D. A. C. ON / OFF Switch :The A.C. can be switched ‘ON’ bypressing the switch (D) on the A.C.control panel provided the bloweris ‘ON’ and the engine is running.The indicator lamp will show thatthe A.C. is ‘ON’.

Indicator

E. Recirculation / Fresh AirSwitch :

In HVAC version to put aircirculation mode in recirculation,press switch ‘E’. The indicatorlamp will show air circulation isin recirculation.To put vehicle in Fresh moderelease switch ‘E’. Indicatorlamp will be ‘OFF’.

In A.C. version, air circulationmode can be selected bypressing knob ‘E’.In recirculation mode, air insidethe vehicle is circulated againand again. In Fresh mode, airis taken from atmosphere andcirculated in the vehicle.

Recirculation mode can be usedWhile driving in dusty conditionTo avoid traffic pollutionTo get quick cooling/heating asrequired.

Whenever discomfort is felt switchair circulation mode to fresh.

NOTICEThe A.C. can be switched ‘ON’only if the blower is ‘ON’ andengine is running. When A.C.is switched ‘ON’ engine idlingRPM increases marginally, toadjust to the A.C. compressorload. When desiredtemperature is achieved A.C.trips ‘OFF’ automatically.

The A. C. compressor willswitch ‘OFF’ automaticallywhen engine overheats. TheA. C. is automatically switched‘ON’ when the engine coolsdown.

Xenon At a Glance

Indicator

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Normal Heating :

(For vehicles fitted with HVAC &Heating system only)Knob ‘A’ - Suitable temperaturepositionKnob ‘B’ - Suitable blower speedKnob ‘C’ - Towards face & feetA.C. - OFFAir Circulation Switch - Fresh

Quick Heating :All settings as explained beforeexcept air circulation switch torecirculation.Once vehicle is heated, switch backto fresh mode.

Normal Cooling :

A.C. - ONKnob ‘B’ - desired speed positionKnob ‘C’ - towards faceSwitch ‘E’ - suitably as explained

Quick Cooling :

Switch ‘ON’ the A.C. and keep theblower at maximum speed. Keepair direction in face mode. Allvents should be openedcompletely. Keep the aircirculation switch in therecirculation mode andtemperature control switch in themaximum cooling (Blue) position.At maximum cooling, A.C. trips offautomatically when the desiredtemperature is achieved.

In case you find reduction inair flow or foul smell in thepassenger compartment cleanthe evaporator

Demisting :

In rainy season or in areas of highhumidity, mist formation insidewindshield glass is observed. Toclear mist dehumidified air is

HEATING, VENTILATION & AIR CONDITIONING (HVAC)Xenon At a Glance

passed on the windshield glass.The position of control knobsshould be adjusted as follows :A.C. - ONKnob ‘B’ - Desired speed positionKnob ‘C’ -Towards windshieldKnob ‘A’ (for vehicles fitted withHVAC) - at suitable temperatureAir circulation - at suitable position

NOTICEWhen mist clears switch theknob ‘C’ position to Face mode.In high humidity areas, if coldair continues to flow overwindshield, it may cause suddenfogging on outside surface ofwindshield.

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Defrosting :(For vehicles fitted with HVAC unit& HD)In low temperature areas, to clearfrost formation outside thewindshield glass, this setting isused.First start the engine andaccelerate to warm up.Knob 'A' - Maximum hot positionKnob 'B' - Very HighKnob 'C' -Towards windshieldSwitch 'E' - Fresh air modeconditionOnce the windscreen has becomeclear, move the fan switch todesired speed.

Ventilator :The air flow can be adjustedcontinuously with the rotary controlknob at the vents on the dashboard. The air vents can beadjusted upward and downward.

HEATING, VENTILATION & AIR CONDITIONING (HVAC)Xenon At a Glance

Side Ventilators

NOTICEAC Gas charging Quantityshould be 500 + 20 gms.(R 134a-Non CFC)

Refrigerant charged in the airconditioning circuit has beenidentified on the label overfront body member. Use onlyrefrigerant as given in thelabel for topping up orrecharge, i.e. do not chargeR12 (CFC) in the vehicleearlier charged with R134a(Non CFC) or vice versa.Fresh air is taken from thegrill opening provided at baseof windshield glass outsidethe vehicle. Keep theseopenings clear and free fromfallen leaves etc.

NOTICE

Front Ventilators

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Roof Grab Handle :These are provided on all seatsexcept driver seat. This helps incomfortable positioning ofpassengers during journey.

Cigarette Lighter:

With ignition switch in ‘ACC’position, press the cigarette lighterfully in. When heated to specifiedtemperature it pops out. Take thelighter out and light your cigarette.After use place the lighter in itsposition.

NOTICEDo not insert any other partor accessory in cigarettelighter slot. It may damagecigarette lighter.Do not attempt to touch thehot coil of lighter. It may causescalding.

GRAB HANDLE & CIGARETTE LIGHTERXenon At a Glance

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Head Lamp:Head lamps are clear lens typehaving multi focal reflector and areprovided with H4 halogen bulbswith double filament for providingstraight ahead illumination of theroad for the long distance or dipbeam which illuminates the roadimmediately ahead for shortdistance visibility. It also containsside indicator lamp and a parkinglamp.

1 Main/Dip Beam2 Direction Indicator3 Position/Parking Lamp

Tail Lamp:The tail lamp assemblyincorporates the following

1. Parking Lamp 2. Brake Light3. Direction Indicator 4. Fog Lamp

Side Repeater Indicator LampFront Fog Lamp

4. Rear Fog Lamp

LAMPSXenon At a Glance

Fog Lamp :Front and rear fog lamps areprovided for your convenienceand they can be operated byrotating the Selector on Combiswitch.

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High Mounted Stop Lamp:High mounted stop lamp isprovided on the tail gate, and itglows whenever foot brake isapplied.Registration Plate Lamps:Two concealed lamps are providedfor il lumination of the rearregistration number plate.

1. High Mounted Stop Lamp2. Registration Plate Lamps

Door Lamp :These are provided on the innerside of the front and rear doors towarn the traffic coming from therear that the door is open.

Door Puddle Lamp :This is provided on the bottom sideof the doors to assist the user foreasy entry and exit during night.

LAMPSXenon At a Glance

Engine Compartment Lamp :This lamp is provided for yourconvenience in case of engineinspection/service.

2

1

Door Lamp

Door Puddle Lamp

Engine Compartment Lamp

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Front interior light with readinglamps:Interior roof lighting and readinglamps with inbuilt switches areprovided on the roof near the rearview mirror.

The central rectangular switch hasthree positions:ON - The lamp will come ‘ON’ aslong as switch is in this position.DOOR - In this position the lampcomes on when either of the doors

are opened. When the door isclosed, the lamp will not go ‘OFF’immediately, but remain ‘ON’ for5-8 sec. This helps settling in theseat and inserting the key in theignition switch. When the key isturned to the ‘IGN’ position, thelamp goes ‘OFF’ immediately.

OFF - In this position the lamp willnot come ‘ON’ at all. Tworectangular shaped push type ‘ON/ OFF’ switches are providedseparately for the right and leftreading lamps.

Rear Reading Lamps (Dual CabModel Only):

A roof mounted lamp with tworeading lamps is provided above therear seat. One rectangular shaped‘ON / OFF’ switch is provided foroperating right and left readinglamps.

LAMPSXenon At a Glance

Turn indicator lamps on outermirror:A Stylish turn indicator lamp isprovided on outer mirror for bettersignaling at night driving.

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Sun visors:Two adjustable sun visors areprovided inside the cab above thewindshield to prevent sun glare.Lower the lower the sun visors toprotect the eyes from brightsunlight. The sun visors can alsobe moved sideways towards thedoor.

SUN VISOR & MIRRORSXenon At a Glance

1. Sunvisor 2. Vanity Mirror

2

1

A Vanity Mirror has been providedon the back of the Co-driver’ssunvisor.

NOTICEWhen not in use keep thesunvisors in their original positionotherwise they may block thedriver’s vision.

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Outer Rear View Mirror:Motorised Rear View Mirrors arefitted on both front doors and canbe adjusted to the desired positionwith the help of a switch providedon the driver side door. The switchfacilitates the driver to adjust themirrors without lowering the windowglasses and without moving fromhis/her position.1. Move the main switch to L (for

left side) and R (for right side).2. Use the 4 positions of the knob

to adjust the rear view mirrorsto correct angles.

REAR VIEW MIRRORSXenon At a Glance

Inner Rear View Mirror:Antiglare Mirror - The antiglaremirror is fitted inside the cab.Provision has been made for twopositions:1. Normal position2. Antiglare positionUse antiglare position only whennecessary, as it reduces rear viewclarity.

21

1. Anti-glare Rear View Mirror2. Operating Knob

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Glove Box:The glove box is located on thedash board in front of the co-driver’sseat. The glove box can be lockedwith the ignition key.

Cup holder , Coin holder andAsh Tray :

These are provided for yourconvenience.

Utility pocket/box: Utility pocketis provided to the door to keepmagazines/books etc.

GLOVE BOX, CUP HOLDER & UTILITY POCKETXenon At a Glance

Rear Bottle Holder & utility pocket / box

Front Bottle Holder & utility pocket / boxGlove Box

1. Coin holder 2. Ash Tray(Portable)

21

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Xenon At a GlanceWINDOW GLASS

Power Windows :The windows glasses are electricallyoperated. Each door has a switchthat controls its window. Turn theignition key to ‘ACC’ and operatethe switch to raise or lower thewindow.To open the windows: Driver andco-driver windows are providedwith single touch express downfeature. Once you push the knobdown window will open fully. Forrear windows, release the switchwhen you want the window to stop.To close the window: Pull thefront portion of the switch and holdit. Release the switch when youwant the window to stop. Vehiclescenter console has a main powerwindow control panel by which anyof the passenger windows can beoperated. When the lock switch isin ‘UNLOCK’ position, then only therear windows switches can beoperated.

WARNINGEnsure that the driver controlledswitch is in “LOCK” position whenchildren are in the vehicle toprevent them from injuring bytheir hands / fingers gettingpinched by inadvertent operation/ It is the responsibility of the

driver other occupants of thevehicle to ensure that the key isremoved from the ignition lockbefore leaving the vehicle. Keephands or any part of the bodyaway from the windows while thewindows are being wound up/closed.

Power window switch (On dualcab Rear Doors): Individualwindow dual cab switches havebeen provided only on the reardoors.To close the door window glass pullthe knob up and to open, push theknob down

1. Front Left2. Front Right3. Rear Left4. Rear Right5. Push Type Lock / Unlock Button

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Fuel Tank Flap Opening:

The fuel flap is located on the leftrear side of the vehicle. The fuelflap can be opened by pulling theopening lever located at the righthand side of the driver seat.

WARNINGFuel vapour is extremelyhazardous. Always stop theengine before refueling andnever refuel near sparks or openflames.

FUEL FLAP OPENINGXenon At a Glance

Fuel flap opening lever

Fuel flap

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Xenon At a GlanceGEAR SHIFT LEVER & PARKING BRAKE

Parking Brake :

1. Parking brake lever2. Release ButtonA. Parking brake Released ConditionB. Parking brake Applied Condition

NOTICE

Gearshift Lever & ShiftingPattern:

The gearshift lever is mounted onthe centre console between the twofront seats. The gearshift pattern isshown on the gear lever knob.

The reverse gear should beengaged only when the vehicleis stationary. Wait for5 seconds after declutching toensure smooth engagement ofthe reverse gear.

The mechanical parking brakewhich acts only on the rear wheelsis provided on your vehicle. Theparking brake lever is locatedbehind the gearshift lever. To applythe parking brake, pull the lever upfully. The indicator light on theinstrument panel will go ‘ON’.To release it, pull the lever upslightly, press the release buttonand push the lever down. The

parking brake indicator on theinstrument panel will go ‘OFF’ whenthe parking brake lever is fullyreleased.

NOTICEApply the parking brakeproperly before leaving thevehicle & release it beforemoving.Use the parking brake forholding the vehicle on a downgradient and put vehicle inreverse gear.Use the parking brake forholding the vehicle on a upgradient and put vehicle in 1stgear.

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Anti Theft/ Immobiliser andKeyless Entry System :This system is essentially an anti-theft security system, which has akeyless operation for door unlock/lock. It immobilizes the vehicle bydisabling starter motor, ignition andfuel supply in case of unauthorisedentry.

The system consists offollowing :1. One User "Remote" with LOCK

and UNLOCK button for nor-mal use.

2. Body Control Module.3. "Lock Indicator Warning" on

dashboard for indication of"mode" of the system.

Features :Locking/ unlocking the vehiclefrom distant place. (Refer armmode)

Immobilisation of vehicle &continuous flashing of turnindicators, if theft is detected(Refer Armed Panic).Protection when user forgets tolock using remote.(Refer AutoArm Mode).Immobilisation of vehicle if theftis detected in Auto Arm mode.(Refer Auto Arm immobilised)Finding the vehicle. (Refervehicle seek).Manual central door locking/unlocking (Refer central doorlocking feature).Continuous flashing of turnindicators in case ofemergency. (Refer ForcedPanic).Auto lock and unlock (ReferAuto lock and unlock).

ANTI THEFT/ IMMOBILISER AND KEYLESS ENTRY SYSTEMXenon At a Glance

Unlock Lock

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DESCRIPTION OF MODES ANDUSAGE OF "REMOTE" ARMMODE:Used to lock the vehicle fromDistant place (Do not use Mech.Key). Press "LOCK" on UserRemote.

Additional/ new remote can beadded. Stolen remote can bedisabled. (Refer LearningAdditional Remote/UnlearningLost Remote).

Modes of the system :

State of Immobiliser Meaning / Function of the state

Disarmed Vehicle can be drivenArmed Vehicle cannot be driven.

Immobiliser is sensing forunauthorised entry.

Armed Panic/ Vehicle cannot be driven.Immobilised Fuel, ignition, starter supply is cut.Auto Armed Vehicle cannot be driven.

Immobilised Fuel, ignition, starter supply is cut.Auto Armed (Immobiliser is sensing for

unauthorised entry.)

ANTI THEFT/ IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)Xenon At a Glance

Gives single flash. Locks alldoors. Gives delayed flashthrough turn indicators afterlocking.Lock Indicator on dashboardstarts blinking (typically once in1.5 sec.)The vehicle arms (i.e. Vehiclecannot be driven. If attempted,the system goes to Armed PanicMode). Press UNLOCK to disarmthe vehicle.If any of the doors, bonnet orhatchback is not properlyclosed before locking, systemgoes to Armed Panic mode.Press UNLOCK to disarm thevehicle.

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ANTI THEFT / IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)Xenon At a Glance

UNLOCK/ DISARM MODE :Used to UNLOCK the vehiclefrom Distant Place. (Do not useMechanical Key)Press ‘UNLOCK’ on UserRemote.Gives one flash on turnindicators.Unlocks drivers door (Press‘UNLOCK’ again to unlock otherdoors.Lock Indicator on dashboardstops blinking.The vehicle disarms (User candrive the vehicle).When Lock Indicator ondashboard is blinking the vehiclecannot be driven. PressUNLOCK to disarm the vehicle.

ARMED PANIC MODE :In Armed Mode, if Theft is detected(door opened/Key inserted inignition switch/cranking attempted)vehicle immobilises, hoofing andflashes of turn indicators for about25 to 30 seconds (To stop theflashing press any button on theuser Remote). To mobilise thevehicle press UNLOCK once again.AUTO ARM MODE :Protection when user forgets tolock the vehicle using remote.

In Unlock mode, after the key istaken out of the Ignition switchand leaving the vehicle (door isopened and closed), vehiclearms automatically in 55 sec.(i.e. Vehicle cannot be drivenwithout pressing UNLOCK buttonon the User remote. If attempted,vehicle goes to auto armedimmobilised mode)

As an additional securitymeasure, the system has abackup facility. In Unlock modeafter taking the key out ofIgnition switch, the vehicle armsautomatically in 55 sec., even ifno door activity is detected.The Lock Indicator on thedashboard starts blinking oncein 1.5 seconds.

When Lock Indicator ondashboard is blinking, the vehiclecannot be driven. Press UNLOCKto disarm the vehicle.

AUTO ARMED IMMOBILISEDMODE :In Auto Armed Mode if Theft isdetected (Key inserted in ignitionswitch/or attempt to crank)Lock Indicator on the dashboardstarts blinking at faster rate and thevehicle immobilises. When LockIndicator on dashboard is blinking

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ANTI THEFT / IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)Xenon At a Glance

the vehicle cannot be driven. Pressunlock to disarm the vehicle.

CAR SEEK :It is used to find the vehicle. Press‘LOCK’ on User Remote when thevehicle is locked. (Operating Range7.5 meters)

Gives three flashes on turnindicators and remains armed.

CENTRAL DOOR LOCKINGFEATURE :

All doors can be locked/unlockedby manually locking/ unlocking thedriver’s door (using mechanicalkey/knob)

FORCED PANIC MODE :

Press ‘LOCK’ and ‘UNLOCK’on User Remote simultaneously.

Turn indicator lamps startflashing continuously.

Press any button on the remote tostop flashing.

AUTO LOCK AND UNLOCK :(If fitted)(When driving the vehicle)

1. Whenever vehicle is cranked andengine is fired, all doors will lockautomatically after 5 sec., if alldoors are closed. If any one of thedoors is open, then locking will nottake place.

2. After the key is taken out fromthe Ignition switch, the systemautomatically unlocks thedriver’s door.

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EMERGENCY DISARMINGPROCEDURE :This procedure is applicable incase of lost remote & system inarmed / Auto armed / immobilisedstate i.e. cluster led is blinking1. Enter the vehicle by opening

the door through physical key& close the door.In case the vehicle is in armedcondition, the system will enterarmed panic in immobilisedstate-will hoot (if provided) andflash for 30 seconds.

2. Open driver door or turn onhazard switch.

3. Turn ignition ‘ON’ and ‘OFF’3 times within 5 seconds.

4. If step 3 is not completed within5 seconds the system willremain in immobilised state andthe cluster LED will continueflashing.

5. On successful completion ofstep 3, the system will comeout of the immobilised state toenter emergency disarmingstate. (This state is similar to theimmobilised state without thehooting and side indicatorflashing).The cluster LED will stopflashing and remain ‘OFF’ for5 seconds.

6. After step 5 the LED startsflashing (0.5 second ON,0.5 second OFF) for maximum9 counts the user.Must count the number of LEDflashes and turn ignition ‘ON’ assoon as this count matches thefirst digit of secret code (defaultsecret code 3333). The LED willstop flashing.

7. Switch ‘OFF’ the ignition.

8. The user must enter the 2nd, 3rd

and 4th digit of the secret codein a similar fashion as describedin step 6 & 7 above.

9. After successful entry of all thefour digits of secret codes thecluster LED stops flashing. Thesystem will dis-armed andvehicle will get mobilised.

10.Close driver door or turn ‘OFF’hazard switch.

11. In case of any error in enteringthe secret code digits the LEDcontinuous to flash and thesystem remains in immobilisedstate to re-enter secret code(default secret code 3333).Perform step 10 and start theprocedure from step 2 onwards.

12.All previously learned remoteswill get unlearnt.

13.Vehicle engine is released for5 cranks (configurable) only.

Xenon At a GlanceANTI THEFT / IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)

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14.The vehicle can be cranked anddriven.

LEARNING OF NEW REMOTE :This procedure is applicable incase of lost remote and system inarmed / auto armed / immobilisedstate I.e. cluster LED is blinking.

Step 1-12 mentioned above,should be completedsuccessfully and then followsteps 1,2 below, within 30 sec.(Configurable)

1. Open driver door (OR turn ‘ON’hazard switch).

2. Turn ignition ‘ON’ & ‘OFF’5 times within 10 sec.

3. The system enters the learnmode. The LED on instrumentcluster will remain ON for 5 sec. (Configurable)

4. Press any key on the remoteonce within 5 sec.

5. On successful learning of theremote, system gives singlehoot with flash.

6. Repeat step 4 & 5 above forlearning other remote(Maximum 4 remotes)

7. Learning mode will be exited in5 seconds, if any of theremotes is not learnt during thistime. The learning process hasto be repeated.

CHANGING OF SECRET CODE:This procedure is applicable incase when the user wants tochange the secret codeChanging of the code will bepossible when the cluster LED isblinking1. Enter the vehicle by opening

the door through physical key,close the door.In case the vehicle is in armedcondition, the system will enter

armed panic - will hoot (ifprovided) & flash for30 seconds.

2. Switch ‘ON’ the parking lights.3. Turn ignition ‘ON’ and ‘OFF’

3 times within 5 sec.4. If step 3 is not completed within

5 sec. the system will remainin immobilised state and thecluster LED will continueflashing.

5. On successful completion ofstep 3, the system will come outof the immobilised state and theprocedure for entering newsecret number can be started(This state is similar to theimmobilised state without thehooting and side indicatorsflashing)

6. The LED starts flashing (0.5sec. ON / 0.5 sec. OFF) for max. 9 counts.

Xenon At a GlanceANTI THEFT / IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)

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Xenon At a GlanceANTI THEFT / IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)7. The user has to enter the

existing secret number. Theuser must count number of LEDflashes and turn the ignitionswitch ON as soon as the countmatches the “1ST” digit of theexisting secret code. The LEDwill now stop flashing.

8. Switch OFF the ignition.9. The user must enter the 2nd,

3rd and 4th digit of secretcode in similar fashion asdescribed in step 6,7 and 8above.

10. After successful entry of all the4 digits of existing secretcode, the cluster LED stopsflashing for 10 sec.

11. If a wrong secret code isentered, the LED continues toflash and the system remainsin immobilised state. To reentersecret code, switch OFF the

parking lights and startprocedure from step 2onwards.

12. Repeat steps 7, 8 and 9 butwith the new 4 digit number.The digits to be entered canbe from 1 to 9. Aftersuccessful entry of all 4 digitsof new secret codes the clusterLED stops flashing for 10 sec.

13. Again repeat the steps 7, 8and 9 with the same new 4digit number. After successfulentry of all the 4 digits of newsecret code, the cluster LEDstops flashing for 10 sec.

14. If the new secret code enteredtwice is not matching then theflashing of side indicators willstart for 5 sec. To restart theprocedure of entering newcode, steps from 12 onwardsto be performed. Cluster LEDstarts flashing after 10 sec.

15. If secret code entered twice ismatching then the systemgives information of newlyentered code with theequivalent number of LEDflashes for each digit, with a5 sec. gap between 2 digits.

16. Switch OFF the parking lights.17. The newly entered secret

number to be used here afteremergency dis-arming andremote learning.

NOTICENo remote will get unlearnt withthis procedure. During thisprocedure any key pressedfrom the remote will be ignored.

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Xenon At a GlanceANTI THEFT / IMMOBILISER AND KEYLESS ENTRY SYSTEM (IF FITTED)

Remote - Battery Replacement(replace every year for normal use)1 . Place the remote button-side

facing down and removescrews.

2 . Change the battery withGOLDEN POWER Battery GP23A or equivalent (eg:-Duracell MS21/ MN21).

3 . Put back the screws.4 . Press any button and check

that the LED on the remoteglows.

5 . Change the default PIN numberusing above procedure.

GUIDELINES FOR USER :The vehicle does not start(Engine does not crank/fire)Check the Lock Indicator onthe dashboard. If it is blinkingthen the vehicle is not supposedto start (Arm Mode/Auto Arm

Mode). Press UNLOCK buttonon the User Remote and thenstart the vehicle.If the turn indicators are blinking,pressing the UNLOCK button ofthe User Remote will stop theblinking of the lamps. The nextpressing of the UNLOCK buttonof the User Remote will unlock/disarm the vehicle and then thevehicle can be driven. Contactthe dealer if the vehicle stillcould not be started.Pressing UNLOCK/LOCKdoes not UNLOCK/ LOCK thevehicle.If the turn indicators are blinking,pressing UNLOCK/ LOCK willstop the blinking of lamps. Thenext UNLOCK/ LOCK press willactually unlock/disarm thevehicle and the vehicle can bedriven.

Battery Low Indication :1 . Operating Distance has come

down2 . LED on user remote flashes

whenever UNLOCK/ LOCKbutton is pressed on the remote(under normal batteryconditions, the LED on the userremote lights continuouslywhenever UNLOCK / LOCKbutton is pressed).

3 . Replace the battery to getincreased range.Press any of keys on remote,if LED of the remote iscontinuously ‘ON’, meansbattery is OK. If it is blinking,then remote battery is to bereplaced.

NOTICERemote may not be operative innear transmission vicinity of highpower antenna (like TV).

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KEYS & DOOR LOCKGetting Started

Keys:The key operates all locks andIgnition switch.

A code number is stamped on theplate attached to the key set.Detach this plate and store at safeplace (Not in the vehicle). Thisreference number is necessarywhile getting duplicate keys fromyour Authorised Dealer. It advisableto keep another key at safe placefor use in case of emergency.

NOTICEDo not use locally made keys,get a duplicate key through yourauthorized dealer.

Front Doors (Driver & Co-driver)Locking / unlocking doors withkey from outside :Both front doors (drivers & co-driver) have separate lockingfacility. Front doors can be lockedor unlocked from outside with key.

Insert the key and turn it anti-clockwise (A) to open or clockwise(B) to lock the door. Pull the Doorhandle to open an unlocked door.

Locking without a key frominside:All the doors can also be locked orunlocked independently from insideby pressing or pulling the knob.

WARNINGWhen locking doors this way, donot leave the key inside thevehicle.

Unlock

Lock

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Opening The Doors FromInside :All doors can be opened frominside. To open pull the dooropening lever / latch.

Tail Gate Locking / Unlocking:To open the tail gate pull the swinghandle outwards, and just byclosing the tail gate to its originalposition, it gets self locks.

DOOR LOCK & CHILD LOCKGetting Started

Location of door opening lever / latch

Childproof Lock :Both the rear doors on dual cabmodel are provided with child prooflock. Push the lock lever locatedon vertical face near the lockupward before closing the door.The door which has been lockedcannot be opened from inside, itcan be opened only from theoutside.

CAUTIONDeactivate the childproof lockwhen not required.

Tail Gate Swing Handle

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SEAT, SEAT ADJUSTMENTS & SEAT BELTSGetting Started

Seats :Bucket type seats are providedwith a position lever, lumbersupport and recliner handle knob.

1. Seat Back Recliner and seatposition lever :To change the seatback angle, lean forward slightly andraise the lever ( 1 ).Then lean back tothe position you want and release it.

Head Restraint :

Adjustable head restraints areprovided for bucket seats in front.Neck rest for rear bench seat(Dual Cab) cannot be adjusted. Toincrease the height lift up and leaveat desired click position. To reducethe height, press the unlock button& push the head restraint downwards.

2. Moving the Seat Forward &Backward:

To adjust the seat position, lift thelever ( 2 ) then slide the seat to thedesired position and release the lever.Make sure the seat is locked inposition.

3. Lumber Support Adjustment:

Use the lumber operating handle ( 3 )to increase or decrease support to thelumber region of the back to give afatigue free seating position, especiallyon long journey.

1. Lever for Seat Movement (Forward &backward)

2. Seat Back Recliner and seat positionlever.

3. Lumbar Support Adjustment LeverPoor Adjustment Good Adjustment

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SEAT BELTSGetting Started

Fastening of Seat belts

Seat beltIt is a mandatory requirement thatseat belts be used and correctlyadjusted. It is strongly advised thatdriver and all passengers wear seatbelts, while traveling. Belts aredesigned to afford a substantialmeasure of restraint to the wearerin certain common accident andother driving situations. Yourvehicle is equipped with inertiareel, lap/sash seat belts for alloccupants. It is recommended thatyou carefully follow instructionsgivenbelow :

CAUTIONWhen using seat belts, observethe following :

Use belt for only one personat a time. Do not use a singlebelt for two or more people -even children.

It is dangerous to put a beltaround a child being carriedon occupants lap.After inserting the tab, makesure that the connection issecure and belt strap is nottwisted.Be careful not to damage beltwebbing or hardware, andtake care that they do not getcaught or pinched in the seator doors.Inspect belt systemperiodically. Check for cuts,frays, and loose parts.Damaged parts should bereplaced.Keep belts clean and dry. Ifthey need cleaning, use a mildsoap solution or lukewarmwater. Never use bleach, dye,or abrasive cleaners — theymay severely weaken belts.

Replace belt assembly if it hasbeen used in a severe impact.It should be replaced even ifdamage is not visible.

Seat belts fastening

To put seat belt on, grasp the tongueand move it across your body untilit can be engaged with the buckle.Push the tongue into the buckleuntil a positive “click” is heard.

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SEAT BELTSGetting Started

Adjustment of Seat Belts - Lap /

Sash Belts :

After fastening seat belt, removeslackness from lap portion of beltso that it fits snugly, by graspingsash part of the belt and pulling itgently towards your shoulder.Inertia reel will then take up theslack, allowing sash section to fitcorrectly against your upper body.Inertia reel allows freedom ofnormal movement to reach forwardor across the vehicle but will lock

Seat-belt Precautions for Baby,Small Child & Pregnant Woman :

TATA MOTORS strongly urges thatthe driver and passengers in thevehicle be properly restrained atall times with the seat-belts. Failureto do so could increase the chanceof injury and / or the severity ofinjury in accidents.Unfastening of Seat belts

when webbing is tugged veryquickly, or with any rapid changein vehicle motion, such asmoderately hard braking.

Unfastening Seat Belts :

To unfasten belt, press releasebutton marked “PRESS” locatedon the buckle, and tongue will bereleased.

Seat-belt Adjusting Knob : Toadjust the Seat belt pull the knoband slide it vertically.

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WARNINGSeat belts are designed to bearupon bony structure of thebody, and should be worn lowacross the front of pelvis or thepelvis, chest and shoulders, asapplicable; wearing the lapsection of the belt across theabdominal area must beavoided.

SEAT BELTSGetting Started

Baby or Small Child :Use child restraint systemappropriate for the child until thechild becomes large enough toproperly wear the vehicle’s seat-belts.

If a child is too large for a childrestraint system, the child shouldsit in the seat and must berestrained using the vehicle’s seat-belt.

Also use the seat-belt while thechild is in the middle seat.According to accident statistics,the child is safer when properlyrestrained in the rear seat than inthe front seat. Child restraintsystems are available. TATAMOTORS recommend the use ofa type which fits to your vehicle.Before installation, always read themanufacturer’s instructions.

Do Not install a rearward facingchild seat in the front passengerseat if a front passenger airbag isfitted. An inflating airbag couldimpact with the seat causingserious injury, or even death for thechild.Pregnant Woman :TATA MOTORS recommends theuse of a seat-belt. Ask your doctorfor specific recommendations. Thelap belt should be worn securely andas low as possible over the hips andnot to waist.

WARNINGSeat belts should be adjustedas firmly as possible,consistent with comfort, toprovide protection for whichthey have been designed. Aslack belt will greatly reducethe protection afforded to thewearer.Care should be taken to avoidcontamination of the webbingwith polishes, oils andchemicals and particularlybattery acid. Cleaning maysafely be carried out usingmild soap and water. The beltshould be replaced if webbingbecomes frayed,contaminatedor damaged.It is essential to replace theentire assembly after it hasbeen worn in a severe impacteven if damage to theassembly is not obvious.

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STEERING WHEEL ADJUSTMENTGetting Started

Steering Wheel PositionAdjustment :

You can adjust the steering wheelto suit your driving position. Adjustthe steering wheel position asfollows before you start driving.

Adjust the seat to a comfortableposition.

The lever to tilt the steeringwheel is located under steeringcolumn. Pull the lever down andhold in that position.

Move the steering wheel up ordown to the desired position.Position the wheel in such away that all the instrumentpanel gauges and warninglights are visible.

Release the lever & keep thelever in up position Make surethat steering wheel is securelylocked by moving up and down.

WARNINGBelts should not be worn withstraps twisted.

Each belt assembly must onlybe used by one occupant; itis dangerous to put a beltaround a child being carriedon the occupant’s lap.

WARNINGNo modifications or additionsshould be made by the userwhich will either prevent theseat belt adjusting devicesfrom operating to removeslack, or prevent the seat beltassembly from being adjustedto remove slack.

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Before Driving, please ensure toCheck : (Refer maintenanceSection )1. Tyre pressure2. Coolant level3. Engine oil level4. Brake fluid level5. Clutch fluid level6. Water in windshield washer

reservoir7. Power steering oil level8. Battery electrolyte level9. Fuel level

Adjust

1. Front seat2. Rear view mirrors

Ensure

1. Bonnet is properly closed.2. All doors are properly closed.3. Seat belts are fastened.

4. All switches & lamps areworking.

5. Gear shift lever is in neutralposition.

6. Parking brake is released.

Preparing to Drive

The following checks andadjustments should be done beforeyou start driving the vehicle.

Ensure all mirrors, windows andoutside lights are clean andunobstructed. Remove dust,frost, snow or ice if any, onthese.

Check that any items you maybe carrying inside with you arestored properly or fasteneddown securely.

Check adjustment of steeringwheel. (Refer getting startedsection)

If the doors are not properlyclosed you will get a audiowarning/indicator light as soonas you insert the ignition keyin the switch. Make sure alldoors are properly closed andlocked.

If the seat belts of driver &co-driver are not fastened youwill get an audio warning /Indicator light as soon as youturn the key to ignition position.Fasten your seat belt ensureco-driver and passenger seatshave also fastened the seat belt.

Check and ensure that all thegauges and indicator lights inthe instrument panel areworking.

CHECKS BEFORE DRIVINGDriving

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Windshield Washer :Always keep windshield glassclean to avoid any distraction invisibility. Ensure proper working ofwipers and condition of wiper blade.Ensure that windshield washerreservoir is full. Do not operate wiperalone when the windshield glass isdry this would damage thewindshield.

Headlights :Keep headlight lenses clean. Checkfor operation of headlamps in bothhigh/low beam condition. Check forcorrect focusing of headlamps. Useonly recommended type bulbs. Usewith care the high beam as its glaremay dazzle the driver of theoncoming vehicle, the conditioncould cause an accident.

Side Indicators / HazardWarning :Ensure that all side indicators/hazard warning lights are alwaysin working condition and they areused when required.Horn :Ensure the horn is workingproperly. Horn provides safety toother road users by alerting yourpresence.Brakes :Ensure brakes are workingproperly. Check brake fluid level inreservoir. Do not drive the carwhen brake warning lamp is 'ON'.Tyres :Check the condition of tyres forany abnormalities. Maintain correcttyre pressure, it is very importantparticularly when subjected toextreme condition, such as highspeed, high load and high outsidetemperature. Do not use worn orbald tyres on the front wheels.

First Aid Kit :First aid kit is provided in yourvehicle. This is for use in case ofminor injuries. It is to be regularlychecked for any disintegration andshould be updated regularly.

DrivingSAFETY CHECKS

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Seat Belt :Seat-belts are life saving equipment,use of seat-belts reduces thechance of injury and severity ofinjury in case of an accident. It isstrongly recommended that allvehicle occupants should alwayswear seat-belts, while vehicle is inmotion.

Influence of Vehicle Alcohol :Avoid driving under the influencesof alcohol or drugs. Alcohol anddrugs will severely impair yourcontrol of the vehicle and increasethe risk of injury to yourself andothers.

Mobile Phones :Avoid using mobile phones whiledriving your vehicle. This coulddivert your attention from the roadand result in an accident.

Fatigue 'Rest Revive Survive' :Do not attempt driving when you feeltired. Long distance driving can tireyou and fatigue can dull yourreflexes and judgment. This can beavoided by taking breaks at regulartwo hourly intervals.

DrivingSAFETY CHECKS

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INSTRUCTIONS TO IMPROVEFUEL ECONOMY :

Your vehicle's fuel economy ismainly dependent on your style ofdriving.To operate your vehicle aseconomically as possible, use thefollowing driving suggestions.

Avoid Excessive Idling :

Stop the engine and start it again,if you have to wait for more than aminute while you are stopped.

Avoid Fast Starts andUnnecessary Stops :

Start off slowly from traffic lights orstop signs to prevent increased fuelconsumption and shortening ofengine life. Avoid unnecessarydeceleration (stopping or slowingdown) and then accelerating whichuses more fuel.

Fuel Economy Speeds :

Gear Speed (kmph)

1st 152nd 303rd 454th 605th 80

DrivingFUEL SAVING TIPS

NOTICE

Always Maintain a CleanEngine Air-Filter :

The amount of air supplied willreduce due to clogged air-filter,resulting in wastage of fuel due toincomplete combustion.

Avoid Incorrect Tyre Pressures :

Under-inflated tyres result inincreased running resistance of thetyres, leading to wastage of fuel.(Refer tyre maintenance section)

Proper Driving Practices :

Keep a safe distance from othervehicles to avoid braking suddenly.

Do not rest your foot on theclutch pedal. It does not allowfull engine power to betransmitted to the vehicle andreduces clutch life.

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Starting The Engine :Before starting1. Apply parking brake.2. Ensure gear lever is in neutral.A. Insert the key in steering and ignition lock and turn

it to ‘ON’ position.B. Press the clutch pedal fully.C. Now crank the engine.D. If the engine does not start turn the key to off position

and try after 30 seconds.NOTICE

After starting run the engine in idle speed for atleast 30 seconds. Do not press accelerator pedalwhile starting the engine to avoid damage toturbocharger.

STARTING, STOPPING THE ENGINERunning-in Period :Avoid rapid acceleration and prolonged high speedrunning of the engine while using the new vehicle forthe first 1500-1800 km of operation.Do not exceed the following vehicle speed duringrunning in period.Gear Box :

Gear box has all synchromesh gears including reverse.The 5th gear is an over drive.When shifting the gear up or down make sure you pressthe clutch pedal fully and shift to the next gear and thenrelease the clutch pedal gradually.

Gear 2H/4H 4Lkm/hr km/hr

1st2nd3rd4th5th

20 840 1665 26

95(90)* 38(36)*110 44

Driving

Stopping The Engine :Before switching off the engine, run the engine in idlecondition for atleast 30 seconds and then switch off.This will allow the engine oil to lubricate theturbocharger, till its speed is fully reduced and alsoallow the unit to cool down.Above precautions will ensure a longer life andperformance from the turbocharger.

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Vehicle Speed during up shift

Gear 2H/4H 4Lkm/hr km/hr

1-22-3

3-4

4-5

25 1045 18

75 30

100 40

Vehicle Speed during down shift

Gear 2H/4H 4Lkm/hr km/hr

2-1

3-24-3

5-4

15 6

25 1045 18

65 (60)* 26 (24)*

Gear Change Speeds During Downshift :

STARTING, STOPPING THE ENGINEDriving

Before shifting in to reverse gear bring your vehicleto a complete stop and depress the clutch pedal fully.

Do not shift into reverse gear with vehicle movingforward.

While changing gear it is recommended to shift at thespeeds given in the table.

You can get extra braking from the engine when slowingdown by changing to a lower gear.

This can help you to maintain a safe speed and preventyour brakes from overheating while going down a steephill.

CAUTIONAvoid excessive reviving up of engine rpm.

CAUTIONRunning Engine under idle condition for longduration and also in high idle (fly-up rpm) shouldbe avoided

Gear Shifting :Gear Change Speeds During Upshift :

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2H - Rear wheel drive4H - Four wheel drive (High)4L - Four wheel drive (Low)

Transfer Case (for 4 x 4vehicles)Transfer case allows driver toselect 2 or 4 wheel drive operation.Your vehicle is fitted with 2 speed,part time electric transfer case.Transfer Case Selector Switch :This switch is electrically operated& mounted on dash board, and isprovided with 3 selector positions.2H- Only rear wheels are drivenand transfer case operates at 1:1ratio.4H- All four wheels are driven andtransfer case operates at 1:1 ratio.4L- All four wheels are driven andtransfer case operates at 2.48:1speed reduction ratio.

GEAR SHIFTING (4X4)

Automatic Hub Lock :When 4 wheel drive is selected,automatic hub locks axle shaft towheel hub. This occurs when thevehicle driven in either forward orreverse direction.

Limited Slip Differential :(4x4 version only)A standard differential deliverstorque equally to each wheel. Incase one wheel loses traction andbegins to spin, the differentialdistributes rotary speed unequally

but with same torque. This cancause wheel with good traction toslow down or stop while the wheelwhich lost traction rotates withincreased speed. Such a situationcan prevent the vehicle from moving.Limited slip differential provided inthe rear axle takes care of suchsituations. However during normaldriving, differential action takesplace in the same manner as in astandard differential.

1. Four Wheel Drive OperationIn 2-H mode, only the rear twowheels of the vehicle are poweredby the engine and the front wheelsare merely pushed. By shifting tofour wheel drive mode (4H or 4L)the rear as well as the front axlesare driven by the engine throughthe transfer case and transmittingengine power to all four wheels.This gives the vehicle increasedtraction. In 4H mode, the

Driving

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DrivingGEAR SHIFTING (4X4)transmitted engine torque andvehicle speed remain the same asin 2H. However, when you shift to4L mode, engine torque ismultiplied and vehicle moves at lowspeed in the same gears withincreased traction. 4L mode isprovided for negotiating sharpgradients or driving through loosesoil/sand.

2. Shifting from 2H to 4H :Shift selector switch mode from 2Hto 4H. 4WD HI indicator will turnON.

Shifting is possible during driving.

3. Shifting from 4H to 2H :Shift selector switch mode from 4Hto 2H. 4WD HI indicator light willturn OFF.

Shifting is possible during driving.

Free Wheeling of Front Hub :

After shifting from 4H to 2H, foreffecting free wheeling of frontwheels, direction of vehicle motionneeds to be changed. If in 4H modethe vehicle was moving forward thenstop it, wait and then engagereverse gear. (If it was movingreverse in 4H mode then stop it,wait and then engage forward gearof main gear box.) After stoppingand changing the gear the vehiclemust travel in opposite direction fora minimum of three meters, for freewheeling.

4. Shifting from 4H to 4L

Stop the vehicle in safe area.Press clutch pedal.Shift selector switch mode from4H to 4L. 4WD LO indicatorlight will turn ON.

5. Shifting from 4L to 4HStop the vehiclePress clutch pedalShift selector switch mode from4L to 4H. 4WD HI indicator lightwill turn ON.

CAUTIONDo not exceed the followingspeeds :4H (4WD High Range) 100 km/ h.4L (4WD Low Range) 40 Km/ h.

CAUTIONIn case of malfunctioning inshifting from 4H to 4L or 4L to4H, respectively 4L or 4H lightwill flash continuously. Do notmarch the vehicle in suchcases.

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WARNINGDo not use 4H or 4L modescontinuously on dry and hardsurfaced road except forchecking operation. It cancause extensive damage totransmission & tyres.With ignition ‘ON’ 4H & 4Lindicator lamp on panel shouldglow for a few seconds onlyand then go off. Continuousillumination of 4L & 4H lampsindicates a fault in transfercase or in its electrical circuit.

NOTICEFour wheel drive facility is apowerful tool which enables thevehicle to traverse terrain whichis otherwise inaccessible to twowheel drive vehicles. However, itmust be used judiciously andcarefully. Do not takeunnecessary risks and attemptthe impossible. Familiariseyourself thoroughly with thevehicle and its abilities beforeattempting serious off roaddriving.

DrivingGEAR SHIFTING (4X4)

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DrivingBRAKINGBrakes :The brake system on this vehicleis an advanced vacuum assistedhydraulic brake system, equippedwith:

Brake booster : This assists thedriver in braking with anergonomic pedal force on brakepedal;Tandem Master Cylinder, for failsafe braking.Twin pot calipers, for efficientenergy absorption.LCRV - Load ConsciousReducing Valve, to avoid rearwheel locking in extreme loadcondition.Auto adjusted rear brakes whichare designed for trouble freeperformance.

The system is designed with an Hcircuit, this has an advantage ofproviding minimum braking even ifone circuit fails, however the pedal

will be harder to press and stoppingdistance will increase. At the sametime brake indication light wouldglow on dash board.If you observe any abnormality withthe in brake system contact yournearest TATA Motors authorizedworkshop.In case of failure of vacuum supplyto the brake booster the vehicle canstill be stopped with a higher pedaleffort. In case of vacuum failure orbrake circuit failure, slow down thevehicle by shifting to a lower gearand lifting your foot from theaccelerator pedal. Pull to the sideof the road as soon as it is safe.

CAUTIONBrake system failure is veryhazardous. It is best to have yourvehicle towed, but if you drivethe vehicle in this condition, beextremely cautious.Have your vehicle attended toimmediately.

Put your foot on brake pedal toapply brake. But do not ride thebrakes as they may overheat andreduce efficiency andperformance may be impaired.The brake lights may confuse theother road users behind you.Use the engine to assist the brakesby shifting to a lower gear andlifting your foot from acceleratorpedal.Constant application of brakeswhile going down hill builds heatand reduces braking efficiency.Check your brakes after drivingthrough deep water. Apply thebrakes moderately to feel if theyare normal. If not, apply themgently and frequently until they do.With wet brakes you should beextra cautious and alert in yourdriving.

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DRIVING IN ADVERSE CONDITIONSDriving

Driving Through Water :

Never venture to drive throughwater when it flows over guard rails.The engine may be seriouslydamaged, if attempting a deepwater crossing.If the situation demands that youhave to drive through water then;

Keep engine in fast idling andcrawl the vehicle in low gear.After driving through waterapply brakes several times todry liners and to regain originalbraking.

Do not attempt to start the engineif vehicle gets flooded due to waterincrease.

Tow the vehicle to a safe place.Take the vehicle to nearestAUTHORISED Workshop to checkfor the entry of water into thecylinders.It will also be necessary to replacethe lubricants of engine, gearbox,transfer case, front axle and rearaxle if water has entered.Get the starter and alternatorchecked.Driving on a Rainy Day :

Check brakes, steering andwindows.Check tyres for wear and tyrepressure.

Check wiper blades for properfunctioning.Avoid harsh braking and sharpturns. It may cause loss of controland lead to skidding.For slowing down, change to alower gear and brake gently.Keep lights ON if visibility is poor.Night Driving :

Dip the head lamps for oncomingtraffic during night driving.Maintain a speed such that you canstop within illuminated distance ofhead lamps.

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DRIVING IN ADVERSE CONDITIONSDriving

Use side indicators for lanechange or turning.

Put on the hazard warningswitch in cases of hazardousparking or if your vehicle isdisabled to warn the passingtraffic.

Climbing Sharp Gradients onLoose Surfaces :

Select gear to suit gradient gear.Apply power smoothly so that thereis no loss of traction by over-revving of the engine.Choose the smoothest as possiblepart of the slope and select theappropriate gear so that gear

changing in the middle of the climbis not required.Changing gears in the middle ofthe climb can cause loss ofmomentum and engine stalling.Shifting to lower gear has to bedone cautiously to avoid loss oftraction.Under no conditions should thevehicle be moved diagonallyacross a hill. The danger is in lossof traction and sideways slippage,possibly resulting in tipping over.If unavoidable, choose as mild anangle as possible and keep thevehicle moving.If the wheels start to slip within fewfeet of the end of the climb, motioncan be maintained by swinging thesteered wheels left and right,thereby providing increased grip.If the vehicle stalls or lossesheadway while climbing a steephill, make a quick shift to reverse

and allow the vehicle to move backwith the control of enginecompression.Descending Sharp Gradients :

Depending on the severity of thegradient, shift into appropriategear. Use engine brakingjudiciously without over-revving theengine.Brake application under suchsituations should be done verysmoothly to avoid loss of control.Select appropriate gear so thatgear changing or clutchdisengagement is not involvedwhile descending the gradient.

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Incase of EmergencyJACK LOCATION, WARNING TRIANGLE & FLAT TYRE REPLACEMENT

Advance Warning Triangle :

There is an advanced warningtriangle provided with your vehicle.In case there is a breakdown andthe vehicle is parked at the side ofthe road, then the triangle is to beused as per instructions givenbelow:

1) Remove advance warningtriangle from case andassemble.

2) Place the triangle on the roadbehind the vehicle.

3) The triangle must be at least50 meters behind the vehicle inthe same lane of traffic.

4) Increase the distance to150 meters on a highway or ifon the crest of a hill where itobscures the view. A bad / hill topobscures the view.

If you have Flat Tyres :1) Reduce vehicle speed gradually

keeping it in a straight line. Movecautiously off the road to safeplace away from traffic. Parkthe vehicle on a level and firmground. Apply parking brake &engage 1st gear.

2) Turn on Hazard warning switch.Keep advance-warning triangleat least 50 meters behind thevehicle as an indication ofbreakdown.

Tool and Jack - Single Cab1. Jack handle 2. Jack

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Incase of Emergency

3) Take out ‘Tool kit & Jack’ fromvehicle which is kept at the rearof the cab below the rearpassenger seat (For crew cab).

4) Rotate jack lever and take outjack.

8) Remove wheel cover (if fitted)and loosen the wheel nuts of flattyre (Do not remove the nuts atthis stage).

9) Set the jack properly at correctjack point as shown and slowlylifting the vehicle with the helpof jack handle by turning itclockwise.

CAUTIONa) Do not lift the vehicle with

someone inside or with a load.b) Raise the vehicle only high

enough to remove andchange tyre.

c) Do not work under the vehiclewhen only supported by a jackas personnel injury mayoccur. Use vehicle supportstands.

d) Do not start or run the vehiclewhile supported by jack.

e) The jack must be used on firmlevel ground where possible.

5) Spare wheel is located at therear of the vehicle under the loadbody.

6) Remove the spare wheel-mounting nut. Remove the sparewheel.

7) Chock the wheel, which isdiagonally opposite to the flattyre.

JACKING POINTS, FLAT TYRES REPLACEMENT

Jack Location at Rear

Jack Location at Front

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SPARE WHEELIncase of Emergency

Spare Wheel Carrier Removaland Fitment Procedure Removalof Wheel :

a. Remove the nut which is on thelong bolt beneath the wheel rimof the spare wheel.

b. Insert the spare wheel carrierspanner through the sparewheel access hole on the loadbody at the rear and locate theshaft of the spare wheelassembly.

c. Rotate the spare wheel carrierspanner with the help of thewheel spanner in the counterclockwise direction so that therope unwinds and spare wheelstarts coming down.

d. After the spare wheel touchesthe ground, rotate further torelease the tension in rope andpull the wheel from beneath the

vehicle. e. Remove the holderbracket from the wheel rim, bylowering it and taking it out.

Spare Wheel Access Hole

10) Remove wheel-mounting nutsand take out flat tyre.

11) Roll the spare wheel intoposition and align the holes inthe wheel with studs. Thenreinstall the wheel nuts (taperend inward) and tighten themas much as you can by hand.

12) Lower the jack completelythen tighten the wheel nuts oneby one. Put the wheel coverback.

13) Restore all the tools and jackat their respective location.

14) Place the flat tyre at sparewheel location and tighten themounting nuts properly.

CAUTIONCheck tyre pressure and nuttightness of changed wheel atnearest Service station. Also,get the punctured tyre repaired.

Spare Wheel Location

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SPARE WHEEL & LIMP HOME MODEIncase of Emergency

Limp Home Mode :

When water gets accumulated inwater sedimenter “water in fuelindicator lamp” on instrumentcluster remains ON continuously.

This causes the vehicle to run on“Limp Home Mode”; there is adrastic reduction in performanceof the vehicle in Limp Home Mode.

NOTICEAt initial “Key-ON” the water infuel lamp indication on thedashboard glows for 2 secondsand goes ‘OFF’ automatically. Ifthis lamp does not glow, vehiclehas to be taken to the servicestation for verification andnecessary attention.

Fitment of Wheel :

a. Place the spare wheel beneaththe vehicle in such a way thatthe wheel disc is facingupwards.

b. Put the holder bracket insidethe wheel rim. First locate onelug on the edge of the centrehole of the wheel rim and thenlocate the other lug in any oneof the bolt holes.

c. Insert the spare wheel carrierspanner through the accesshole at the rear of the vehicleand locate the shaft on thewinch assembly.

d. Start rotating the spare wheelcarrier spanner, using the wheelspanner in clockwise directionso that the wheel starts movingup.

e. Adjust the wheel by rotating itby hand slightly so that the

locating bolt goes into one ofthe holes on the wheel rim.

f. Tighten the wheel properly, sothat it is not moving whenpushed by hand.

g. Put the nut on the long bolt frombeneath the wheel rim andtighten it. It is a good practiceto tighten the assemblyoccasionally to remove anyloosening of rope which mayoccur while running the vehicle.

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Connect Leads In The Order AsShown In The Sketch :

STARTING THE ENGINE WITH JUMP LEADSIncase of Emergency

Starting The Engine With JumpLeads :The engine with a dischargedbattery may be started bytransferring electrical power froma battery in another vehicle.Due care must be taken as anydeviation from the followinginstructions could lead to personalinjury resulting from any batteryexplosion, as well as damage tothe electrical systems in bothvehicles.

CAUTIONDo not allow battery electrolyteto come in contact with eyes,skin, fabrics or paintedsurfaces. The fluid containssulphuric acid which can causeinjury and severe damage.Wear rubber gloves, to avoidrisk of contact.

To lessen the risk of injury, weareye protection when working nearany battery.

Jump start bettry

Discharged bettry

Make sure that the batteryproviding the jump start has thesame voltage as the battery inyour vehicle (12 V). Its capacitymust be approximately thesame as the original batterycapacity. The voltage andcapacity are given on thebatteries.Do not disconnect thedischarged battery from thevehicle.Switch off all unnecessaryelectrical loads.Do not lean over the batteryduring jump starting.Do not allow the terminals of onelead to touch those of the otherlead.Apply the hand brake. Keep thegearshift lever in neutral.Do not connect the lead to thenegative terminal of thedischarged battery.The connection of the positivelead should be as far away fromthe discharged battery as

possible and as close to thestarter motor.Route the leads so they cannotget caught up with rotating partsin the engine compartment.The engine of the vehicleproviding the jump start can beallowed to run during starting.

Attempts to start the engine of thevehicle with the discharged batteryshould be made at intervals of oneminute and should not last morethan 15 seconds. After starting,allow both engines to idle forapproximately 3 minutes with theleads still connected.

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TOWING THE VEHICLE

Two Hook Location at Front

Two Hook Location at Rear

Incase of Emergency

Towing the Vehicle :For towing a vehicle, the bestway is to use a towing operator.Alternatively use a rigid tow bar.Avoid using a flexible cable orrope as your vehicle may crashinto the vehicle towing your carwhen it stops suddenly.Switch ‘ON’ the hazard warningsignals of both vehicles to warnother road users.Where possible, keep theengine idling so that powersteering assistance and brakevacuum are available.Limit the speed to 20-30 kmph.In case of brake failure, use theparking brake to control thevehicle.

Front and Rear Tow HookLocation :

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Incase of EmergencyROUTINE SERVICE

Be extremely careful to preventinjury to yourself and others anddamage to your vehicle when usingthis manual for inspection andmaintenance.

The ignition and fuel systems arehighly important in view of emissioncontrol and for efficient engineoperation. Similarly the brakesystem for safety. Don’t tamperwith them.

All inspections and adjustmentsmust be made by a qualifiedtechnician. We stronglyrecommend that all servicingrelated to these systems be doneby an authorized Tata dealer.

Owner Maintenance :

Routine Service :We highly recommend that theseitems be inspected at least everyweek.Engine Oil Level, Engine coolantLevel, Brake Fluid Level, WasherFluid Level, Battery, Tyre inflationpressure.

Do it Yourself :Improper or incomplete servicemay result in problems.Several maintenance procedurescan be done only by a qualifiedservice technician with specialtools. Improper do it ourselfmaintenance during the warrantyperiod may affect warrantycoverage. If you’re unsure aboutany servicing or maintenanceprocedure, have it done by anauthorized Tata dealer.

WARNINGMaintenance Procedures :Performing maintenance workon a vehicle can be dangerous.You can be seriously injuredwhile performing somemaintenance procedures. If youlack sufficient knowledge andexperience or the proper toolsand equipment to do the work,have it done by qualifiedtechnician.

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ENGINEPreliminary Trouble Shooting

These tips are given for your guidance. Such preliminary jobs are to be carried out in an emergency. In normalcases the problems should be attended to in an authorised Tata workshop by following the repair proceduresgiven in the Workshop Manual.

PROBLEM OBSERVED PROBABLE CAUSE ACTION TO BE TAKEN

ENGINE1. Engine not cranking Dead battery, loose or improper Get battery checked and / or

changedbattery / electrical connections Jump start using another battery

Clean & tighten connections2. Engine cranks but does not start Air in the fuel system Get the air removed by squeezing

the primer (pear) pump.Check leakages

3. Check Engine lamp continue Some faults are detected by the Get the vehicle checked andto glow, even after start ECU. rectified at Authorised workshop

4. Engine overheats Coolant level low, coolant leakages Check and correct leakagesTop up coolant

Hose collapsed/torn Get the hose replacedLow engine oil level Add oilCap not sealing properly Fit the auxiliary water tank cap

correctlyEngine cooling fans not working Get it rectifiedBrakes binding Get it rectified

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ENGINEPreliminary Trouble Shooting

PROBLEM OBSERVED PROBABLE CAUSE ACTION TO BE TAKENElectric fan not working Get defect rectifiedHigh delivery pressure in A.C. Get defect rectifiedrefrigerant circuitRadiator fins clogged Clean itRadiator water passage clogged Get it rectifiedThermostat defective Get it rectified

5. Charging indicator continuously Battery not getting charged due Get the belt tension adjustedremains ON to loose belt Replace if broken

6. Poor pickup Air in the fuel system Remove the airClogged fuel filter Clean / Replace the elementClogged air filter Clean / Replace the elementClutch slipping/out of adjustment Get it rectifiedBrakes grabbing Get it rectified

7. Belt squeal Loose belt Get belt tension adjustedBelt glazed Get belt replaced

8. Low engine oil pressure indicator Pressure transducer faulty, Do not run the engine extensively.‘ON’ when engine is running even and/or oil pump faulty Take the car to the nearestthough engine oil level is within Authorised Service outlet & getmaximum/minimum marking the fault rectified

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CLUTCH & BRAKEPreliminary Trouble Shooting

PROBLEM OBSERVED PROBABLE CAUSE ACTION TO BE TAKEN

CLUTCH1. Clutch slipping Improper pedal travel Adjust pedal travel

Oil on clutch disc Clean or replace disc

2. Noisy clutch Pressure plate & diaphragm Contact Authorised Servicespring rattling outlet

Release bearing broken/worn out Replace3. Clutch hard shifting Check push rod of the slave Replace slave cylinder if

cylinder for any stickiness necessary

BRAKES1. Poor brakes Insufficient brake fluid Get the brake fluid filled

Air in the system Get the air removedPedal travel excessive due to Rectify automatic adjusterexcessive shoe gapVacuum leakage Rectify the leakageBrake oil (line) leaking Replace the leaking lineOil on the drum/liners Get the liners cleaned/

replace seals if leakingWorn brake lining / pads Get the liners replacedDefective / worn parts Get them replaced

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BRAKES & STEERINGPreliminary Trouble Shooting

PROBLEM OBSERVED PROBABLE CAUSE ACTION TO BE TAKEN2. Brake pulling to one side Oil on the brake lining Clean the brake lining

One side shoe/pad worn Get the shoe/pad replacedLoose brake anchor plate Tighten the boltsOne side brake pipe clogged Get the brake line cleanedDefective tandem master Rectify/Replace tandem mastercylinder cylinder

3. Brake Squeal Defective brake lining ReplaceGlazed lining Clean or replace liningLoose rivets. Install rivets properlyWrong lining Install correct liningShoe return spring broken ReplaceFront pads rubbing on the disc Get it corrected

STEERING SYSTEM1. Hard steering Less fluid in the power Get the fluid topped up to the

(For power steering) steering tank correct levelAir in the system Get the air removed by bleeding

the systemLoose pump belt Get the belt correctly adjustedLow tyre pressure Adjust to correct value

2. Poor Returnability Grabbing of linkages Check & rectifySteering gear disturbed Check & adjust

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ELECTRICAL & SUSPENSIONPreliminary Trouble Shooting

PROBLEM OBSERVED PROBABLE CAUSE ACTION TO BE TAKENELECTRICAL1. Battery charge & engine oil Battery terminal loose or Check connections

pressure lamp in cluster not disconnectedoperating when key is in 'IGN' Battery completely dead Get the battery properlyposition Bulb fused connected

Fuse blown Get the battery chargedLoose/open connections Get the alternator & charging

circuit checkedGet the bulb checked

2. Non functioning Electrical Fuse blown in the circuit Replace the fuse if blownaccessories such as power Loose connectors. Get the connection properlywindows, head lamps, fuel & tightened/fixedtemperature gauge, RPM meter, Circuit relay/controllers loose in Fix the relay firmlywiper & washer unit and all the baselamps etc. Defective components Get the defective components

replaced at an AuthorisedService outlet

SUSPENSION

1. Abnormal or excessive tyre wear Tyre out of balance Check balance and/or adjust ifrequired

Steering geometry disturbed Adjust steering geometryTyres not adequately inflated Adjust tyre pressure

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SUSPENSIONPreliminary Trouble Shooting

PROBLEM OBSERVED PROBABLE CAUSE ACTION TO BE TAKEN

Wobbly wheel or tyre Replace wheel or tyreDefective tyre Replace tyreHub play not proper Adjust hub playBrake grabbing Check and rectifyExcessive braking Modify driving habit

2. Abnormal noise from front end Worn, sticky or loose tie Replace tie rod end, suspensionrod ends, lower ball joints OR arm, tie rod or drive shaft jointstie rod in side ball joints.Warning noise for pad wear Replace pador mounting Repair mountingWorn suspension arm bushings ReplaceLoose wheel nuts Tighten wheel nutsLoose suspension bolts or nuts Tighten suspension bolts or nutsBroken or damaged wheel bearing ReplaceExcessive hub play AdjustLoose caliper housing bolts Check & tighten

3. Suspension bottoms Over loaded Check loading

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FUSES & RELAYSElectrical Maintenance

1. Fuse & Relay Box2. Maxifuse Box

2

1

Cabin Fuse Box

Maxifuse Box

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83

FUSES & RELAYSElectrical Maintenance

FUSE

S &

REL

AY B

OX

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84

Bulb Specification :DESCRIPTION LOCATION CAP TYPE SPECIFICATION QTY

Headlights (Halogen II4) Head lamp P43t 12V 60/55W 2Front direction indicator Front BAU 15s 12V 21W 2Side repeater indicator Side W2.1x9.5d 12V 21W 2Tail lamp rear direction indicator Rear BA15s 12V 21W 2 Stop Light Tail Lamp BA 15s 12V 21W 2 Parking Light Head lamp BA9s 12V 4W 2

Tail Lamp BA 15s 12V 10W 2Registration no. plate light Registration plate light BA 15s 12V 10W 2Reverse Indicator lights Tail Lamp BA 15s 12V 21W 2Warning and illumination lamps Instrument ClusterHead light (main beam) 1.4 W wedge type 12V 1.4W 1Turn Indicator 1.4W wedge type 12V 1.4W 2Battery charging indicator 1.4W wedge type 12V 1.4W 1Glow plug Indicator 1.4W wedge type 12V 1.4W 1Low oil pressure indicator 1.4W wedge type 12V 1.4W 1Malfunction indicator lamp (MIL) 1.4W wedge type 12V 1.4W 1Check Engine indicator 1.4W wedge type 12V 1.4W 1Over speed indicator 1.4W wedge type 12V 1.4W 1Water in fuel sedimenter indicator 1.4W wedge type 12V 1.4W 1Brake fall + Parking brake indicator 1.4W wedge type 12V 1.4W 1Rear fog lamp 1.4W wedge type 12V 1.4W 1Gauge illumination light 1.4W wedge type 12V 1.4W 6Driver compartment light Cab roof SV 8.5 12V 10W 1 (For Pick-up Cab)Driver compartment light Cab roof SV 8.5 12V 10W 2 (For Crew Cab)Engine compartment light Engine compartment BA 15s 12V 21W 1A/C Back Light A/C Control Hsg. W2 x 4.6d 12V 1.2W 6

Electrical MaintenanceBULB SPECIFICATION

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The headlamps are provided withHalogen lamp and leveling devicewith single fitment for providingstraight ahead illumination of theroad for long distance or a dip beamwhich il luminates the roadimmediately ahead for shortdistance visibility. Use dip beam toavoid inconvenience /blinding thedrivers of oncoming vehicles.

Head lamps adjustment should bealways carried out at the authorizedservice outlet with the help of thescreen.

Headlamp Bulb Replacement:

Switch OFF the headlamps &ensure that the bulb is not hot.

Open the engine hood andremove the headlamp protectivecover of the main / dip beamlamp.

BULB REPLACEMENTRemove the locking clip toremove the main beam lamp withconnector.

Disconnect the lamp from theconnector and Replace withnew one with same rating andwith right orientation.

Connect and place the bulbright position, lock with clip andscrew the protective cover.

Remove other bulbs by twistingthe bulb holder, afterreplacement fix holder.

Switch On the headlamp andcheck lightning.

CAUTIONDon’t touch or clean theheadlampas it will damage themirror finish of the surface.

1. Rear Protective cover2. Main beam lamp3. Parking lamp4. Direction lamp5. Head lamp leveling motor

Electrical Maintenance

The horizontal and verticaladjustments of the headlamp beamcane be done by setting the knobof leveling motor.

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BULB REPLACEMENTElectrical Maintenance

When replacing the headlampsbulb, handle it by gripping the cap.Protect the glass from contactswith your skin or hard object. Ifyou touch the glass, clean it withspirit & clean cloth. Afterreplacement of the bulb in anyemergency get the head lampadjustment done at an authorizedservice outlet at the earliest.

CAUTIONHalogen head lamp bulbs getvery hot when illuminated. Oil,perspiration or a scratch on theglass can cause the bulb tobreak due to the heat

Tail Lamp :

Bulbs Replacement :Remove all bulbs by twisting thebulb holder after replacement fixthe holder.

3

3

2

11

3

2

Fog Lamps :Front and Rear fog lamps can beremove by twisting the bulb holder.After replacement fix the holderwith the bulb.

Registration Plate Lamps :Two concealed lamps are providedfor il lumination of the rearregistration number plateHigh Mounted Stop Lamp :High mounted stop lamp isincorporated in the rear tail gateat the rear and it glows wheneverservice brake is applied.

1. Parking Lamp2. Direction indicator Lamp3. Parking & Stop Light4. Rear fog lamp & Reflector

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WASHING & CLEANINGVehicle Care

solvents that remove the top layerof the finish coat. Polish yourVehicle, if the finish does not regainits original shine after using wax.Cleaning of Carpets :Vacuum clean the carpet regularlyto remove dirt. Dirt will make thecarpet wear out faster. Periodicallyshampoo the carpet to keep itlooking new.Use carpet cleaners (preferablyfoam type). Follow the instructionsthat come with the cleaner, applyingit with a sponge or soft brush. Keepthe carpeting as dry as possible bynot adding water to the foam.Cleaning of Windows, Front &Rear Glasses :Clean the windows inside andoutside with commercially availableglass cleaners.

Vehicle Care :The Vehicle is subjected to manyexternal influences such as climate,road conditions, industrial pollutionand proximity to the sea. Theseconditions demand regular care ofthe Vehicle body. Dirt, insects, birddroppings, oil, grease, fuel andstone chippings should be removedas soon as possible.

Washing :Do not wash the Vehicle in directsunlight, wash in shade. Spray theVehicle thoroughly with a cold waterjet (Vehicle on a washing pit orhoist). Mix Vehicle shampoo in thewash water. No solvent (fuel,thinner) need be used.

NOTICEAvoid wiping of painted surfacein dry condition as it may leavescratches on the paintedsurface.

Use a soft bristle brush, sponge orsoft cloth and rinse it frequentlywhile washing. When you havewashed the whole exterior, dry it witha chamois or soft cloth. After dryingthe Vehicle, inspect it for chips andscratches that could allow corrosionto start. Apply touch up paint wherenecessary.

NOTICEInteriors of the Enginecompartment cleaning with highpressure water should beavoided.

For Vehicles With Rear ViewCamera :Use cover for camera duringwashing.Polishes :Polishes and cleaners can restoreshine to the painted surface thathas oxidised and become dull. Theynormally contain mild abrasives and

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WASHING & CLEANINGVehicle Care

This will remove the haze that buildsup on the inside of windows. Use asoft cloth or paper towels to cleanall glass and plastic surfaces.Maintaining The Vehicle WhenNot In Extended Use :Park the Vehicle in covered, dryand if possible well-ventilatedpremises. Engage a gear.Remove the cables from the batteryterminals (first remove the cablefrom the negative terminal).Make sure the handbrake is notengaged.Clean and protect the painted partsusing protective wax.Clean and protect the shiny metalparts using commercially availablespecial compounds.Sprinkle talcum powder on therubber windscreen wiper and rear

window wiper blades and lift themoff the glass.Slightly open the windows.Cover the Vehicle with a cloth orperforated plastic sheet. Do not usesheets of imperforated plastic asthey do not allow moisture on theVehicle body to evaporate.Inflate the tyres as per thespecification and check it atregular intervals.Check the battery charge every sixweeks.Do not drain the engine coolingsystem.Proper Cleaning :In order to protect your vehicle fromcorrosion it is recommended thatyou wash your vehicle thoroughlyand frequently in case :

1. There is a heavy accumulationof dirt and mud especially on theunderbody.

2. It is driven in areas having highatmosphere pollution due tosmoke, soot, dust, iron dust &other chemical pollutants.

3. It is driven in coastal areas.4. The underbody must be

thoroughly pressure washedafter every three months.

In addition to regularly washing yourvehicle, the following precautionsneed to be taken.Please Take The FollowingPrecautions :1. Always wash your vehicle in

shade, avoiding direct exposureto sunlight during washing.

2. Dry wiping your vehicle maylead to the formation of

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GENERAL PRECAUTIONSVehicle Care

scratches and hence alwaysuse a soft cloth and clean waterwhile wiping your vehicle.

3. Always keep your vehicle parkedin a well ventilated shade.Exposure to heat with entrappedmoisture promotes corrosion.

4. Avoid driving on gravel roads,as the possibility of paint chipoff due to the impact of stonesis high. If you are driving onfreshly tarred road, checkimmediately afterwards for anystains & clean them.

5. External contamination in theform of sap or industrial fall-out may mar or develop spotson a new finish. Hence avoidparking your vehicle neartrees, which are known to dropsap, or near factories, whichgive out heavy smoke.

6. The acid content in birddroppings may damage thenewly painted f inish andhence any bird dropping mustbe immediately washed off.

It is suggested to wash the vehicleby hand with cool and clean waterusing a soft cloth or sponge. Pleasedo not use soap but a car shampoorecommended by your dealer.

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Maintenance

Opening & Closing the BonnetOpening :1. Ensure that the vehicle is in

neutral gear with the parkingbrake applied.

2. Pull the bonnet release leverlocated under the right handcorner of the dash board. Thebonnet will pop up slightly.

3. Raise the bonnet slightly andwith your finger lift thesecondary lock lever locatedunder the bonnet centre.

4. Lift the bonnet up. Pull thebonnet stay rod from its clipand insert the free end into theslot in the bonnet, slide stay rodoutward to secure.

OPENING & CLOSING THE BONNET

Bonnet Release Lever

Location of Bonnet Release Lever

Bonnet Opening Secondary Lock Lever

Closing :

1. To close the bonnet disengagethe stay rod & clamp it properly.

2. Lower the bonnet and drop itfrom a short height to shut.

CAUTIONEnsure that the bonnet isproperly locked before driving.Do not press the bonnet ontothe bonnet lock.

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MaintenanceENGINE COMPARTMENT

ENGINE COMPARTMENT ( 2.2L DICOR)

1. Brake fluid reservoir 2. Engine Oil Filling Cap 3. Clutch fluid reservoir4. Engine Oil Dipstick 5. Power steering reservoir 6. Fuse Box7. E.C.U. 8. Fuse box / Relay 9. Battery

10. Radiator Cap 11. Auxiliary tank 12. Wind shield washer container13. Air Filter 14. Service Indicator

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Air Filter :AIR FILTER & ENGINE OIL

Manintenance

1. Engine Oil Filling Cap 2. Dip Stick

Engine Oil Level Checking :

Warm up the engine to normaloperating temperature.Turn it off and wait 5 minutes forthe oil to return to the oil panBe sure the Vehicle is on a levelsurface.Pull out the dipstick, wipe it clean,and reinsert if fully.Pull it out again and examine theoil level. It should be between ‘Min’& ‘Max’ level. If not, top up withrecommended engine oil.

The air filter element should beperiodically cleaned. Replace theair filter element with a new one,when air cleaner service indicatorshows red band, even aftercleaning.Always use a genuine air filterelement.

The air filter is located on the LHside of the engine compartment.a) When a vehicle is driven under

dusty conditions, frequent

cleaning and replacement of theair-cleaner element isnecessary.

b) Clogged air-cleaners lead togreater intake resistance andresult in increased fuelconsumption. Using lowpressure compressed air, blowoff dust on the air cleanerelement. If the air cleanerelement appears to be choked,replace it with a new one.1. Air Filter 2. Service Indicator

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ENGINE COOLANT & BRAKE FLUIDMaintenance

Engine Coolant Level :

1. Engine Coolant Filling Cap2. Radiator Cap

The coolant level is visible throughthe translucent reservoir. It shouldbe between max. & min. marks. Ifit seems less, add premixed coolantinto the auxiliary tank upto the max.mark. Put the cap back properly.

CAUTIONNever remove the filler cap whenthe engine is hot. Use only brandedpremixed ready to use coolant.

WARNINGDo not remove radiator cap whenengine is hot. It may causeserious injury.

Brake Fluid Level :

The level of the brake fluid must bebetween the min. & max. marks onthe side of the brake fluidcontainer. If the level falls below themin. mark, add recommendedbrake fluid. (Refer chapter - Fuels,coolants & lubricants)In case of spongy or hard pedal orlow brake efficiency, pleasecontact the nearest AuthorisedService outlet.

Brake Fluid Container

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Power Steering Reservoir :CAUTION1. Do not allow brake fluid to

make contact with the skin oreyes.

2. Do not allow brake fluid tosplash or spill on the paintsurface as it will damage thepaint. In case of spillage,wipe it off immediately.

POPWER STEERING FLUIDManintenance

The level of the power steering fluidmust be between the min. & max.marks on the side of the powersteering fluid container. If the levelfalls below the min. mark, addrecommended fluid. (Refer chapter- Fuels, coolants & lubricants)In case of leakage or hard steering,please contact the nearestAuthorised Service outlet.

CAUTIONDo not start the engine withoutoil in the power steering system.

Power Steering Fluid Container

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LOAD CONSCIOUS PRESSURE REDUCING VALVEMaintenance

Load Conscious PressureReducing Valve (LCRV) :A LCRV is required in the brakesystem during severe braking.That time, most of the car weightis transferred to the front, and thefront brakes do most of thebraking. The rear wheels are leftwith but little traction and in thiscondition, under high pressure,they have a tendency to skid.The valve is installed in the line tothe rear brake drum. During heavybraking the valves limits thepressure to the rear wheels & thisallows rear wheels to keep turninginstead of locking up and skidding.If any alteration is done in Rearsuspension the performance ofthis valve will be impaired.The valve stem gap should beadjusted whenever rear spring ischanged.

Adjustment :Valve Setting Method :With link ‘C’ in hole ‘B’ andvehicle in unladen condition, setthe gap between valve piston stem& adjusting screw to 1.0 -1.2 mm

(as shown in figure) with the helpof adjusting screw and locknut.Tighten locknut of adjusting screw.Then engage the link ‘C’ in hole ‘A’i.e. upper hole of the bracket.

LCRV mounting bracket on Frame

Hole “A” - After LCRV gap setting,clamp the LCRV link here

LCRV Unit

Hole “B” - Initialy insert LCRV linkhere & set the LCRV gap

LCRV mounting bolted on bracket

LCRV LINK mounting bracket onRear Axle

LINK “C”

X

1.0 to 1.2mmLever

Lock Nut

Adjusting Nut

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CLUTCH FLUID & FUEL SEDIMENTERMaintenance

Clutch Fluid Level :

Water Draining from SedimenterClutch Fluid Container

The level of the clutch fluid must bebetween the min. & max. marks onthe side of the clutch fluid container.If the level falls below the min. mark,add recommended clutch fluid.(Refer chapter - Fuels, Coolants &Lubricants)

Water Draining Procedure fromSedimenter :

The water sedimenter is part of thefuel filtration system, fitted to thechassis frame, near fuel tank belowthe vehicle. It is used in the fuelsupplying system in order to reducethe water content in the fuelprovided to the DICOR system.A water sensor is fitted to the watersedimenter in order to indicate tothe driver that the sedimenter hasto be drained. Whenever water infuel sedimenter indicator glows ininstrument cluster, the water need

to be drained from the sedimenter.Water drain operation to be doneon sedimenter.Procedure :1 Stop the engine, and wait until

pressure stabilizes.2 Unclip one of the hydraulic

connections (either inlet oroutlet) and the electric connectorof the water sensor.

3 Place a container underneaththe water sedimenter.

4 Unscrew the water sensor about2-3 turns.

5 Wait until all the water hasdrained out of the watersedimenter.

6 As soon as the flow is free ofwater, screw the water sensorto the required torque.

7 Clip the hydraulic connector andthe electric connector to thewater sensor.

8. Use hand primer / Pear pumpto refill the line before restarting.

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FUEL FILTERS & PRIMING / PEAR PUMPMaintenance

Fuel Filters :

Fuel Filter

Fuel filter separates dust particlesfrom the fuel & allows clean fuel into the common rail system. It alsoseparates & stores water.

Priming Pump / Pear Pump :

Priming / Pear Pump

This is used for priming the fuelmanually after overhauling of theengine or after refitment of fuellines or after changing either fuelfilter or sedimenter Pump, bymeans of priming pump / pearpump until all air in the fuel lineremoved. Before cranking theengine ensure that there is no airin the fuel system.

NOTICEDo not loosen the HP lines ofDICOR system for bleeding theair from fuel system.

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WINDSHIELD WASHER & TYRESMaintenance

Windshield Washer :

Windshield washer fluid containeris located behind the front righthand side panel and its filler neckis provided near auxiliary tank inthe engine compartment.

NOTICEDo not add detergent or anysolvent in the windshield washingwater.

Tyres : to tell if pressure loss is causedby a tyre problem and not byvariation between gauges.

Keeping the tyres properly inflatedgives you the best combination ofriding comfort, handling, tyre lifeand better fuel efficiency.

Over inflation of tyres makes thecar ride bumpy and harsh. Tyresare more prone to uneven wearand damage from road hazards.

Under inflated tyres reduce yourcomfort in car handling and areprone to failures due to hightemperature. They also causeuneven wear and more fuelconsumption.

Check for inflation and condition ofyour car tyres periodically.

Inflation :Check the pressure in the tyreswhen they are cold.

You should have your own tyrepressure gauge and use it at alltimes. This makes it easier for you

1. Under inflation -Excessive Side Tread Wear

2. Correct Tyre Pressure -Uniform Tyre Wear

3. Over inflation -Excessive Centre Tread Wear

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TYRES

CAUTIONEvery time you check inflationpressure, you should alsoexamine tyres for damage,foreign objects & wear.

Recommended Tyre Pressures :For 4x2 Vehicle

CAUTIONBumps or bulges in the treador the side of the tyre.Replace the tyre if you findeither of these conditions.Cuts, splits or cracks in theside of the tyre. Replace thetyre if you notice this on thefabric or cord.Excessive tread wear or nonuniform tyre wear.

Repairing a Tyre/Tube :Mark the tyre position suitably(if original colour dot mark is notvisible) with respect to valve stemhole to ensure that the tyre isrefitted in the original location onthe wheel rim.Ensure that balancing weights arenot disturbed during removal oftyres.

Check the balance weight prior tothe removal of the tyre. If found

PSI

Laden

Unladen4444

WheelsVeh.

condition

FR

Tyre 215/75 R16

4450

FR

For 4x4 Vehicle

Maintenance

Tyre 205 R16Veh.condition PSI

Laden

Unladen2929

Wheels

FR

2944

FR

loose, mark its location on the rim& refit properly.

Balance the wheel after everydismantling and assembly of tyreon the wheel rim.

While fitting wheels on the vehicleensure that wheel pins are free fromdust, scratches, dirt, dents, etc.

Ensure the tube being replaced hasthe correct valve.

NOTICEDo not apply any oil on the wheelpins. Wipe off the oil if present.

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Special Care for Tubeless Tyres : (if fitted)

1. While removing tyre from wheel rim and mountingit back on wheel rim, take precautions not to damagetyre bead. Use tyre removal and assemblymachines. Damage or cut on tyre bead may causegradual loss of air and deflation of tyre.

2. Do not scratch inside of tubeless tyre with metallicor sharp object. Tubeless tyres are coated withimpermeable layer of rubber from inside which holdsthe air inside the tyre. Removal of this layer due toscratching may cause gradual loss of air anddeflation.

3. If wheel rim gets damaged in service, get the wheelrim repaired/replaced immediately. Running thevehicle with damaged rim may cause deflation oftyre and subsequent dislodging of tyre from rim.

4. Maintain recommended inflation pressure. Over-inflation, in particular, may cause puncture orbursting of tyre.

NOTICELife and wear pattern of tyres depends on variousparameters like tyre pressure, wheel alignment,wheel balancing, tyre rotation, etc. It also largelydepends on vehicle speed, load carried, usage,driving habits, road conditions, tyre quality, etc. Incase fault is suspected to be due to poor quality oftyres, the same may be taken up with concernedtyre manufacturer.

Tyre Rotation :To help increase tyre life and distribute wear moreevenly you should have tyres rotated at specifiedintervals or earlier depending on the operation of vehicle.The illustrations shows how to rotate tyres when normalspare wheel is included in tyre rotation.

CARE FOR TUBELESS TYRES & TYRE ROTATIONMaintenance

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WHEEL ALIGNMENT, BALANCING, CATALYTIC CONVERTER MAINTENANCEMaintenance

Wheel Alignment :

Incorrect wheel alignment causesexcessive and uneven tyre wear.Check wheel alignment atspecified intervals. Wheelalignment values are given below :

Caster : 30 ± 30 ’

Camber : 00 ± 30 ’

Toe in : 2 to 5 mm

On vehicles with torsion barsuspension, wheel alignmentneeds to be checked only afteradjusting chassis height as perprocedure. Chassis height for 16inch tyre is 510 ± 3 mm Checkand maintain tyre pressureperiodically to obtain longer tyrelife.

Wheel Balancing :

Wheels of your vehicle arebalanced for better ride comfortand longer tyre life. Balancingneeds to be done whenever tyreis removed from rim.1. Permissible imbalance for tyre

with rim = 250 gm-cm max.2. Total balance weight should be

within 140 gms on each side.3. Relocate the tyre if the weight

required to balance is morethan 140 gms.

4. Balance weights are availablefrom 10 gms to 140 gms insteps of every 10 gms and from15 gms to 135 gms in steps ofevery 10 gms.

5. Do not use more than onebalance weight on one side.

Care for the Catalytic Converter

The catalytic Converter does notrequire any special maintenancehowever, following precautionshould be taken for the effectivefunctioning of the converter andto avoid damage to the Converter.

It is mandatory to use Dieselfuel with sulphur content lessthan 0.035 %. Use of any otherdiesel fuel can increase thepollutants.

CAUTIONAvoid parking the vehicle overinflammable materials, such asdry leaves, grass etc., as theexhaust system is hot enoughto initiate ‘FIRE’.

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Check the battery for properelectrolyte level and corrosion onthe terminals.

1. Check the battery forelectrolyte level against themarking on the battery outercase.

2. Check the battery terminals forcorrosion (a white or yellowishpowder). To remove it, cover theterminals with a solution ofbaking soda. It will bubble upand turn brown.

3. When this stops wash it off withplain water. Dry off the batterywith a cloth or paper towel.

4. Coat the terminal with petroleumjelly to prevent future corrosion.

Use a proper spanner to loosenand remove cables from theterminals.

Always disconnect the negative(-ve) cable first and reconnectit last.

Clean the battery terminals with aterminal cleaning tool or wire brush.Reconnect and tighten the cables,coat the terminals with petroleumjelly.Ensure that battery is securelymounted.If you need to connect the batteryto a charger, disconnect bothcables to prevent damage to thevehicle’s electrical system.

Battery : NOTICEDuring normal operation, thebattery generates gas which isexplosive in nature, a spark oropen flame can cause thebattery to explode causing veryserious injuries.Keep all sparks & open flamesand smoking materials awayfrom the battery.Getting electrolyte in your eyesor on the skin can cause severeburns. Wear protective clothingand a face shield or have askilled technician to do thebattery maintenance.The battery contains sulphuricacid (electrolyte) which ispoisonous and highly corrosivein nature.

BATTERYMaintenance

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FUEL, LUBRICANTS & COOLANTSImportant Technical Information

ITEM SPECIFICATION COMPANY & BRAND QTY

ENGINE OIL 15W40 API CH4 CASTROL - Castrol GTX (Diesel)+MB 228.3 HPCL - HP Dieselino (T)CH4 7.5 Litres

EXXON MOBIL - Mobil Super 1000 TM 15W/40

COOLANT Class-II/JIS K2234 SUNSTAR - Golden Cruiser Premium 1400M Approx.(Antifreeze agent + HPCL - HP Thanda Raja P 8 - 8.5 LitresSoft water) CASTROL - Radicool

GEARBOX OIL Synthetic 75W90 CASTROL - Castrol Syntro 75W90.GL4GL4 HPCL - Gear Oil HP Gear EP 75W90(T) 1.6 Litres

EXXON MOBIL - Mobillube 1 SHC 75W90

REAR AXLE OIL & 85W140 WITH CASTROL - Castrol extra long life Rear axle oil 85W-140 2.2 Ltrs (Rear)FRONT LIVE AXLE Anglamol 6043 HPCL - HP Gear Oil XP 85W140 T2 1.2 Ltrs (Front)OIL (7 %) EXXON MOBIL - Mobilube HD 85W140

POWER STEERING Power Steering CASTROL - TQDOIL Oil Dexron IID HPCL - HP -ATF Dex II 1.4 Litres

EXXON MOBIL - Mobil ATF 220

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NOTICE

WARNING

Fuel : High Speed dieselconforming to IS1460 or EN 590 orequivalent is recommended to beused as fuel.At very low temperatures fluidity ofdiesel may slow due to paraffinseparation. It is thereforenecessary to mix supplementaryfuel with summer or winter gradediesel. The supplementary fuel tobe used is kerosene or aviationturbine fuel.Ratio for mixing of supplementaryfuel and diesel are shown in thetable.

Do not mix gasoline or alcoholwith diesel. This mixture cancause an explosion.

CAUTIONDue to the precise tolerance ofdiesel injection systems, it isextremely important that the fuelbe kept clean and free from dirtor water. Dirt or water in thesystem can cause severedamage to Dicor system.

Do not add fuel additives withdiesel.

Use low sulphur content fuel havinga cloud point that is at least 10degrees below the lowest expectedfuel temperature. Cloud point is thetemperature at which wax crystalsbegin to form in diesel.

Viscosity of the fuel must be keptabove 1.0 centistoke to provideadequate fuel system lubrication at400C.

Important Technical InformationFUEL, LUBRICANTS & COOLANTS

Ambienttemperatureupto Deg. C

PercentageSummer

grade dieselSupplementary

fuel

Upto 00 to -10

-10 to -15

1007050

03050

Ambienttemperatureupto Deg. C

PercentageWinter

grade dieselSupplementary

fuel

Upto -15-15 to -20

-20 and below

1007050

03050

Care should be taken that dieseland supplementary fuel arethoroughly mixed before filling.

Sulphur Content : (0.005% BS-III)

Where an oxidation catalyticconverter is fitted, it ismandatory to use Diesel fuelwith sulphur contents as under.Use of any other diesel fuel canincrease the pollutants.

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Important Technical InformationENGINE OIL

Engine Oil : Recommendedgrade of engine oil confirming tomulti grade oil 15W40 API CH4 andMB 228.3 specifications & rangeof ambient temperature at whichthese can be used are as follows :

Ambienttemperatureupto Deg. C

Engine oil grade

-10 & above-20 to 0

-10 & below

SAE 15W40SAE 10W30SAE 5W20

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Important Technical Information

Rear Axle (Spicer)A. Oil Level Plug B. Drain Plug

Transfer Case (4x4 vehicles)A. Oil Level Plug, B. Drain Plug

Gear box (G-76)A. Oil Level Plug, B. Drain Plug

OIL FILLING & DRAIN POINTS

Front Live Axle (4x4) (Spicer)A. Oil Level Plug, B. Drain Plug

Engine (2.2 L Dicor)A. Oil Filling Cap B. Dip Stick

Engine Oil Drain Plug

A

B

B

A

A

B

A

B

AB

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TECHNICAL SPECIFICATION

Important Technical Information

1. ENGINE :

Model : TATA 2.2L DICOR BS-III

Type : Direct Injection Common Rail TurboCharged Intercooled Diesel Engine

No. Of Cylinders : 4 Inline

Bore / Stroke : 85 mm x 96 mm

Capacity : 2179 cc

Max. Engine Output : 103 kw (140 ps) at 4000 rpm asper 80/1269/EEC

Max. Torque : 320 Nm (32 mkg) at 1700-2700rpm as per 80/1269/EEC

Compression Ratio : 17.2 : 1

Firing Order : 1 - 3 - 4 - 2

2. CLUTCH :

Type : Single plate dry friction diaphragmtype.

Outside diameter : 240 mmof clutch lining

Friction area : 503 sq. cm. (Approximately)

3. GEAR BOX :

Model : GBS-76-5/4.1 with overdrive

Type : Synchromesh on all gears.

No. of gears : 5 forward, 1 reverse.

Gear Ratios : 1st - 4.102nd - 2.223rd - 1.374th - 1.005th - 0.77Rev. - 3.75

4. TRANSFER CASE (4X4) :

Type : With electrical shift arrangementmounted on gear box with electroniccontroller unit.

Drive Option : 4x2 - Ratio - 1:14x4 High - Ratio 1:14x4 Low - Ratio 1:2.48

5. REAR AXLE :

Type : Single Reduction, Salisbury TypeRear Axle with Hypoid Gears andSemi-Floating Axle Shafts & Withlimited slip differential.

Ratio : 3.73 (41/11)

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TECHNICAL SPECIFICATION

Important Technical Information

Load conscious : Provided for rear brakespressure reducingvalve

Parking brake : Cable Operated MechanicalLinkages Acting on Rear Wheels.

10. FRAME

Type : Ladder Type Cranked Frame withBoxed Section Long Members &Welded Cross Members. Depth :110 mm (max.) Width : 60 mm. TowHooks at Front & Rear.

11. SUSPENSION

Front : Double Wishbone Type with Torsion Bar.

Rear : Parabolic Leaf Springs.

Shock Absorber : Hydraulic Double Acting TelescopicType at Both Front & Rear.

Antiroll Bar : At Front.

12. WHEELS & TYRES :

Tyres & Tyre Pressure: 205 R 16 Tubeless tyre (For 4X2)Unladen: Front 29 PSI (200kPa)

Rear 29 PSI (200kPa)Laden: Front 29 PSI (200kPa)

Rear 44 PSI (300 kPa)

6. FRONT AXLE

Type : Independently suspended

7. LIVE FRONT AXLE

Type : Independently suspended withautomatic hub locks

Ratio : 3.73 (41/11)

8. STEERING

Type : Power Steering

Ratio : 18.2:1, 18.9:1 (Alternate)

Steering Wheel : 400 mm dia. 4 Spoke Steering Wheel

Steering column : Provided with Tilt Mechanism forHeight Adjustment.

9. BRAKES

Service brakes : Vacuum Assisted IndependentHydraulic Brakes on Front and Rearwheels through Tandem MasterCylinder & Tandem Booster.

Front brake : 296 dia. Ventilated Disc Brakes withTwin Pot Calliper.

Rear brake : 295 dia. Drum Brake with AutoAdjuster.

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TECHNICAL SPECIFICATION

Important Technical Information

215/75 R 16 Tubeless tyre (For 4X4)Unladen: Front 44 PSI (300kPa)

Rear 44 PSI (300 kPa)Laden: Front 44 PSI (300 kPa)

Rear 50 PSI (350 kPa)

Wheel rims : 5.5 J x 16 (Premium versions - Alloywheel rim ; Economy versions-Steel wheel rim).

Wheel rim covers : Standard with Steel Wheel Rim(Economy Versions).

No. of wheels : Front - 2, rear - 2, spare - 1

13. FUEL TANK :

Type : Made Out of Steel Sheet.

Capacity : 65 litres

14. ELECTRICAL SYSTEMS

System Voltage : 12 volts (-ve earth)

Alternator Capacity : 125 Amperes.

Battery : 12 V, 80 Ah MF

15. PERFORMANCE :

Max. speed : 160 kmph

Max. gradeabilityat rated GVW : 41 % (4x2 vehicle)

41 % (4x4 vehicle 4x2 mode)90 % (4x4 vehicle 4x4 mode)

16. WEIGHTS (kg) :

Complete vehicle kerbweight as per ISO:1176(with sparewheel and tools): 1860 (FAW-1070) (RAW-790)

Gross Vehicle Weight : 2950 (FAW-1240) (RAW-1110)

Max. Permissible FAW : 1400

Max. Permissible RAW : 1800

17. LOAD BODY - Crew Cab :

Type : Pick-up type all Steel, Non - IntegralLoad Body, 90 deg Hinged Rear TailGate with Latch and Handle atCentre.

18. NET LOADING SPACE IN METERS :

(Len. x Wid. x Ht.) : 1.43 x 1.41 x 0.40 - Crew Cab

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INFORMATION AT A GLANCE - DIMENSIONS

Important Technical Information

DIMENSIONS - TATA XENON CREW CAB

Wheel Base : 3150Track Front : 1571Track Rear : 1571

Overall Length : 5125Max. Width : 1860

Front Overhang : 870

Rear Overhang : 1105Overall Height (Unladen / laden) : 1765 / 1730Minimum Turning Circle Dia. : 12.0 m

Minimum Turning Clearance Circle Dia. : 12.9 mGround Clearance : 200 mm

19. MAIN CHASSIS DIMENSIONS AS PER ISO:612 IN MM NOMINAL)

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LOCATION OF AGGREGATE NUMBER

Vehicle Identification

Gearbox Number (G-76)

Chassis Number plate on Tie Member Vehicle identification Number (VIN) onFrame

Transfercase Number Plate (4x4)Engine Number Punch Location

Vehicle identification Number

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LOCATION OF AGGREGATE NUMBER

Vehicle Identification

Rear Axle Number (Spicer)Front Live Axle Number (4x4)

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PDI ServiceSERVICE RECOMMENDATIONS

PRE- DELIVERY INSPECTION :

Following jobs are to beperformed at PDI :1. Wash & Clean the vehicle

thoroughly.2. Road test the vehicle. Check

for proper functioning ofEngine, Clutch, Transmissionaggre-gates, steering, Brakesetc.

3. Check vehicle behaviour :Pulling to LH/RH, Wobbling,Self centering, Accelerationetc.

4. Static test : Start engine &check for idling rpm &Maximum rpm (look for anyabnormal noise), Watertemperature etc.

5. Check Engine oil level. Levelis acceptable if found betweenmid and max mark.

6. Check for any leakages ofengine oil.

7. Check for any leakages in thefuel system.

8. Check Coolant level intransparent auxiliary tank.Acceptable if level foundbetween mid and max.

9. Check for any Leakages ofcoolant.

10. Drain water from fuel waterseparator.

11. Check hose, clamps & pipesat all locations in coolingsystem.

12. Check hose, clamps & pipesat all locations in air intakesystem.

13. Check for leakages of gearbox oil.

14. Check for Proper fitment ofgear shift level rubber boot.

15. Check level of Clutch andbrake fluid. Acceptable iffound between mid and max.

16. Check for oil leakages inclutch/brake circuit.

17. Check clutch/brake pedal freeplay.

18. Check for fitment of split pinsat Tie rod ball joints, Stub axles.

19. Check for fitment of greasenipples at all locations.

20. Check for leakages of frontlive axle oil (if applicable).

21. Check for leakages of rearaxle oil.

22. Check tightness of propellershaft Centre bearing bracketmounting nut & bolt (8 mkg).

23. Check Power steering oil levelin reservoir. Acceptable iffound between min & maxmarks.

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24. Check for oil leakages inpower steering circuit.

25. Check for Steering wheel freeplay.

26.Check functioning of all bulbs.27.Check for proper functioning of

blinkers, horn, head lamp,parking light, reverse light, wipersystem, washer system etc.

28.Check headlamp alignment andadjust if necessary.

29.Check tightness of electricalconnection at battery, StarterMotor, Alternator & Starterrelay.

30.Check all fuses.31.Check all the earth points for

looseness.32.Check for functioning of all

gauges/meters/warning lamps.33.Check connectors in all

electrical circuits.

34.Check for proper opening andclosing of doors.

35.Check functioning of doorlocks, latches and windows.

36.Check for any complaints oncab fittings, instrument panel,glove box etc.

37.Check and tighten hand loosefasteners.

38.Check for any breakages,bends, failure of anycomponent/assembly/unit.

39.Check for any fouling betweentwo components which maylead to leakages or othercomplaints. Check for foulingof fuel lines, brake pipes, clutchpipes, air intake pipe, powersteering hydraulic pipe, clutch/brake linkages, accelerator rodetc.

PDI ServiceSERVICE RECOMMENDATIONS

40.Grease with grease gun :All locations appearing inlubrication chart.

NOTICEWhile delivering a long storagevehicle (more than 6 monthsfrom production month), service/maintenance operations asprescribed by us for longstorage, also needs, to becarried out before delivery.

NOTICEDo not wash DICOR systemcomponents with forced water.

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1. THE VEHICLE HAS BEEN BUILT TO GIVE YOU THOUSANDSOF KILOMETERS OF ECONOMICAL AND TROUBLE-FREEPERFORMANCE. THIS IS HOWEVER, POSSIBLE ONLY IFTHIS VEHICLE IS SYSTEMATICALLY MAINTAINED ANDOPERATED STRICTLY ACCORDING TO THEINSTRUCTIONS CONTAINED IN THIS BOOK.

2. THE FREE SERVICES SHOULD BE AVAILED OF, AT THEFOLLOWING KM & TIME RANGE

1st Free Service At 1,000 - 1,500 km OR 1 month ,whichever is earlier

2nd Free Service At 5,000 - 5,500 km OR 12 months,whichever is earlier

3rd Free Service At 15,000 - 15,500 km OR 24 months,whichever is earlier

4th Free Service At 30,000 - 30,500 km OR 36 months,whichever is earlier

5th Free Service At 45,000 -45,500 km OR 48 months,whichever is earlier

3. The respective service coupon should be detached and handedover to the concerned Servicing Agency for the serviceperformed.

The selling dealer should fill up details of vehicle perticularson the inside cover page of the Owner’s Manual.

4. These services can be satisfactorily performed only by one ofour Authorised Dealers’/TASC’s/TASP’s Workshops in India,irrespective of the dealer who sold the vehicle, provided thevehicle is sent to them at the kilometerages specified and thatthis service book is produced before them.

The vehicle is entitled to pre-delivery service with free labour.After the delivery of the vehicle, in the subsequent ‘5 freeservices’ labour would be free but materials, if any wouldbe charged for.

All services, other than the above, must be paid for both formaterials and labours; material at prevailing rates for the quantityconsumed and labour at our scheduled rates available with ourAuthorised Dealers/TASCs/TASPs.

5. In the event of a schedule Service not performed within specifiedkilometers the respective coupons will be detached by theAuthorised Dealer’s Workshop when the vehicle is sent to themnext. Should a major service have been missed, all the workslisted for such service must be performed when the vehicle istaken next to one of our Authorised Dealer’s/ TASC’s/TASP’sWorkshop.

6. It is an important condition of our sales policy that nowarranty claims shall be entertained by us unless allservices upto time of the claim arising have beenperformed on the vehicle by one of our AuthorisedDealer’s / TASC’s/TASP’s Workshops.

Service ScheduleSERVICE OPERATIONS TO BE PERFORMED BY CUSTOMER

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Failure to carry out the services listed in this book can causeconsiderable damage to the vehicle and inconvenience to you.It is, therefore, in your own interest to take your vehicle to oneof our Authorised Dealer’s, TASC’s, TASP’s, Workshop forservicing.

7. All our Authorised Dealer’s/TASC’s Workshops have beenequipped with special tools and are manned by technicalpersonnel trained by us. Besides, they have adequate stocksof genuine spare parts for replacement purposes, should theneed arise. Our Authorised Workshops are therefore in aposition to render you any expert advice and service your vehiclemay need. Please give them an opportunity to serve you, sothat you may obtain economical and trouble free performancefrom your vehicle.

8. For any technical advice concerning your vehicle, pleasecontact the nearest Authorised Dealer.

Service ScheduleSERVICE OPERATIONS TO BE PERFORMED BY CUSTOMER

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Service ScheduleSERVICE OPERATIONS TO BE PERFORMED BY CUSTOMER

1 Check engine oil level in sump, Top up, if necessary. Daily

2 Check coolant level in auxiliary tank, top-up, if necessary with mixtureDaily

of clean soft water and recommended anti-freeze additive in specified ratio.

3 Check and get rectified leakage of oil, fuel, brake/clutch fluid and coolant, if any. Weekly

4 Check tyre pressure. Inflate tyres to specified pressure, if necessary. Weekly

5 Check level of clutch & brake fluid in containers, top up, if necessary. Monthly

6 Lubricate accelerator linkage with oil can. Monthly

7 Grease with grease gun : (Where grease nipple is provided). Tie rod ball joints, Draglink ball joints, Idler arm ball joints and Centre link ball joints. Rear spring pins. 5000 km / MonthlyPropeller shaft sliding yoke.

8 Check the performance of brakes by applying & releasing, when engine is running. MonthlyGet it adjusted from Authorised Workshop if required.

9 Check oil level in power steering tank & top up if necessary Monthly

10 Check headlamps, gauges & instruments for proper functioning. As and when requiredGet it rectified if necessary

Note : Do not wash DICOR system components wth forced water

Sr.No. OPERATION FREQUENCY

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Service ScheduleSERVICE OPERATIONS TO BE PERFORMED BY CUSTOMER

11 Check exhaust system & Exhaust Gas Recirculation (EGR) system. Get it rectified,Monthlyif necessary.

12 Tyre rotation 15,000 km

13 Wash the vehicle & clean the condenser with compressed air. As required

14 Check Air Filter service indicator. If RED BAND appears, clean the air filter. If ‘RED BAND’ As and whenreappears even after cleaning, get the air filter element replaced. red band appears.

15 Wheel balancing Whenever a tyre isremoved from wheel rim.

16 Check front tyre wear pattern. If there is an uneven tyre wear, get the frontAs requiredwheel alignment checked & adjusted. (If wear is uniform, do not disturb.)

17 Check water level in windscreen washer container & top up if necessary As and when required

Precaution to be taken while cleaning engine compartment :It is recommended to use dry low pressure air. Do not use pressurised water.

Sr.No. OPERATION FREQUENCY

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Service Maintenance ScheduleSERVICE OPERATIONS TO BE PERFORMED AT WORKSHOP

GENERAL1 Wash the vehicle & Clean the condenser with compressed air Every Service x x x x x x x x x2 Check & Top up Fluids if required: Coolant, Brake / Clutch Every Service x x x x x x x x x

Fluid, Battery Electrolyte, Power Steering Oil, Engine Oil, GearBox Oil, Transfer Case & Front Axle (4X4) / Rear Axle Oil

3 Drain water accumulated in Sedimenter Every Service x x x x x x x x x(OR Whenever warning lampglows)

4 Check fuel, brakes, power steering and clutch lines for leakages Every Service x x x x x x x x x5 All standard checks as per job card Every Service x x x x x x x x x6 Check & ensure normal working of engine using Diagnostic Every Service x x x x x x x x x

Equipment.2.2L DICOR ENGINE

1 *Clean air cleaner filter element, Change if red band appears x x x x x x x xon service indicator even after cleaning

2 *Change engine Oil and Oil filter. x x x x x x xOR 1 Years whichever is earlier

3 Check All accessory Drive belts, adjust tension if required, x x x x x x x xchange if damaged OR 1 Years whichever is earlier

4 Change fuel filter 30,000 km x x xOR 2 Years whichever is earlier

5 *Replace air filter element (OR if RED band appears on 45,000 km x xService Indicator)

OPERATION FREQUENCY 1- 5 15 30 45 60 75 90 1051.5

X 1000

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Service Maintenance ScheduleSERVICE OPERATIONS TO BE PERFORMED AT WORKSHOP

OPERATION FREQUENCY 1- 5 15 30 45 60 75 90 1051.5

X 1000

6 Change coolant in the cooling system 60,000 km xOR 2 Years whichever is earlier

7 Change Sedimenter / Water separator 1,05,000 km x8 Change Timing Belt & Timing Belt Idler 1,05,000 km x9 Change vacuum hoses for Vacuum Modulator, Turbocharger, 60,000 km x

EGR valve & throttle valveGEAR BOX

1 *Change oil in gear box x(First at 45,000 KM, there after every 90,000 KM)

2 Change oil in transfer case (for 4X4) 45,000 KM x x3 Clean breather in gear box (also Transfer case in case of 4X4) Every Oil Change x x

PROPELLER SHAFT1 Grease propeller shaft with grease gun (at slip joint - splines 15,000 km x x x x x x x

end) & Check mounting bolts for looseness. Tighten if necessaryCentre bracketFRONT AXLE (for 4x4) / REAR AXLE

1 Change oil in axle x x(First at 15,000 KM, there after every 75,000 KM)

2 Clean breather in Axle 15,000 km x x x x x x x

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Service Maintenance ScheduleSERVICE OPERATIONS TO BE PERFORMED AT WORKSHOP

OPERATION FREQUENCY 1- 5 15 30 45 60 75 90 1051.5

X 1000

SUSPENSION & STEERING1 Grease idler arm (seal type idler arm)& leaf springs shackle 15,000 km x x x x x x x2 Check wheel alignment & balancing, chassis height & 15,000 km x x x x x x x

adjust if necessary3 Check condition of rubber bushes in the following & replace if 30,000 km x x x

necessary. 1) Top wishbone 2) Lower wishbone 3) Anti roll bar4 Check shock absorber, its bushes & replace if necessary 30,000 km x x x5 Grease steering spindle and sleeve 30,000 km x x x6 Check & adjust front wheel bearing play & Change grease in 45,000 km x x

front hubs7 Change oil in power steering system & change filter element 75,000 km x

CLUTCH & BRAKES1 Check parking brakes, adjust if necessary 15,000 km x x x x x x x2 Check front brake pads & rear brake linings. Replace if necessary 15,000 km x x x x x x x3 Change Clutch & Brake Fluid 30,000 km x x x

(Or 2 years whichever is earlier)ELECTRICALS

1 Check headlamp focusing & functioning of other electrical x x x x x x x xequipment

2 Check specific gravity of battery electrolyte 30,000 km x x x

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Service Maintenance ScheduleSERVICE OPERATIONS TO BE PERFORMED AT WORKSHOP

OPERATION FREQUENCY 1- 5 15 30 45 60 75 90 1051.5

X 1000

HVAC1 Check the HVAC System for Satisfactory Performance & attend Every Service x x x x x x x x x

if requiredWHEELS & TYRES

1 Tyre rotation 15,000 km x x x x x x xLOAD BODY

1 Check and ensure proper tightening and alignment of load 15,000 km x x x x x x xbody fasteners. Check condition of rubber mounting.

2 Check and ensure proper locking of Tail gate. Adjust if necessary Every service x x x x x x x x x

* Under severe driving conditions, additional maintenance is required. Please Refer to “Additional Maintenance Schedule undersevere driving conditions”:Precautions to be taken while cleaning engine compartment : It is recommended to use dry low pressure air. Do not use pressurisedwater.

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Service Maintenance ScheduleSERVICE OPERATIONS TO BE PERFORMED AT WORKSHOP

ADDITIONAL MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS :A.. Driving in conditions such as Patrolling, Taxi, Pickup Van, Vehicle Towing, with Trailer TowingB. Driving on Dusty / Sandy roadsC. More than 50% (in terms of kms) driving in heavy city trafficD. Frequently operating in mountainous area

ITEM INTERVAL CONDITION

A B C D

1 Engine Oil & Oil Filter Change every 7500 kms. x x x x

2 Air Filter Element Clean at every 7500 kms. &replace at 30,000 kms. x

3 Front (for 4X4) & Rear Axle Oil Change Change First at 15000 kms x x x x& thereafter at 45,000 kms.

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PDI

1500

5500

15,000

30,000

45,000

60,000

75,000

90,000

105,000

120,000

RecommendedService

At kmDate

OdometerReading

KMs.

RepairOrder

No.

ServicingDealer's

Signature& Stamp

135,000

150,000

165,000

180,000

195,000

210,000

225,000

240,000

255,000

270,000

285,000

RecommendedService

At kmDate

OdometerReading

KMs.

RepairOrder

No.

ServicingDealer's

Signature& Stamp

Record of Service Performed

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Record of Service Performed

300,000

315,000

330,000

345,000

360,000

375,000

390,000

405,000

420,000

435,000

450,000

465,000

480,000

495,000

510,000

525,000

540,000

555,000

570,000

585,000

600,000

RecommendedService

At kmDate

OdometerReading

KMs.

RepairOrder

No.

ServicingDealer's

Signature& Stamp

RecommendedService

At kmDate

OdometerReading

KMs.

RepairOrder

No.

ServicingDealer's

Signature& Stamp

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Record of Repairs Carried Out

Chassis No. -

Date OdometerReading KMs

RepairOrder No.

Servicing Dealer’sSignature & StampParticulars of Repair

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Record of Repairs Carried Out

Chassis No. -

Date OdometerReading KMs

RepairOrder No.

Servicing Dealer’sSignature & StampParticulars of Repair

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Record of Repairs Carried Out

Chassis No. -

Date OdometerReading KMs

RepairOrder No.

Servicing Dealer’sSignature & StampParticulars of Repair

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TTTTTaaaaata Xenonta Xenonta Xenonta Xenonta XenonTTTTTaaaaata Xenonta Xenonta Xenonta Xenonta Xenon

TTTTTaaaaata Xenonta Xenonta Xenonta Xenonta Xenon TTTTTaaaaata Xenonta Xenonta Xenonta Xenonta Xenon

1FREE

LABOURL -

3FREE

LABOURL -

PDIFREE

LABOURL -

2FREE

LABOURL -

Chassis No. ......................................

Engine No. .......................................

Gear Box No. ...................................

At 5,000 - 5,500 km OR 12 months whichever earlier

please bring your vehicle for this service as per details

given in the Service Schedule.

WORK DONE TO MY SATISFACTION

Sign. of Customer ......................................

Speedo Reading ........................................ Km. seal O.K. / Broken

R.O. No. ..................................................... Date ............................

Dealer's / Authorised Service Centre's

Stamp & Signature .........................................................................

At the time of delivery of vehicle please ensure

pre-delivery inspection has been carried out as per details

given in the Service Schedule.

Chassis No. ......................................

Engine No. .......................................

Gear Box No. ...................................

WORK DONE TO MY SATISFACTION

Sign. of Customer ......................................

Speedo Reading ........................................ Km. seal O.K. / Broken

R.O. No. ..................................................... Date ............................

Dealer's / Authorised Service Centre's

Stamp & Signature .........................................................................

Chassis No. ......................................

Engine No. .......................................

Gear Box No. ...................................

Rear Axle No. ..................................

At 10,000 - 10,500 km OR 24 months whichever earlierplease bring your vehicle for this service as per detailsgiven in the Service Schedule.

WORK DONE TO MY SATISFACTIONSign. of Customer ......................................

Speedo Reading ........................................ Km. seal O.K. / Broken

R.O. No. ..................................................... Date ............................

Dealer's / Authorised Service Centre's

Stamp & Signature .........................................................................

Chassis No. ......................................

Engine No. .......................................

At 1,000-1,500 km OR 1 month whichever earlierplease bring your vehicle for this service as perdetails given in the Service Schedule.

WORK DONE TO MY SATISFACTION

Sign. of Customer ......................................

Speedo Reading ........................................ Km. seal O.K. / Broken

R.O. No. ..................................................... Date ............................

Dealer's / Authorised Service Centre's

Stamp & Signature .........................................................................

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131

44444FREEFREEFREEFREEFREE

LABOURLABOURLABOURLABOURLABOURL -L -L -L -L -

55555FREEFREEFREEFREEFREE

LABOURLABOURLABOURLABOURLABOURL -L -L -L -L -

TTTTTaaaaata Sumo Gta Sumo Gta Sumo Gta Sumo Gta Sumo Grrrrrandeandeandeandeande

Chassis No. ......................................

Engine No. .......................................

Gear Box No. ...................................

Rear Axle No. ..................................

At 20,000-20,500 km OR 24 months whichever earlier

please bring your vehicle for this service as per

details givenin the Service Schedule.

WORK DONE WORK DONE WORK DONE WORK DONE WORK DONE TTTTTO MY SAO MY SAO MY SAO MY SAO MY SATISFTISFTISFTISFTISFAAAAACTIONCTIONCTIONCTIONCTION

Sign. of Customer ......................................

Speedo Reading ........................................ Km. seal O.K. / Broken

R.O. No. ..................................................... Date ............................

Dealer's / Authorised Service Centre's

Stamp & Signature .........................................................................

TTTTTaaaaata Sumo Gta Sumo Gta Sumo Gta Sumo Gta Sumo Grrrrrandeandeandeandeande

Chassis No. ......................................

Engine No. .......................................

Gear Box No. ...................................

Rear Axle No. ..................................

At 30,000-30,500 km OR 36 months whichever earlier

please bring your vehicle for this service as per

details givenin the Service Schedule.

WORK DONE WORK DONE WORK DONE WORK DONE WORK DONE TTTTTO MY SAO MY SAO MY SAO MY SAO MY SATISFTISFTISFTISFTISFAAAAACTIONCTIONCTIONCTIONCTION

Sign. of Customer ......................................

Speedo Reading ........................................ Km. seal O.K. / Broken

R.O. No. ..................................................... Date ............................

Dealer's / Authorised Service Centre's

Stamp & Signature .........................................................................

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