i

TATA Motors Limited l Mumbai l Pune l

(This owner’s manual is advised to be kept in the vehicle, at all time.)

Tata SpacioOwner’s Manual & Service Book

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Do you know ?

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

you are privileged to have the following :

1. Owner’s Manual & Service Book

2. Battery warranty Card

3. First Aid Kit

4. Advance Warning Triangle

5. Jack and Handle

6. Spare Headlamps Bulbs - 2 Nos.

7. Spare Fuses - (Provided in fuse box)

8. Pre - delivery inspection and service.

9. Complimentary diesel in the fuel tank.

10. Tool Kit

a. Wheel Spanner

b. Screw Driver

c. Ring Spanner (8-9)

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

You are also entitled for :

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

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

We welcome your suggestions for better service.

Should you require any assistance, please contact WorksManager of Tata Motors Dealership or TASC.

EXCELLENT CUSTOMER SUPPORT FOR TOTALSATISFACTION

OUR TOLL FREE NO. 1800 209 6688

iii

FOREWORD

Thank you for selecting TATA SPACIO vehicle of your choice.

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

This book gives you all the information necessary for making yourownership of the vehicle, a thoroughly satisfying experience.

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

Should you need any special assistance, please call on our AuthorisedDealer.

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

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

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

Use of genuine parts, designed and manufactured to our exactingstandards, are the best way to maintain your vehiclein peak operating condition. Please do not use substitutes.They always prove costlier in the long run.

Failure to use genuine parts can invalidate any futurewarranty claims.

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

The information and specification given in this bookare valid as on the date of printing. Tata Motorsreserves the right to make changes in design andspecifications and / or to make additions to orimprovements in this product without obligation toinstall them on products previously sold.

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Contents

Foreword iii

Environmental Protection 1

Warranty – Terms & Conditions 3

Do’s 5

Dont’s 7

Aggregate Numbering 8

Handling

Key 9

Door Flaps 9

Sun Visors 10

Rear View Mirror 10

Seats 11

Seat Belt 13

Vehicle Jack & Tools 15

Instrument Cluster 16

Gauges 17

Indicators 17

Ignition Switch 18

Combination Switch 19

Turn Signals 19

Lights 19

Front Windshield wiper/washer 20

Hazard Warning 21

Headlamp leveling switch 21

Interior Roof Lamp 22

Bonnet Opening & Closing 23

Driving Controls 24

Gear Shift Lever 25

Parking Brake 25

Spare Wheel 26

Air conditioning (if fitted) 27

EGR system (if fitted) 29

Catalytic converter (if fitted) 30

Preparing the vehicle for the drive 31

Driving Instruction

Before Driving 34

Gear Shifting 34

Driving Instructions 35

Braking 35

Stopping the engine 36

Fuel Economy 36

Towing the Vehicle 37

Driving Safety 38

Vehicle Maintenance

Engine Compartment 40

Engine Oil Change 41

Engine Oil Filter Change 41

Air Filter 42

Fuel System Bleeding 43

Fan Belt Tension Adjustment 43

Clutch System Bleeding 44

Cooling System 45

Brake System 46

Brake System Bleeding 47

Brake Adjustment 48

Parking Brake Adjustment 49

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Contents

Wheels & Tyres 50

Wheel Change 50

Wheel Alignment 50

Tyre pressure 50

Wheel Balancing 51

Tyre Rotation 52

Headlamps 52

Headlamp Adjustment 52

Headlamp Bulb replacement 54

Fuse Box 54

Bulb Specifications 55

Care & Cleaning of the vehicle 56

Fuel 58

Lubricants 58

Coolants 59

Recommended oils, lubricantsand filling capacities 60

Technical specifications 61

Special Instructions 64

Service Schedule 66

Record of Service Performed 69

Abbrevations

Tata Motors sales andservice set-ups A-1

Tata MotorsDealers Network B-1

Free service coupons

1

Environmental Protection

TATA MOTORS is committed toproduce vehicles using environmentallysustainable technology. A number offeatures have been incorporated in TataMotors Passenger Car Vehicles whichhave been designed to ensureenvironmental compatibilitythroughout the life cycle of the vehicle.We would like to inform you that yourvehicle meets Emission norms and thisis being regularly validated at the stageof manufacturing.

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

Driving

l Avoid frequent and violentaccelerations.

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

devices requiring high powerconsumption during slow trafficcondition.

l Monitor the cars fuel consumptionregularly and if it shows a rising trend,get the car immediately attended atour Authorised Service Centre.

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

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

l Shift to higher gears as soon aspossible. Use each gear upto 2/3rd ofits maximum engine speed. A chartindicating gear shifting speed isgiven in this book.

Maintenance of the vehicle

l Ensure that recommended

maintenance is carried out on thevehicle regularly at our AuthorisedService Outlets.

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

l Use only recommended brands andgrades of lubricants and cleanuncontaminated fuels.

l Get your vehicle checked for emissionperiodically by authorised dealer andregularly renew the P.U.C. certificate.

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

l Do not pour used oils or coolants intothe sewage drains, garden soil or openstreams. Dispose the used filters andbatteries in compliance with thecurrent legislation.

l Do not allow any unauthorisedperson to tamper with engine

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settings or to carry modifications onthe vehicle.

l Never allow the vehicle to run out offuel.

l Parts like brake liners, clutch discshould be vacuum cleaned. Do notuse the compressed air for cleaningthese parts which may spread thedust in the atmosphere.

While carrying out the servicingor repairs on your vehicle, you shouldpay keen attention to some of theimportant aggregates,which greatly affect emission. Thesecomponents are :-

1. Fuel injection pump, Injectors/Nozzles

2. Air intake & Exhaust systemespecially for leakages

3. Cylinder head for valve leakage

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

Environmental ProtectionEnvironmental Protection

5. Turbocharger and intercooler (iffitted)

6. Catalytic converter

This Owner’s Manual contains furtherinformation on driving precautions andmaintenance care leading toenvironment protection. Pleasefamiliarise yourself with these aspectsbefore driving.

3

Warranty Terms and conditions

We WARRANT each TATA SPACIOvehicles & parts thereof manufactured byus to be free from defect in material andworkmanship, subject to the followingterms & conditions :

1. This warranty for the engine (Tata497SP) fitted in the vehicle shall be fora period of three years from the dateof sale of the vehicle, or 3,00,000 kmsof its running, whichever occuringearlier.

The warranty for the rest of the vehicleshall be for 18 months from the dateof sale of the vehicle, irrespective ofthe distance covered. However, forthe cars used for commercialapplications (including those usedfor hire or reward viz those operatingwith a yellow number plate), thewarranty shall be limited to 18months 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 being

brought to us or to our dealerswithin the warranty period. Theparts so repaired or replaced shallalso be warranted for quality andworkmanship but such warrantyshall be co-terminus with thisoriginal warranty.

3. Any part which is found to bedefective and is replaced by us underthe warranty shall be our property.

4. As for such parts as tyres, batteries,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 bylaw, all such rights as we may haveagainst such parties under theirwarranties in respect of such parts.Our Dealers/TASC’s will assist thepurchaser in taking up the complaintwith the respective manufacturersand their decision on the warrantywill be final.

5. This warranty shall not apply if thevehicle or any part thereof is repairedor altered otherwise than inaccordance with our standard repairprocedure, or by any person otherthan from our sales or serviceestablishments, our authoriseddealers or service centres or servicepoints in any way so as, in ourjudgement which shall be final andbinding, to effect its reliability, norshall it apply if, in our opinion whichshall be final and binding the vehicleis subjected to misuse, negligence,improper or inadequate maintenanceor accident or loading in excess ofsuch carrying capacity as certified byus, or such services as prescribed inour Owner’s Manual and Service Bookare not carried out by the buyerthrough our sales or serviceestablishments, our authoriseddealers or service centres or servicepoints.

6. This warranty shall not cover normalwear and tear or any inherent normaldeterioration of the vehicle or any ofits parts arising from the actual use

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Terms and conditionsWarranty

of the vehicle or any damage due tonegligent or improper operation orstorage of the vehicle. This warrantyshall not apply to normalmaintenance services viz. oils & fluidchanges, head lamps focussing,fastener retightening, wheelbalancing, tyre rotation, adjustmentof valve clearance, fuel timing,ignition timing and consumables likebulbs, fuel filters and oil filters etc. Thiswarranty shall not apply to anydamage or deterioration causedby environmental pollution or birddroppings. This warranty shall notapply to V-belts, hoses and gasleaks in case of air conditionedvehicle. Slight irregularities notrecognised as affecting thefunction or quality of the vehicle orpar ts, such as s l ight noise orvibration, defects appearing onlyunder par t icular are i rregularoperations or items consideredcharacteristic of the vehicle.

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

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 al l other obligations orl iabi l i t ies on our par t and weneither assume nor authorise anyperson to assume on our behalf,any other liability arising from thesale of the vehicle or anyagreement in relation thereto.

9. The buyer shal l have no otherrights except those set out aboveand have, particular, no right torepudiate the sale, or anyagreement or to claim anyreduction in the purchase price ofthe vehicle, or to demand anydamages or compensation forlosses, incidental or indirect, orinconvenience or consequentialdamages, loss of vehicle, or loss oft ime, other wise, incurred oraccrued.

10. Any claim aris ing from thiswarranty shall be recognised onlyif it is notified in writing to us or toour concerned dealer without anydelay soon after such defect ascovered and ascertained under thiswarranty.

11. This warranty shal l standterminated i f the vehicle istransferred or otherwise alienatedby the buyer without our pr iorwritten consent.

12. We reserve our rights to make anychange or modif ication in thedesign of the vehicle or its parts orto introduce any improvementtherein or to incorporate in thevehicle any addit ional par t oraccessor y at any t ime withoutincurr ing any obligation toincorporate the same in thevehicles previously sold.

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Do’s

1. Use recommended oils andlubricants only.

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

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

4. Clean air filter element regularly.Replace filter element when serviceindicator shows red band even aftercleaning the filter element or, at 40,000km in clean condition or 25,000 km industy condition.

5. Ensure periodic servicing as permaintenance schedule.

6. Insist on use of genuine spare parts.

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

8. Check tyres for damage from time totime and remove any foreign bodiesembedded in treads.

In case of tyre replacement or repairsdue to puncture have the wheelbalanced. Keep grease, oil and fuelaway from the tyres. In case ofuneven tyre wear get the vehicleattended to by any of our authorisedservice set-ups.

9. Maintain correct tyre pressure.

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

11. Observe correct polarity whenconnecting battery terminals.

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

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

Friendly notes Do’s

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14. Start the vehicle always in the 1stgear to avoid premature clutch wear.

15. Keep both foot and parking brakesproperly adjusted.

16 Before engaging reverse gear,ensure that vehicle has come to astop, declutch, wait for a few secondsand shift into reverse gear.

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

18. In case of emergency parking orbreakdown on road, pull the hazardwarning switch to flash all the blinkerlights to warn other road users.

19. Release parking brake beforedriving off.

20. Release the ignition key as soon asengine starts.

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

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

23. In case of engine not starting firstcheck the fuse of fuel injectionpump solenoid.

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

25. Ensure doors are properly closed.

Where Air conditioning system isinstalled

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

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

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

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

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

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

Do’s

Friendly notes Do’s

7

Dont’s

1. Do not start the vehicle if Brake Failindicator is ‘ON’.

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

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

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

5. Do not run engine without RadiatorCap. Use genunine Cap only, to keepsystem pressurised.

6. Do not overtighten engine oil filter.

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

Friendly notes Dont’s

8. If your vehicle has a turbochargedengine, do not stop the engine atonce, allow it to run at idling speedfor atleast 1 minute. Also do notaccelerate engine till the engine oilpressure has built up.

9. Do not cause heating of AC pipe(where fitted), while welding/brazingin its viscinity.

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

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

12. Do not put your hand inside thecondenser fan when the grille isremoved. Disconnect power supply tofan and switch off engine before anymaintenance work, where applicable.

8

Location of chassis and aggregate serial numbers

Chassis number plate Chassis number on frame

Gear box number

Handling

Rear axle number (Spicer) Body shell number plate

FIP number (MICO)

Engine number

Rear Axle number (Tata Motors)

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Handling Key & Central Door Locking

Key

A key has been provided for operationof steering lock cum ignition switch, forlocking and unlocking of driver’s sidedoor, glove box and rear door.

Locking and Unlocking of Doors

From outside : To unlock the door turnkey antilockwise and swing handle (1)upwards. To lock the door turn keyclockwise.

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

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

inside.

Window glasses

For operating window glasses usehandle (4).

3

2

4

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Handling Sun Visors & Rear View Mirror

Sun visor

Two adjustable sun visors are providedinside the cab to prevent sun glare.

Lower the sun visors to protect the eyesfrom bright sunlight. The sun visors alsomoves sideways towards the door.

A Vanity mirror has been provided onthe co-driver’s sun visor.

Rear View Mirror - Outside

Rear view mirror

Rear view mirror is fitted on driver’s andco-driver’s side door. It can be adjustedto the desired positions by hand. Themirror can be folded backwards forconvenience when the vehicle is to bedriven through narrow passages.

The additional adjustable anti-glare rearview mirror is fitted inside the cab. It canbe adjusted in following two positionsby using knob provided on the mirror.

Vanity Mirror

SunvisorsMirror

Rear View Mirror - Inside

1. Normal position

2. Anti-glare position

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

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Seat Adjustment lever

2

1

Seats

Driver’s seat

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

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

achieved push down the handle to lockthe seat.

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

Do not adjust seat while driving.

Co-driver seat

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

In few versions soft cushioned adjustabletype seat is provided for co-driver. Middle seats

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

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

Middle Seat

Handling Seats

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Handling Seats

4 5 6

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

Luggage space where rearjump seats are folded

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

Front facing rear seat

1

13

Handling Seat belt

For folding back, pull the strapas shown in figure

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

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

1 2 3

Seats at rear

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

1. Lift the seat squab and hold againstbackrest.

2. Engage strap with the hook on seatsquab.

3. Fold the seat stand.

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

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

Front facing third row seat (Optional)

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

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

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

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Handling Seat belts

SEAT-BELT ARRANGEMENT ON VARIOUS FRONT SEATS

Seat-Belt Arrangement on Bucket Seat

1. Anchor

2. Webbing

3. tongue

4. Buckle

3

2

Seat-Belt Arrangement on Bench Seat

1

SEAT BELT

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

Fastening the belt

Insert belt tongue into buckle, a positivelocking ‘ click ’ indicates correct and safeassembly.

Releasing the belt

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

Belt adjustment

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

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

To tighten (shorten) the belt.

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

To loosen (lengthen) the belt.

Tilt the adjuster by means of the grip andslide it along the strap until suitably adjusted.

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

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

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CAUTION

l The belt is designed for use of only one person.l It is not intended for children under 10 years.

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

l Avoid twisting the straps during use.

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

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

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

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

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

Vehicle Tools & Jack

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

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

Handling Adjustable Headrestraint

Jack

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Handling Instrument cluster

Instrument cluster

1

2

3 4 5 6 7 8

10

9

1. Fuel Gauge

2. High Beam Indicator

3. Battery Charging Indicator

4. Turn signal indicator left

5. Speedometer

6. Odometer

7. Turn signal indicator right

8. Oil Pressure indicator light

9. Parking brake cum brake fluidlevel indicator

10. Coolant temperature gauge

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1. Fuel gauge

It indicates the approximate level of fuel in tank.

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

2. High beam indicator(Blue)

3. Battery chargingindicator light. (Red)

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

4. Turn signal indicator

(Left) (Green)

5. SpeedometerIt indicates vehicle speed in km/h.

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

7. Turn signal indicator(Right) (Green)

Handling Gauges & Indicators

8. Oil pressureindicator light (Red)

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

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

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

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

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

In case of such an event, get your vehicle checked atauthorised service centre for leakages in brake system.

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

18

Handling

Ignition switch :

Ignition switch is fitted on steering column of the vehicle

l to start the engine.

l to switch on and off the electrical system other than listedbelow.

Horn, parking lamps and hazard warning indicators are notconnected through this switch and operate independently.

l to switch on and off the accessories only.

The switch is located on the steering column support and hasthe following key positions:

ACC

By turning the key to ‘ACC’ position power supply to accessories isswitched on.

ON

By turning the key to this position all remaining electrical systemsbecome operative and lamps of battery charging indicator, low oilpressure and brake fluid level cum parking brake indicator will comeon.

START

Turn the key further clockwise to start position (spring loaded) to operatestarter motor. As soon as the engine starts release theignition key, so that key can come back to ‘ON’ position and starter motordisengages. Vehicle is driven in this position. Engine stopcable is provided to stop the engine.

Ignition Switch

Ignition switch

Ignition switch key positions

19

Combination Switch

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

Turn Signals

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

Position ‘4’ - Turn signal left

Position ‘5’ - Turn signal right

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

Lights

Lights are operated by turning the knob of combination switch as indicatedbelow:

First notch (P L position)

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

Second notch ( H L position)

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

Handling Combination Switch

Combination switch

Combination switch (RH side)

34

52

1

20

Wiper motor operating lever

Handling Combination Switch and Wiper / Washer

OFF - Position

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

Position ‘1’ - High beam

‘2’ - Low beam

‘3’ - High beam flash

High beam flash (No. 3 position)

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

Front Windshield wiper / washer

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

Position

‘OFF’ - Wiper motor switched ‘OFF’

‘INT’ - Wiper sweeps intermittently

‘LO’ - Low speed of wiper motor

‘HI’ - High speed of wiper motor

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

21

Headlamp leveling Switch

Hazard warning switch

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

Headlamp leveling switch : (if provided)

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

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

Sr. No. Loading conditions Switch position/ Marks assigned

1. Unladen + one person in driver seat 0

2. Driver + co-driver 0

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

4. All the seats occupied 1

5. Laden (all the seats occupied + luggagein boot space to achive permissible load onthe rear axle.) 2

6. Driver + evently distributed load in the bootto obtain permissible load on corresponding axle 3

Handling Hazard Warning Switch and Headlamp Leveling Switch

Hazard warning switch

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

22

Handling Roof Lamp, Bonnet opening & closing

2

3

Roof lamps and courtesy lamp

A roof lamp is mounted in the middle of the compartment.

The roof lamp switch has 3 positions:

1. OFF

2. ON

3. Door open

Courtsy lamp

A courtsy lamp is provided above the rear view mirror inside the cab.

The roof lamp switch has 2 positions:1. OFF

2. ON

1

1. Lamp off2. Lamp on3. Door

Courtsy lamp

Roof lamp

23

Bonnet opening lever

Bonnet opening and closing

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

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

Ensure that the bonnet is fully locked before driving off.

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

24

Handling Driving Controls

Driving Controls

1. Steering Wheel *

2. Instrument Cluster

3. Combination Switch

4. Head Lamp Leveling Switch

5. Steering Lock cum Ignition Switch

6. Bonnet Opening Lever

7. Clutch Pedal

8. Brake Pedal

9. Accelerator Pedal

10. Gear Shift Lever

11. Horn Pad

12. Glove Box

* Four spoke steering wheel for vehicles with Power Steering

25

Gear Shifting Pattern

Handling Gear shift lever and Parking Brake

Gear shift lever

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

Parking brake (Floor moutned)

The parking brake is mounted on floor between RH door and driver’s seat.

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

Ensure parking brake is released before driving the vehicle.

Parking Brake

26

Spare Wheel

Handling Spare wheel

Spare Wheel

Spare wheel is mounted on tubular structure at tail gate.

Wheel spanner provided with the vehicle can be used to loosen and tightenthe bolts of the spare wheel mounting.

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

27

AC Control Switch

Assy. cooling unit

Air conditioning (If fitted)

The vehicle has been fitted with anefficient air conditioning system forair cooling.The bolwer can be run at threedifferent speeds i.e. low. medium andhigh.The clockwise movement of the ACcontrol notch gives graduallyminimum to maximum cooling effect.

Precaution while using the carcooler during long distance driving

When long distance driving is doneat high speeds, the compressor rpmis high and thus the cooling becomeshigh. Additionally if thermostat is setto maximum cool position, icing mayoccur on the evaporator due toovercooling. This icing reduces airflow and the cooling becomes poor.Thus it is recommeded to have suchdriving at maximum air flow and lowtemerature setting of the themostat.

Handling Air conditioning & Ventilation (if fitted)

}

Air conditioning system comprisesthe following equipment andaccessories

• Compressor• Condenser with fan• Receiver dryer• Pressure safety switch• Expansion valve• Evaporator• Bolwer• Engine fast idling control device• Assembly thermo control

(Thermister, thermo amplifierPotentiometer)

AC Control Switch location

28

Handling Air conditioning & Ventilation (if fitted)

Note

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

Air vents

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

Cleaning the condenser

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

Check for any abnormal noise from compressor

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

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

Precaution

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

29

Handling Taking care of the environment

TAKING CARE OF ENVIRONMENT :

TATA Spacio (Bharat stage III) vehicles are equipped with the EGR(Exhaust Gas Recirculation) System and catalytic converter to reduceexhaust pollution.

EGR SYSTEM (if installed) :

The 497SP DLNA engine is fitted with EGR pipe, vacuum tubes, EGRelectropneumatic switch, EGR switch on FIP throttle lever andassociated electrical circuitry. With this, controlled amount of exhaustgas is mixed with intake air of the engine, in part load and speedconditions. This helps in reducing harmful pollutants.Along with EGR System your vehicle is also fitted with diesel oxidationcatalytic converter to reduce exhaust pollution.

For care of catalytic converter please refer next page.

30

Handling Taking care of the environment

CATALYTIC CONVERTER :

Tata Spacio is fitted with Diesel Oxidation Catalytic Converter toreduce exhaust pollution. The two way Catalytic Converter hascoating of precious metals which enables conversion of pollutants.

Care of the Catalytic Converter :

The Catalytic Converter does not require any special maintenancehowever, following precaution should be taken for the effectivefunctioning of the converter and to avoid damage to the Converter.

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

Parking Warning :

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

31

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

1. Fuel level in tank

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

2. Engine oil levelCheck engine oil level before starting the engine or at least 20minutes after stopping the engine. Top up if oil level is less thanmidway between upper and lower marks on the dipstick.

The oil level should not exceed the ‘MAX’ mark.

USE ONLY THE GENUINE CO-BRANDED OILS.

Handling Preparing the vehicle for the drive

Fuel Filling Cap

3. Coolant level

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

USE GENUINE CO-BRANDED COOLANT

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

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

32

Brake Fluid Container Clutch Fluid Container

Handling Preparing the vehicle for the drive

6. Check condition and tension of fan belt. Adjust tension ifnecessary.

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

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

Do not overfill. Use only co-branded brake fluid.9. Check level of clutch fluid in plastic container. Top up if

necessary. Do not overfill as this would result in spillage duringclutch operation.

Checking Belt Tension

NOTICE

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

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

Keep battery terminals clean and tight. Apply petroleumjelly / vaseline on terminals for protection against corrosion.Secure covers provided over terminals.

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

33

Windshield washer water reservoir

Handling Preparing the vehicle for the drive

Use only GENUINE CO-BRANDED clutch fluid.

10. Check level of water in Windshield washer reservoir. Top upwith clean water if required.

Use good quality cleaning solvent available in the market inthe ratio as specified by its manufacturer.

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

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

13. Check condition of wiper blades, replace if rubber profileis damaged.

14. Check level of oil in steering gear box.

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

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

1

2

Rear axle oil filler / level plug

34

Driving instruction

Start the engine and observe that :

l Low oil pressure indicator light goes‘OFF’

l Battery charging indicator light goes‘OFF’

l ENSURE THAT PARKING BRAKE ISRELEASED (INDICATOR LAMP ‘OFF’)

l VEHICLE IS NOW READY FOR ADRIVE.

l DO NOT ALLOW VEHICLE TO ROLLBACK ON GRADIENTS.

During running - in period :

i.e. first 2,000 km of operation :

Do not exceed the following vehiclespeeds:

Speed in km/hr.

Gear Min Max

First - 20

Second 15 35

Thrird 25 55

Fourth 35 75

Fifth 45 Max speed

l Avoid rapid acceleration andprolonged high speed running of theengine.

l Avoid sudden braking.

l Retighten wheel nuts to 12-15 mkg.torque after first 100 km of running ofa new vehicle and after every wheelchange.

Driving and Gear Shifting

BEFORE DRIVING

Check

l Fuel level

l Coolant level

l Engine oil level

l Tyre pressure

l Brake and clutch fluid level

l Door flaps are firmly closed

Adjust

l Driver seat

l Rear view mirrors

Ensure

l Gear shift lever is in neutral position.

l All switches and lamps are working.

l Brake fail indicator is ‘OFF’

l Fuel level indicated on fuel gaugeis above reserve mark

35

Driving instruction Driving instructions and braking

Driving Instructions

DRIVE SAFELY AND JUDICIOUSLY. REMEMBER SAFETY FIRST.l Depress clutch pedal fully before shifting gears. This will ensure

longer synchro cone life.

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

l Start the vehicle in first gear only.

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

Recommended speeds for gear changes :

Gear Speed in km/hr.

1st to 2nd 20

2nd to 3rd 35

3rd to 4th 60

4th to 5th 80

l Engage reverse gear, only when vehicle is stationary.

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

Braking

l While braking on turns apply brakes gently.

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

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

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

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

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

36

Driving instruction Stopping the engine and Fuel Economy

Stopping the engine

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

b. Release the accelerator pedal.

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

Fuel Economy

a. Drive smoothly, accelerate gradually and anticipate stops.

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

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

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

e. Do not ride the clutch. Do not use clutch pedal as foot rest.f. Depending on traffic conditions, a constant speed should be

maintained.The vehicle uses more fuel, every time you speed up or slow down.

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

Ignition switch

Ignition switch key positions

37

Towing the Vehicle

• For towing the vehicle, the best way is to use a recovery van.

• Alternatively use a rigid tow bar.

• Avoid using flexible cable or rope as your vehicle may crash intotowing vehicle when it stops suddenly.

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

• Keep the engine in idling so that power steering assistance isavailable. This will also built the vacuum for the brakes.

• In case of brake failure, use parking brake to control the vehicle.

Towing the vehicleDriving instruction

38

Mobile phones

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

Fatigue 'Rest Revive survive'

Do not attempt driving when you feeltired, sleepy long distance driving cantire you very much and fatigue can dullyour reflexes and judgment. Take a breakand get refreshed at intervals.

SAFETY CHECKS

Windshield wiper/windshield washer

Always keep windshield glass clean toavoid any distraction in visibility. Ensureproper working of wipers and conditionof wiper blade. Ensure that windshieldwasher reservoir is full. Do not operatewiper alone when the windshield glassis dry this would damage the windshield.

Headlights

Keep headlight lenses clean. Check foroperation of headlamp in both high/low beam condition. Check for correctfocusing of headlamps. Use onlyrecommended type of bulbs. Do notuse the high beam unless it is inevitable.Its dazzle may glare the driver of theoncoming car thus causing an accident.

DRIVING SAFETY

Seat-Belt

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

Influence of Alcohol

Avoid driving under the influence ofalcohol or drugs. Alcohol and drugswill severely impair your control ofthe vehicle and increase the risk ofinjury to yourself and others.

Driving instruction Driving Safety

39

Side indicators / Hazard warning

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

Horn

Ensure the horn is working properly. Hornprovides safety to other road users byalerting your presence.

Brakes

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

Tyres

Check the condition of tyres for anyabnormalities. Maintain correct tyrepressure, it is very important particularlywhen subjected to extreme condition, suchas high speed, high load and high outsidetemperature. Do not use worn or bald tyreson the front wheels.First Aid Kit

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

Advance Warning Triangle

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

Place the triangle on the road behind thevehicle when it stranded on the road. The

triangle must be at least 50 meters behindthe vehicle in the same lane of traffic.

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

Driving SafetyDriving instruction

40

Vehicle maintenance Engine Compartment

ENGINE COMPARTMENT

1. Engine oil filling 2. Dip Stick 3. Battery

4. Radiator Cap 5. Service Indicator 6. Air Filter

7. Auxiliary Reservoir (Coolant tank) 8. Windshield washer fluid container 9. Brake fluid container

10. Clutch fluid container

329 10 1

7

8

6

5 4

41

Vehicle maintenance Changing engine oil & oil filter

Changing engine oil

The engine oil should be drained while it is still hot.

a. Unscrew sump drain plug and allow the oil to drain out for 20 minutes.

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

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

d. Clean the bowl thoroughly and insert a new genuine full flow filtercartidge into the bowl.

e. During reassembly fill the filter bowl first with one litre of engine oil.Reassemble the filter to the top cover. This is done so that when the engineis started, the oil can immediately flow to the bearings and the timerequired by the toil to attain the correct pressure is minimised. If thisinstruction is ignored the bearings may get damaged. The oil filter mustbe kept clean as far as possible to protect the engine components fromrapid and excessive wear and tear due to abrasion. Tighten the centrebolt to 4 mkg. torque.

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

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

h. Start engine and allow it to runfor a few minutes and stop the engine.

i. After 20 minutes check oil level indicated on the dipstick. It should be atthe upper mark, if not, top up.

Caution :

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

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

2

3

1

42

Vehicle maintenance Air Filter & Fuel Tank

1. Air Filter 2. Service Indicator

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

ii. Improper dimensions which cannot prevent unfiltered oil getting mixedwith filtered oil. Since it is extremely difficult to distinguish betweengenuine and non-genuine filter elements.

Obtain these only from an Authorised Service Outlet.

Engine Air Filter

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

Always use genuine air filter element.

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

Check the element for puncture and pin holes by a light source. If found okayrefit the filter element and the cover.

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

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

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

Air filter service indicator

43

Fuel System Bleeding

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

a. Loosen bleeding screw on primary fuel filter.

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

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

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

e. Tighten the plunger knob.

Fan belt tension adjustment

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

Belt tension adjusting procedure :

a. Loosen bottom mounting bolt of the alternator.

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

c. Loosen the lock nut.

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

Vehicle maintenance Fuel filter and Fuel system

1

24

3

1. Lock nut 2. Adjusting nut3. Clamping bolt 4. Clamping piece

3

1

2

4

44

Vehicle maintenance Bleeding clutch system

Bleeding clutch slave cylinder

Clutch Fluid Container

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

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

f. Tighten bottom mounting bolt.

g. Recheck belt tension.

Clutch system bleeding

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

The procedure for bleeding the system is as follows :

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

b. Remove dust cap from slave cylinder bleed screw and clean the screwthoroughly. Attach bleeding tube to bleed screw and place other end oftube in a clean glass jar containing sufficient clutch fluid to submergetube end.

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

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

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

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

45

Cooling system :

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

coolant passages, especially in the radiator core.

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

3. Defective/stuck thermostat.

4. Loose fan drive belt.

5. Coolant leakage from system.

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

Prevention of rust formation :

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

The total capacity of the cooling system is approx. 12 litres. Fill the radiatorauxiliary tank upto ‘FULL’ mark.

Changing of coolant in the cooling system :

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

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

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

d. Fill the auxiliary tank upto ‘FULL’ mark.

e. Ensure no leakage in the system.

Vehicle maintenance Cooling system

Engine Coolant Container

46

Brake system

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

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

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

Brake system bleeding

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

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

Proceed as follows for bleeding the brake system :

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

b. Remove dust cap at each bleed screw and clean the area around it.c. Attach the bleed tube to the front left calliper bleed screw and place

the other end in a clean jar containing sufficient fluid to submerge theend of the tube.

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

Vehicle maintenance Brakes

Bleeding front wheel cylinder

47

Vehicle maintenance Brakes

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

f. Replace the dust cap on bleed screw.

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

During the bleeding process keep the following points in mind :

1. Ensure that the fluid level in the fluid container does not fall low enoughto cause air to be drawn into the hydraulic system.

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

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

4. Always use recommended brand of brake fluid.5. As brake fluid absorbs moisture from the atmosphere, we recommend

changing of brake fluid in the system annually.6. Take care to see that the brake fluid is not spilled on the paint work.

Bleeding rear wheel cylinder

Brake Fluid Container

48

Brake adjustment

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

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

For adjusting rear wheel brake shoes proceed as follows :

1. Put chocks on front wheels.

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

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

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

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

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

7. Check and readjust parking brake, if necessary.

8. Remove front wheel chocks.9. Test drive vehicle for proper brake function.

Vehicle maintenance Brakes

Adjusting the rear brakes

1. Adjustment Screw

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

49

Adjustment of parking brake :Ensure that all four rear brake shoes have been properly adjusted.

1. Put chocks on front wheels.

2. Jack up the rear axle.

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

4. Tighten the parking brake adjustment nut (1) till rear wheelsstart jamming and cannot be rotated.

5. Release the parking brake and ensure that wheels are rotatingfreely., then tighten check nut (2). Operate parking brake a fewtimes to ensure proper operation.

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

6. Lower down the rear axle.

7. Remove chocks from front wheels.

Vehicle maintenance Parking brake

1. Parking Brake Adjustment Nut2. Check Nut

2

1

50

Wheels and tyres

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

Wheel change

When changing wheels use the jack provided with the vehicle.

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

Wheel alignment

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

Vehicle maintenance Wheels and tyres

correct tyre pressure to obtain longer tyre life.

Recommended tyre pressures :( with cold tyres )

At Unladen Laden(Rated GVW)

Front 38 psi 38 psi(2.6 bar) (2.6 bar)

Rear 38 psi 47 psi(2.6 bar) (3.3 bar)

Jack location at front Jack location at rear Tightening wheel nuts

51

Vehicle maintenance Wheels and tyres

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

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

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

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

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

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

Wheel balancing

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

Repairing a tyre / tube

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

Replacing a tyre / rim.

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

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

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

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

4. Balance weights are available from 10 gm to 90 gm in steps of10 gm and from 80 to 140 gm in steps of 20 gm.

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

52

Tyre rotation

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

Vehicle maintenance Wheels and tyres, Electrical system

Headlamps

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

The head lamp also incorporates a parking lights.

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

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

Adjusting head lamps focus with the help of screen

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

On the marked up screen as shown in figure, area above horizontaland inclined lines (shaded) is called ‘Dark zone’ and the area below itis called ‘The illuminated zone’.

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

SCHEMATIC DIAGRAM - TYRE ROTATIONRADIAL PLY TYRES

DIAGONAL PLY TYRES

123456781234567812345678

123456781234567812345678

123456781234567812345678

123456781234567812345678

123123123123123123123123FR

ON

T

REA

R

SPA

RE

WH

EEL

123456781234567812345678

123456781234567812345678

123456781234567812345678

123456781234567812345678

123123123123123123123123FR

ON

T

REA

R

SPA

RE

53

Vehicle maintenance Electrical system

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

When properly adjusted, most brightly illuminated area will be justbelow the intersection point ‘A’ of these two lines.

The Second head lamp is adjusted in a similar manner withoutdisturbing the position of the vehicle and the screen.Now switch ‘ON’ high beam. They will be symmetrical above points.

‘A’ and ‘B’ of intersection of vehicle lines and horizontal lines. It ispossible that high beams may not be exactly symmetrical butfor this reason headlamps should not be realigned.Preferably, the alignment should be done in the dark.No masking of headlamps with black paint is required. If done,this will reduce the intensity of lights.(For adjustment on vehicle fitted with headlamp leveling switch,please refer to page 21)

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

Headlamp alignment on BS - II vehicle

1470 530 530 1470

746

54

Head lamp bulb replacement

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

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

Realign headlamp beam after replacing bulb

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

Fuse Box

In order to protect the cable harness and other equipments fromdamage in case of short circuit and overloads, fuse links are providedin the fuse box.

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

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

Spare fuse links are provided inside the fuse box.

Vehicle maintenance Electrical system

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

Flasher with short circuit protection

If flasher circuit is short circuited or overloaded (more than 110 W)flasher will shut off. It can be reset by momentarily centering theindicator arm of combi switch. If flasher is shutting off or fuse isblowing off repeatedly the flasher circuit should be checked for shortcircuit. Check the flasher separately for its functioning.

Fuse Box

55

Vehicle maintenance Electrical system

Bulb specifications

Description Location Type Specifications Qty.

Headlights Headlamp Halogen 12V 55 / 60 W 2

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

Tail lamp D 12 /1 12V 21 W 2

Side Indicators Side 5 W 5 12V 5W 2

Stop lights Tail lamp D 12 /1 12V 21 W 2

Parking lights Head lamp M 12 /4 12 V 4W 2

Tail Lamp M 12 /6 12 V 10W 2

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

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

Warning and illumination lamps Instrument Cluster

Head light (Main beam) “ W 12 V 2W 1

Turn indicators “ W 12 V 2W 2

Battery charging indicator “ W 12 V 2W 1

Low oil pressure indicator “ W 12 V 2W 1

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

Gauge illumination lights “ W 12 V 2W 4

Roof lamp Cab roof K 12 V 10 W 1

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

56

Vehicle maintenance Care and cleaning of vehicle

= Carpets (if fitted)

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

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

Cleaning exterior of the vehicle

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

= Faded paint.

= Rust on body due to deteriorated paint film.

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

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

Washing

When washing the vehicle, follow the instructions given below.

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

Care and cleaning of the vehicle

Caution

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

Cleaning of vehicle interior

= Floor mat (provided)

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

= Seat belt

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

= Upholstery

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

57

Vehicle maintenance Care and cleaning of vehicle

Protection against corrosion :

The following cause corrosion :

= Moisture trapped in body cavities.

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

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

Corrosion preventive measures have been incorporated in yourvehicle. You can avoid corrosion of your vehicle by performing somesimple periodic maintenance :

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

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

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

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

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

= Remove dirt and mud from body exterior with running water.Use a soft sponge, brush with water. Do not use hard materialwhich can scratch the paint.

= Wash the exterior with water, lightly rubbing with sponge or softcloth. The sponge or cloth should frequently soaked in water.

Caution

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

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

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

Warning

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

Waxing the vehicle exterior

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

= Use only good quality waxes and polishes.

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

= Chrome plated parts should also be waxed.

58

Fuel

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

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

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

Ambient Percentage

temperature upto Summer Supplementary0C grade diesel fuel

upto 0 100 0

0 to -10 70 30

-10 to -15 50 50

Ambient Percentage

temperature upto Winter Supplementary0C grade diesel fuel

upto -15 100 0

-15 to -20 70 30

-20 and below 50 50

Care should be taken that diesel and supplementary fuel are

thoroughly mixed before filling.

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

Lubricants

Recommended lubricants conform to the following specifications:

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

2. ATF Type A - Gearbox oils

3. APIGL 5 - Rear axle and

mechanical steeringgear box oils

Please use only recommended brands for good performance.

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

Use of reclaimed oil is not recommended.

Engine oil

Recommended grades of engine oil conforming to SAE API CF4+specifications and range of ambient temperature at which thesecan be used are given below :

Ambient temperature 0C Engine oil grade

-10 and above SAE 15W/40

-20 TO 0 SAE 10W/30

-10 and below SAE 5W/20

Fuel, lubricants, coolants Fuel, lubricants

59

Fuel, lubricants, coolants Lubricants

Running In oil

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

Autolub 30 : HP

Gear box oil

Use recommended gear oil conforming to ATF Type A specifications.

Rear axle and mechanical steering gear box oil

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

Hub bearing grease (Spicer axles)

Use Lithium base multipurpose grease.

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

Brake and clutch fluid

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

Spicer propeller shaft ( where applicable )

Lubricate slip joint with multipurpose grease - 2.

Lubrication of steering spindle and sleeve

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

Coolants

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

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

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

60

IMPORTANT INFORMATION Co-branded Fuel, Coolants & Lubricants

PLEASE USE ONLY GENUINE OILS, COOLANTS , LUBRICANTS , ANTI- RUST & SOUND DEADENINGCOATS, WINDSCREEN SEALANT, ADHESIVES & FUEL ADDITIVES BRANDED BY TATA MOTORS

FOR OPTIMUM PERFORMANCE OF YOUR TATA SPACIO

ITEM COMPANY BRAND QTYENGINE OIL CASTROL Castrol GTD 15W/40 5.5 Litres

HPCL HP Milcy 15W/40

COOLANT SUNSTAR Golden Cruiser 1400 MANCHEMCO Frostox SFD 12 12 Litres Approx.HPCL HP Thanda Raja P

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

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

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

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

WHEEL BEARING & CHASSIS HPCL HP Multipurpose Grease-2 As requiredPropeller shaft joints, Sliding

Yokes, Vaccum Booster

ANTI RUST TREATMENT DINITROL Dinitrol& SOUND DEADENING WUERTH Wuerth

WIND SCREEN SEALANT ANCHEMCO Terostat 8590 Kit Form

METAL & PLASTIC ADHESIVE ANCHEMCO Terostat 930 310 ml Cartridge

DISEL ADDITIVE IFTEX Iftex Clean System D 250 ml pack*

* Add to Diesel as per the dosage recommended by M/s IFTEX

61

Engine

Model : TATA 497 SP 28 Bharat Stage - IITATA 497 SP 38 - Bharat Stage III

Type : Water cooled direct injection dieselengine

No. of cylinders : 4-inline

Bore / Stroke : 97 mm x 100 mm

Capacity : 2956 cc

Max. engine output : 49.5 kw at 2800 rpm as per MOST/CMVR/TAP-115/11650 kw at 2800 rpm as per MOST/CMVR/TAP-115/116 - For Bharat Stage-II

Max. torque : 180 N-m at 1500 - 2000 rpm as perMOST/CMVR/ TAP-115/116177 Nm at 1500-2000 rpm as per MOST/CMVR /TAP-115/116-For Bharat Stage-II

Compression ratio : 19 : 1

Firing order : 1-3-4-2

Air filter : Dry (Paper) type , remote mounted.

Oil filter : Full flow paper type

Fuel filter : Double stage, fine filtration

Fuel injection pump : Rotary type

Governor : Centrifugal type variable speed.

Engine oil capacity : 5.5 litres (Min)

Weight of engine : 280 kg (Dry)

Radiator frontal area : 2260 sq. cm.

Technical specifications

Clutch

Type : Single plate dry friction

diaphragm type

Outside diameter of : 228 mm

Clutch lining

Friction area : 463 sq. cm. (approximately)

Gear Box

Type : G-76-5/3.87 with overdriveSynchromesh on all gears

No of gears : 5 forward, 1 Reverse

Gear ratios : Gear Ratio1 st 3.87

2nd 2.223 rd 1.37

4 th 1.00

5 th 0.82

Rev. 3.40

Rear Axle

Type : Single reduction, salisbury typewith hypoid gears and semi -floating axle shafts.

Ratio : : (51/11) (50/11) Alternate

62

Width : 60 mm

Suspension

Front : Double wishbone type with coilsprings.

Rear : Semi elliptical leaf springs.

Shock Absorber : Hydraulic double acting telescopictype at front and rear.

Antiroll bar : At front

Wheels and tyres

Tyre : 185 / 85 R 16 105 Q LT

Wheel rims : 5.5 J x 16

No. of wheels : Front - 2, Rear - 2, Spare -1

Fuel Tank

Capacity : 65 litres

Electrical System

System voltage : 12 volts ( -ve earth )

Alternator Capacity : 35 / 40 Amperes Optional : 65 / 75Amperes for AC version

Battery : 12V MF 70Z

Performance

Max. speed at rated GVW : 100 km / hr

Max gradeability at rated GVW : 26 %

Front Axle

Type : Independently suspended

Steering

Type : Optional I - Mechanical SteeringOptional II - Power Steering

Ratio : Optional I - 32.5 to 36.5:1 Variableratio gear boxOptional II - 18.9:1

Steering wheel : 420 mm dia. for Mech. steering400 mm dia. Power steering

Brakes

Service brakes : Vacuum assisted independenthydraulic brakes on front andrear through tandem master

cylinder.

Front : 262 dia. disc brake

Rear : 282 dia. drum brake

Parking brake : Cable operated mechanical linkagesacting on rear wheels.

Frame

Type : Ladder type cranked frame withboxed section long members andwelded cross members

Depth : 110 mm (maximum)

Technical specifications

63

Technical specifications

Main Chassis Dimensions

As per ISO : 612 in mm (Nominal)

(Tolerances as per INTEREUROPE STVZO)

Wheel base : 2425

Track front : 1496

Track rear : 1461

Overall Length : 4352

Max. width : 1700

Front overhang : 782

Rear overhang : 940 over bumper

1170 over spare wheel

Overall height : 2010 / 1925

(Unladen / laden)

Min. turning circle dia. : 10 mm

Min. turning clearance : 11.1 m

circle dia.

Ground clearance (laden) : 190

Weight (kg)

(Tolerances as per INTEREUROPE STVZO)

Complete vehicle kerb

weight as per ISO : 1176

(with spare wheel & tool) : 1750 (FAW 880 + RAW 870)Bharat Stage - II1770 (FAW 935 + RAW 835)1790 (FAW 945 + RAW 845)for A/C version - BS III version

Gross vehicle weight : 2540 (FAW 1000 + RAW 1540)Bharat stage II & III

Max. Permissible FAW : 1050

Max. Permissible RAW : 1520

Passenger Capacity

Option I : 9 + Driver

OptionaII : 8 + Driver

Option III : 5 + Driver

64

Special instructions

1. The vehicle has been built to give you thousands of kilometersof economical and trouble-free performance. This is however,possible only if this vehicle is systematically maintained andoperated strictly according to the instructions contained in thisbook.

2. This chapter contains charts showing lubrication points and theservice schedule.

l PDI - Pre Delivery Inspection

l Daily

l 5,000 km. Service at 5,000 - 5,500 km repeating

at every 10,000 km.

l 10,000 km. Service at 10,000 - 10,500 km repeating

at every 20,000 km.

l 20,000 km. Service at 20,000 - 20,500 km repeating

at every 40,000 km.

l 40,000 km. Service at 40,000 - 40,500 km repeating

at every 40,000 km.

3. Besides the service schedule chart detailing the serviceoperations to be performed Service Coupons (perforated) areincorporated on two sheets. These coupons should be detachedand sent to Customer Support, Passenger Car Division, TataMotors, Pune - 411 018 by the servicing dealer after the serviceis performed. The selling dealer should fill up details of chassisparticulars on the inside cover page.

4. These services can be satisfactorily performed only by one ofour Authorised Dealers’/TASC’s Workshops. The services, printed‘FREE’ on the Service Coupons will be performed free of labourcost at the specified km. of operation by any one of ourAuthorised Dealers’/TASC’s/ TASPs 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.

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 Service Outlets.

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 works listedfor such service must be performed when the vehicle is takennext to one of our Authorised Dealer’s/ TASC’s Workshop.

6. It is an important condition of our sales policy that nowarranty claims shall be entertained by us unless all servicesupto time of the claim arising have been performed on thevehicle by one of our Authorised Dealer’s / TASC’s/TASP’sWorkshops.

Failure to carry out the services listed in this book can causeconsiderable damage to the vehicle and inconvenience to you.

65

It is, therefore, in your own interest totake your vehicle to one of ourAuthorised Dealer’s, TASC’s, TASP’s,Workshop for servicing.

7. All our Authorised Dealer’s/TASC’s/TASP’s Workshops have been equippedwith special tools and are manned bytechnical personnel trained by us.Besides, they have adequate stocks ofgenuine spare parts for replacementpurposes, should the need arise. OurAuthorised Workshops are therefore ina position to render you any expertadvice and service your vehicle mayneed. Please give them an opportunityto serve you, so that you may obtaineconomical and trouble freeperformance from your vehicle.

8. For any technical advice concerningyour vehicle, please contact the nearestAuthorised Dealer.

Special instructions

66

SR.No.

OPERATION FREQUENCYIN km P

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ILY

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SERVICE SCHEDULE

Wash vehicle At every service

ENGINE

1. Check coolant level. Top up if necessary Daily • • • • • • • • • • • • • • • • • • • • • •2. Change coolant in cooling system. Add recommended qty. of Antifreeze agent. 80,000 or two years whichever is earlier

3. Check oil level in engine oil sump, Top up if necessary Daily • • • • • • • • • • • •4. Change engine oil filter cartridge 10,000 • • • • • • • • • •5. Change engine oil 10,000 • • • • • • • • • •6. Clean breather (Engine) 20,000 • • • • •7. Clean pre-filter at feed pump 5,000

8. Change fuel filter element FIRST (1) 10,000 • • • • • • • • • •9. Clean strainer in fuel tank 10,000 • • • • • • • • • •

10. Change both fuel filter elements (1 & 2) 20,000 • • • • •11. Replace air filter when service indicator shows red band even after cleaning or at 40,000 km in clean

conditions or at 25,000 km in dusty conditions 40,000 • •12. Clean air cleaner filter element, change if red band appears on service indicator 5,000 • • • • • • • • • • • • • • • • • • • •13. Check fan belt, adjust tension if necessary, replace if defective 5,000 • • • • • • • • • • • • • • • • • • • •14. Check and adjust valve clearance 10,000 • • • • • • • • • •15. Check thermostat for correct functioning 40,000 • • •16. Check injection nozzles for opening pressure & spray characteristics 40,000 • •17. Lubricate Water pump with grease 5,000 • • • • • • • • • • • • • • • • • • • •

GEAR BOX

1. Check oil level in gear box, Top up if necessary 5,000 • • • • • • • • • • • • • • • • • • • • •2. Change oil in gear box (first at 10,000 and thereafter at every 20,000 km.) 20,000 • • • • • •

67

3. Clean breather on gear box 80,000 •PROPELLER SHAFT

1. Grease propeller shaft U-J cross & sliding yoke 5,000 • • • • • • • • • • • • • • • • • • • •AXLES

1. Check oil level in rear axle, top up if necessary 10,000 • • • • • • • • • • •2. Change oil in rear axle 20,000 • • • • •3. Change grease in rear hubs & adjust bearing play 40,000 • •

SUSPENSION & STEERING

1. Grease idler arm, tie rod & centre link ball joints, (where provided) 5,000 • • • • • • • • • • • • • • • • • • • •2. Grease steering spindle and sleeve 10,000 • • • • • • • • • •3. Check wheel alignment & adjust if necessary (Also at first 5000 km.) 10,000 • • • • • • • • • •4. Change grease in front hub & adjust bearing play 40,000 • •5. Check & adjust steering wheel free play 40,000 • •6. Check oil level in mechanical steering gear box, Top up if necessary 40,000 • •7. Check condition of rubber bushes in the following, replace if necessary, 1) Top Wish Bone

2) lower wishbone 3) Anti Roll Bars 4) Ball joints of rubber boot, upper & lower bump stops. 40,000 • •8. Check shock absorber & its bushes, replace if necessary 20,000 • • • • •

CLUTCH AND BRAKES

1. Check level of clutch & brake fluid in containers, top up if necessary 5,000 • • • • • • • • • • • • • • • • • • • • •2. Check service & parking brakes, adjust if necessary 5,000 • • • • • • • • • • • • • • • • • • • • •3. Check front brake pads & rear brake linings, Replace if necessary 20,000 • • • • •4. Overhaul the following brake components and change the brake fluid in the system 40,000 • •

1) Tandem Master Cylinder, 2) Front Caliper, 3) Rear Wheel Cylinders, 4) Clutch Master

Cylinder & Slave Cylinder

SR.No.

OPERATION FREQUENCYIN km P

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68

SR.No.

OPERATION FREQUENCYIN km

5. Overhaul Vacuum Booster & change the felt and Polyurethane filters along with rubber bellow 40,000 • •ELECTRICALS

1. Check electrolyte level in battery, add distilled water if necessary 20,000 • • • • • •2. Check Specific gravity of electrolyte 40,000 • •3. Check headlamp focussing & functioning of other electrical gadgets & adjust 20,000 • • • • • •4. Apply grease on door latches, door lock striker, bonnet opening lever and lock plate 5,000 • • • • • • • • • • • • • • • • • • • • •5. Apply grease on tail gate hinges & door lock inner ratchet, Lubrication with oil can 40,000 • •6. Tighten all fasteners: front grill, oil sump, oil & fuel lines, fuel filter & mtg. bracket, exhaust 10,000 • • • • • • • • • • •

manifold & pipe, air filter, engine, clutch hsg. radiator mtg., accelerator cable, radiator hose,prop. shaft centre brg. bracket/mounting bolts, U-bolts & nuts of springs, joints of pitman arm,idler arm, centre link, tie rods, upper ball joints of top wish bone, mtg's of lower arm & lowerlink, steering gear box and its mtg. bracket, vacuum & hydraulic line connections, head lampmtg. wheel mtg. nuts, drivers cab seats mountings, axle shaft mtg., anti roll bar mtg., vacuumbooster & tandem master cylinder mtg's, clutch master & slave cylinder mtg., rear anchorplate mtg., front disk brake mtg., fuel tank mtgs., front suspension top rubber mtg. nut.

AIR CONDITIONING SYSTEM (Where fitted)

1. Check compressor belt, adjust tension, Replace if necessary 5,000 • • • • • • • • • • • • • • • • • • • •2. Check bubbles in receiver drier for refrigerant level 5,000 • • • • • • • • • • • • • • • • • • • • •3. Check for leak of gas / oil from pipes, joints, compressor shaft seal & cylinder head 5,000 • • • • • • • • • • • • • • • • • • • • •4. Clean condensor with high pressure water 5,000 • • • • • • • • • • • • • • • • • • • •5. Check fan speeds for proper air flow 5,000 • • • • • • • • • • • • • • • • • • • • •6. Check clutch operation 10,000 • • • • • • • • • • •7. Check system pressure with gauges 20,000 • • • • •

WHEELS & TYRES

1. Tyre rotation (check tyre pressure) 10,000 • • • • • • • • •

SERVICE SCHEDULE

PD

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69

Record of service performed Chassis No. .........................................

Recommended Odometer Repair Servicing Dealer’sService Date reading Order Signature and

km. No. Stamp

At km.

PDI*

5,000*

10,000*

15,000*

20,000*

25,000

30,000

35,000

40,000

* Free labour, material chargeable.

Recommended Odometer Repair Servicing Dealer’sService Date reading Order Signature and

km. No. Stamp

At km.

45,000

50,000

55,000

60,000

65,000

70,000

75,000

80,000

85,000

90,000

70

Record of service performed Chassis No. .........................................

Recommended Odometer Repair Servicing Dealer’sService Date reading Order Signature and

km. No. Stamp

At km.

95,000

1,00,000

1,05,000

1,10,000

1,15,000

1,20,000

1,25,000

1,30,000

1,35,000

1,40,000

Recommended Odometer Repair Servicing Dealer’sService Date reading Order Signature and

km. No. Stamp

At km.

1,45,000

1,50,000

1,55,000

1,60,000

1,65,000

1,70,000

1,75,000

1,80,000

1,85,000

1,90,000

71

Record of repairs carried out Chassis No. .........................................

Date Odometer Repair Particulars of Repair Servicing Dealer’s Signature & Stampreading (km) Order No.

72

Record of repairs carried out Chassis No. .........................................

Date Odometer Repair Particulars of Repair Servicing Dealer’s Signature & Stampreading (km) Order No.

73

ABBREVIATIONS

AC Air Conditioning

ACC Accessories

Amp Amphere

Br Branch

Brg Bearing

cc Cubic Centimeters

Cm Centimeter

Dia Diagonal

EGR Exhaust Gas Recirculation

FAW Front Axle Weight

Fig Figure

FIP Fuel Injection Pump

gm Gram

GVW Gross Vehicle Weight

IGN Ignition

Kg Kilogram

Km Kilometer

Km/h Kilometer per hour

LH Left Hand

Max Maximum

MD Main Dealer

Min Minimum

mkg Meter per Kilogram

Mtg Mounting

No Number

PCBU Passanger Caqr Business Unit

PDI Pre-delivery Inspection

PSI Punds per Square Inch

PUC Pollution Under Control

RAW Rear Axle Weight

RCSM Regional Customer SupportManager

RH Right Hand

RPM Revolution Per Minute

Sec. SecondsSq.cm. Square Centimeter

TASC Tata Motors Authorised ServiceCenter

TASP Tata Motors Authorised ServicePoint

V Volts

W WattsWt Weight

74

75

Customer Support Network

Contents :

Page No.

l Tata Motors Office and Network A-1 to A-3

l Names & Addresses of Tata Motors B-1 to B-32

Main dealers, TASCs & TASPs

CUSTOMER CARECENTRE

TOLL FREE NO.1800 209 6688

TATA SPACIO TATA SPACIO

TATA SPACIOChassis No. ......................................

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

At 15,000-15,500 km 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 .........................................................................

3FREE

LABOUR

TATA SPACIO

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

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

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

At 10,000-10,500 km 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 .........................................................................

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

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

At 5,000-5,500 km 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 that

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 .........................................................................

2FREE

LABOUR

PDIFREE

LABOUR

1FREE

LABOUR

TATA SPACIO

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

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

At 20,000-20,500 km 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 .........................................................................

4FREE

LABOUR

Vehicle record sheet

Model :.................................................................... Key Number : .....................................................................

Type : ................................................................... Chassis Number : .....................................................................

Date of Delivery : ................................................................... Engine Number : .....................................................................

Date of Registration :.................................................................... FIP Number : .....................................................................

Registration Number :.................................................................... Gear Box Number : .....................................................................

Owner’s Name : ................................................................... Rear Axle Number : .....................................................................

Address : ................................................................... Steering Gear Box Number : .....................................................................

Selling Dealer : ...................................................................

Address : ...................................................................

: ....................................................................

....................................................................

Selling Dealer’s Code No.

vi

VERSION DESCRIPTION

2698 6524 R TATA SPACIO ‘S’, 497 SP, Mechanical steering, BenchSeat, 6 Seater, New Suspension, 185/85 R16 105Q LT tyres, Domestic, CMVR 2000

2698 8724 R TATA SPACIO , 497 SP, Mechanical steering, BenchSeat, 10 Seater, New Suspension, 185/85 R16 105Q LT tyres, Domestic, CMVR 2000

2698 9324 R TATA SPACIO SA S, 497 SP, AC, Mechanical steer-ing, Bench Seat, 6 Seater, New Suspension, 185/85 R16 105 Q LT tyres, Domestic, CMVR 2000

2698 9524 R TATA SPACIO SA, 497 SP, AC, Mechanical steering,Bench Seat, 10 Seater, New Suspension, 185/85R16 105 Q LT tyres, Domestic, CMVR 2000

2698 6724 R TATA SPACIO, 497 SP, Mechanical steering, BenchSeat, 10 Seater, TATA Rear Axle, 185/85 R16 105 QLT tyres, Domestic, CMVR 2000

2698 7624 R TATA SPACIO , 497 SP, Mechanical steering, BenchSeat, 9 Seater, New Suspension, 185/85 R16 Q LTtyres, Domestic, CMVR 2000

2698 7724 R TATA SPACIO SA, 497 SP, AC, Mechanical steering,Bench Seat, 9 Seater, New Suspension, 185/85R16 Q LT tyres, Domestic, CMVR 2000

2698 8524 R TATA SPACIO, 497 SP, AC, Mechanical steering,Bench Seat, 10 Seater,New Suspension, TATA RearAxle, 185/85 R16 Q LT tyres, Domestic, CMVR 2000

VERSION DESCRIPTION

2827 2324 R TATA SPACIO, 497 SP, Mechanical steering, BenchSeat, 10 Seater, 185/85 R16 105 Q LT tyres,Domestic, Bharat Stage-II

2827 4124 R TATA SPACIO SA, 497 SP, A.C, Mechanical steering,Bench Seat, 10 Seater, 185/85 R16 105 Q LT tyres,Domestic, Bharat Stage-II

2827 4324 R TATA SPACIO S, 497 SP, Mechanical steering, BenchSeat, 6 Seater, 185/85 R16 105 Q LT tyres, Domestic,Bharat Stage-II

2827 4424 R TATA SPACIO ‘S’ SA, 497 SP, A.C, Mechanicalsteering, Bench Seat, 6 Seater, 185/85 R16 105 QLT tyres, Domestic, Bharat Stage-II

2827 7824 R TATA SPACIO, 497 SP, Mechanical steering, BenchSeat, 9 Seater, New Suspension, 185/85 R16 105Q LT tyres, Domestic, Bharat Stage-II

2827 7924 R TATA SPACIO SA, 497 SP, AC, Mechanical steering,Bench Seat, 9 Seater, New Suspension, 185/85R16 Q LT tyres, Domestic, Bharat Stage-II