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Old 26th May 2013, 12:08   #5161
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Default re: The Tata Safari 2.2L Technical / Problems Thread

Hi All, following are the details for the 5th year annual service, done at 46,320KM on 04.05.2013:

Spares:
BRSD14, Bardahl Special Duty, 0.6L, Rs.875.11
G254718130115, Oil Filter, 1, Rs.195.63
OILCASGTXD, Castrol GTX CH4 15W40, 6.9L, Rs.1,982.65
254701139201, Seal Washer OS Drain Plug, 1, Rs.14.85
OILGEARTQCASTR, Transpower TQ GearBox Oil, 1.5L, Rs.353.72
253409110117, Assy. Fuel Filter Delphi, 1, Rs.1,592.14
CM-TW-AV003, Wash Mitt, 1, Rs.87.34
G62120601615, Lamp WSW 12V 5W Capless, 1, Rs.49.78

Labour:
PAIDOC, Oil Change Service 45000KM Paid, Rs.810.00
401040, Front Wheel Alignment, Rs.405.00
HG, Hub Greasing+Idler Arm Play Removed, Rs.167.00
STDCHK, Sundries, Rs.88.00
VNIT, Nitrogen Filling, Rs.80.00
TR, Tyre Rotation, FOC
053000, Intercooler Hose Pipe Tightening, FOC
293020, Clutch Hose, Pedal Lubricated, FOC

Final Spares Invoice Total: Rs.5,898.10
Final Labour Invoice Total: Rs.1,741.58
TOTAL: Rs.7,640.00/-

Insurance was also renewed on the same day. Cost: Rs.11,107/-.

Hi Rahulk76, updating though lately, on the clutch slave cylinder, pressure plate, and releaser bearing replacement. Though it's softer than before, I now guess the trick is to have it cleaned, which in itself would bring down the effort/heaviness.

Also, the engine bay was making a grating noise for a few months, which turned out to be a loose intercooler pipe, and sadly, was not identified/resolved by a TASC in B'lore. I really appreciate the DTE who identified it in first go of opening the hood at Auto MATRIX. Perhaps it's a recurring problem he encountered, but still happy that it's fixed now. In fact, the response from engine is marginally better after this fix. Assuming the looseness(?) was leading to a drop in torque due to exhaust gas leaking out.

The Safari underwent a partial roof paint job for rust removal during Nov'2012.
Guys, please take due caution in drying off the section where the roof meets the windshield beading. I was careless and paid the price, painfully, for having to remove the windscreen for the complete fix to be done. Since the vehicle was in the TASC, also got the plastic side claddings painted to gray (stupid decision? Maybe, but liked the dual tone paint), as well as dashboard, seats, carpets removed, and floor painted with thick anti-rust primer and a layer of plastic underneath the carpet (this type of material is used in marine applications, foolish decision again? maybe, but decided to go by the 3M technician's suggestion, perhaps after his experience in living in coastal areas, so long). Total expense: Rs.36K/-

5 years seem to have passed in a flash. Thanks to our drive for all the moments of joy spent, and for the confidence given in spot-fixing (hehe, not apt to use during these times) trips to hometown and back!

Cheers.

Last edited by dkamath : 26th May 2013 at 12:11.
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Old 26th May 2013, 18:28   #5162
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Default re: The Tata Safari 2.2L Technical / Problems Thread

Quote:
Originally Posted by dkamath View Post
Hi Rahulk76, updating though lately, on the clutch slave cylinder, pressure plate, and releaser bearing replacement. Though it's softer than before, I now guess the trick is to have it cleaned, which in itself would bring down the effort/heaviness.
Have it cleaned? does it mean opening the bell house and then cleaning it. I noticed that bleeding the slave cylinder helped 50% of original clutch softness.

Quote:
Originally Posted by dkamath View Post
The Safari underwent a partial roof paint job for rust removal during Nov'2012.
Guys, please take due caution in drying off the section where the roof meets the windshield beading. I was careless and paid the price, painfully, for having to remove the windscreen for the complete fix to be done.
What a coincidence, a friend of mine got the same thing done too last year albeit got it covered under paint warranty done. His is 3 year old safari. Apparently, the cause was due to some issue of drying paint procedure done at factory and subsequent acuumulation of moisture getting locked inside thereby leading to rust. The exact spot was LHS side of roof. There were paint pops and boils along the windshield beeding. Perhaps a defect after all ?

dkamath suggest you take AMC. It is wonderful and light on the pocket given the rising costs.

Last edited by Rahulk76 : 26th May 2013 at 18:31. Reason: correction in spellings
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Old 27th May 2013, 10:41   #5163
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Originally Posted by smsrini View Post
I faced a similar condition 2 days back in Ooty.

On ghat roads with ac on, the car was not picking up speed in 1st gear. Same with steep slopes.

I observed this happening after I filled fuel at Gudalur. So on a full tank.

You may not find anything wrong with your engine. Normally this happens when you fill up in plains and go up the mountains. The cold-flow properties of the diesel fuel is not right for the cold climate up in the hills. It causes momentary lack of power in the engine - especially when the engine is cold. The Cetane value for the mountains should be higher in mountains.TSK sir can tell you more on this as he travels in the Himalayas - much colder than any mountains in the south.

I have filled in Ooty/Coonoor whenever I am in Nilgiris and I don't get this 'shortness of breath'. But when I was in Nandi hills, my safari initially had a bout of this. May be the ECU settings are optimized for plains driving condition. If you rev high or keep to the turbo zone of 2500 rpm, Safari engine climbs any hill.
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Old 27th May 2013, 13:44   #5164
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Originally Posted by ankur_gupta10 View Post
Might sound silly, but it just maybe that the knob which adjust where the air has to go, has malfunctioned, or is not set correctly.
Quote:
Originally Posted by Rahulk76 View Post
6 years Nice

Time to get the muck accumulated cleaned up i guess
The issue is resolved, it was a contact point with the blower's sensor which was acting up after getting heated up due to a loose connection. Putting in a piece of paper in the connector has been working fine for the last couple of days now. So far so good.
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Old 27th May 2013, 13:55   #5165
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Originally Posted by Dragonov View Post
The issue is resolved, it was a contact point with the blower's sensor which was acting up after getting heated up due to a loose connection. Putting in a piece of paper in the connector has been working fine for the last couple of days now. So far so good.
Hi Dragonov
Good to hear that your issue is resolved. Can you share the exact location of this "blower's sensor"?
Thanks
R.
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Old 27th May 2013, 15:07   #5166
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Hi Dragonov
Good to hear that your issue is resolved. Can you share the exact location of this "blower's sensor"?
Thanks
R.
Hi Rahul,
As per the TASS am told that there is a sensor to which the Blower wiring is connected. This is directly beneath where your glove compartment is. You need to just go beneath that area and you would see it, though I did not see it in person but yes saw the coupler attached to it which was loose. I guess a person who has prior knowledge can make the difference of which coupler it is, as there are other wires etc too.
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Old 28th May 2013, 19:33   #5167
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Originally Posted by Rahulk76 View Post
Have it cleaned? does it mean opening the bell house and then cleaning it. I noticed that bleeding the slave cylinder helped 50% of original clutch softness.
Let me revert with the exact method used.

Quote:
Originally Posted by Rahulk76 View Post
dkamath suggest you take AMC. It is wonderful and light on the pocket given the rising costs.
Thanks for the suggestion! I guess the vehicle has crossed the age cap (5 years) for the AMC. But let me check on this too.
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Old 2nd June 2013, 11:42   #5168
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Default re: The Tata Safari 2.2L Technical / Problems Thread

Vehicle returned from 5th service @ 44500KMs and I'm horrified to realize the scraping and falling parts when going over the small plastic road bumps inside our apartment complex

I suspect loose nuts & bolts.

This is from Concorde Begur Road, and looks like the driver who delivered the vehicle knew it and quietly left the car or he didn't realize the damage.
Attached Thumbnails
The Tata Safari 2.2L Technical / Problems Thread-img_20130602_110130-large.jpg  

The Tata Safari 2.2L Technical / Problems Thread-img_20130602_110207-large.jpg  

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Old 3rd June 2013, 08:27   #5169
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Default re: The Tata Safari 2.2L Technical / Problems Thread

Symptoms: Sudden loss of power, but no thick black smoke. Max speed 90kmph Feels like driving my old 2003 Indica. Pedal to metal no respite.

Time: Afternoon 3pm

First I thought bad quality of diesel and drained the fuel filter and fuel sedimenter. But no effect a little better 5% maybe.

Casually chatted with fellow bhpian jaysmokeleaves and he immedietly said that it was a classic symptom of blown turbo hose or similar. Was told to check all hoses and tighten up the screws. Special attention to be made to the turbo hose (black in color) near the intake manifold on the left side of the vehicle.
I still donot know the extent of the damage yet, but let the pictures talk taken this morning.

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I felt the hose pipe and it was reecing oil all over. But wait there was something rubbing it also from the engine side. There is no gap. (marked with Pink Marker in the pic below.)

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My question is that is this a classic design failure? Has TML come-up with redesigned turbo hose or what?

The good news is that this circus happened sooner than during the upcoming trip. The vehicle had been for service a little earlier and I had specifically asked them to check for all the hoses and replace if necessary.
Someone didnt do their job and thats what stenches big time.
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Old 3rd June 2013, 10:09   #5170
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Thumbs down re: The Tata Safari 2.2L Technical / Problems Thread

Quote:
Originally Posted by Rahulk76 View Post
Casually chatted with fellow bhpian jaysmokeleaves and he immediately said that it was a classic symptom of blown turbo hose or similar. Was told to check all hoses and tighten up the screws. Special attention to be made to the turbo hose (black in color) near the intake manifold on the left side of the vehicle.

I still don't know the extent of the damage yet, but let the pictures talk taken this morning.
The vehicle had been for service a little earlier and I had specifically asked them to check for all the hoses and replace if necessary.
Someone didn't do their job and thats what stenches big time.
Woah, pretty bad situation there with the hose. Seems like the problem didnt happen suddenly, but developed over time and glad it happens before your trip.

I am wondering why did not the TASS identify the problem of the hose when were told to ?

Please let us know about the outcome of the resolution and also check if Tata has redesigned the hose to avoid rubbing?
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Old 5th June 2013, 12:46   #5171
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Originally Posted by Rahulk76 View Post
I felt the hose pipe and it was reecing oil all over. But wait there was something rubbing it also from the engine side. There is no gap. (marked with Pink Marker in the pic below.)
Attachment 1091866
Hi

I was getting my car serviced at TASS and saw the similar case as in your safari.

There is a bracket attached to the iron pipe (which connects to the intake manifold) which is attached to powersteering pump. That bracket generally breaks off therefore letting that pipe loose. Due to vibrations etc that iron pipe makes a racket inside the engine bay and therefore leads to the hose coming off.

Can you please check if indeed your intercooler to manifold pipe is intact and held securely at the bracket. As i saw it was near the bottom towards the intercooler (red color small silicon hose)?

Tx.
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Old 5th June 2013, 20:00   #5172
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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There is a bracket attached to the iron pipe (which connects to the intake manifold) which is attached to power-steering pump. That bracket generally breaks off therefore letting that pipe loose. Due to vibrations etc that iron pipe makes a racket inside the engine bay and therefore leads to the hose coming off.
Well thats it ! a similar story here. The bracket broke. I dont know since how long.

Its a bad design. Real bad design. Somebody didn't do the proper Finite Element Analysis of this bracket. Kudos to the engineer who designed & tested it

Ill let the picture speak for itself. See how much play is generated due to it.
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The pipe costs 4xx. The rubber hose costs 3xx something and the labour to do it 600 .

The pipe has been ordered, and should land in a FEW days in Pune. (Shipping from Pune-Pune) beat that.

Last edited by Rahulk76 : 5th June 2013 at 20:03.
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Old 6th June 2013, 13:40   #5173
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Originally Posted by Rahulk76 View Post
Symptoms: Sudden loss of power, but no thick black smoke. Max speed 90kmph Feels like driving my old 2003 Indica. Pedal to metal no respite.

Time: Afternoon 3pm

First I thought bad quality of diesel and drained the fuel filter and fuel sedimenter. But no effect a little better 5% maybe.

Casually chatted with fellow bhpian jaysmokeleaves and he immediately said that it was a classic symptom of blown turbo hose or similar. Was told to check all hoses and tighten up the screws. Special attention to be made to the turbo hose (black in color) near the intake manifold on the left side of the vehicle.
I still donot know the extent of the damage yet, but let the pictures talk taken this morning.
Can you please share a high level picture of where this pipe is located. I would like to check in my car also. With the present pics, i am confused, where the exact location is of this pipe.. Thanks in advance.
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Old 6th June 2013, 13:45   #5174
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Default re: The Tata Safari 2.2L Technical / Problems Thread

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Can you please share a high level picture of where this pipe is located. I would like to check in my car also. With the present pics, i am confused, where the exact location is of this pipe.. Thanks in advance.
This is on the left side of vehicle Ankur. (Where the oil filter is present)

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The above pic is taken by placing the phone camera facing towards front side of the vehicle, placed on the Oil Filter of Safari in the engine bay.

Hope that helps.
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Old 6th June 2013, 16:54   #5175
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Default re: The Tata Safari 2.2L Technical / Problems Thread

I know this is a real stupid question to ask after owning the Safari for 3 long years, but is it normal for the AC to give a hissing noise when it starts. My safari AC gives a long "hiss" sound as soon as it is put ON which goes of after a couple of seconds. I am trying to get the safari rattle and noise free and this question came in my mind whether this sound is normal or this is an indication of something wrong?
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