& MICO Bosch Group Fuel Tank + Use proper sealing cap + Drain sediments every month + Clesn thoroughly every sic months + Check low pressure pipes for loskage + Dra water separator (wherever fitted), once a week Feed Pump + Clean hollow screw with sieve! every 2,000 km * Clean preliminary fiter every 500 km * Ghack rubber sealing washer, preter bow nylon valves, spring te fers, + Drain water/sediments every 5000 be + Replace fiter inserts as recommended + Gheok overtiow valve (if provided) for leakage: + Always use genuine MICO fiter inserts + Do not clean fiter inserts Fuel Injection Pump + Check oil level every 8000 kam. Dray excess ol. I level is low, top up with engine «il ‘Only for independent lub. pure! + Replace cil every 1,00,000 km (On, for independent lub pump) * Check overiow valve (tf provided) for eakage + Clean air breather (if provided) every 5,000 km + Use good qualiy high pressure pipes. Claanfluch before iment Injector + No mainisnance is required For Diesel Vehicles SSE 3 9901 (04.2001) PieERRATIC RUNNING/ ~ KNOCKING SOUND Some tips to solve your vehicle problems. 1, ERRATIC RUNNING Probable Cause Remedy Probable Cause Remedy ‘Overtow. valve etickyileaky: Replace Fuel adulterated Replace Airin fuel system Ventiate Filter insor(s) clogged Replace ‘Governor stop lever nat fully disengaged Rectify Air in hel system Ventilate Accelerator linkage looselrestricted Rectify ‘Accelerator linkage loosetrestrcted Rectily Pump injection timing incorrect Readiust Pump injection timing incorrect Reagjust Excess fuel devieo defective Reotily Pump phasing incorrect/unequal delivery Recalibrats Injection pumpifoed pump wern out Recalibrate/averhaiil Pump control rack/toothed quadrant worn-out Replace and recalibrate High pressure pipe joints leaky Rectify/replace High pressure pipe joints leaky Roctiyrelece ijecto Rot sedling in cinder esd Clean seatngiesiace washers High pressure pines reetricted Rectityieplace Spay holes clogged, needle sticky, poor spray Glean/replaoe ‘Spray holes clogged, needle sticky, poor spray Cleanfrepiace Air filter/exhaust system clogged Cleanfeplace Engine compression poor/partially seized Overhaul Engirie compression poor/partially seized Overhaul Valves sticky/springs broken/clearance incorrect Replace/reset Valves sticky/springs broken/clearance incorrect Replace/reset 2. STARTING TROUBLE 3. KNOCKING SOUND Probable cause Remedy Probable cauag Remedy, Battery weak/staner defective Check electrical system. Fue! adulterated Replace Foatiyroplace ump injection tring correct Reacust Giow plugs/srcun defectve Replacelectiy orcut Pump phasing inconectionequal delivery calibrate No fin tank Fil uptanc Purp deliver vale suckering broken Replace & recaloate Fuel adulterated Replace Opening pressure high Recat Tank breatter hol Blocked Clean ‘Nozzle atickin opon postion NH spring broken Replace Low pressure pipes blocked CClean/replace ‘Spry holes clogged, needle sticky, poor spray ‘Gleanvreplace Fiterineort(e) clogged Replace Engine compression poor/partially seized OverhaulSTARTING EXCESS FUEL TROUBLE CONSUMPTION Probable Cause Probable Cause Remedy Vio atcylspirgs rokanelemance incorrect Replaco/osot Airfierfoxaet sytem clogged Cleaireplace ig endrain bowing worn-out, crank shat pay excessive Ovehs Engine comprossion por/partly sized Overhaul Excaasve carbon doposis in combustion chamber Dscarborae ‘Valves tckyeprings broken/cesrance inovect Fepacaonet Cite resus pela lcone Tighon Calin syst fall Recty Cotch pte workout Replace 4, LOSS OF POWER Boakaaagea Ty Reagust an Tame Tyres underinted Infate comocty erated ees Enainescicio ovedaded Avcid overoading Tank breather hols blocked Com Low pressure pipes blocked ‘Clearireplace 5. EXCESS FUEL CONSUMPTION Fier nso) clogged epee Probable cause Overflow valve sticky/leaky Rephce Fuel leaking ‘icin ful sytem Vente Pump ijecton ting incatract ‘AgceleftorInkagslooselrestictad Roatly Excess fl dovice defective Pump itn tring incorrect Readist Idling sped wating oo Figh Masinum spe sting 19 ow Readust Flload/couse 0 deters to oh Injection puied pump woenoxt Recelbratefoverhaud Inicon mar advance incorect Injection timer acance incorest Rensir Opening proseure low High pressure pipa joins aly Recttireplace Spray holes clogged, needle sticky, poor spray Greanreplace High presse pps cesticted Reatiyrepace Nozle needle Ht excessive Replace Injector not sealing n-ylnder head Clean seatingioplce washers | Air itor/eshaust system clogged Creanreplace Postion of orale noomect 2 washers weed) Reatty Engine compression poorpatialy seized Oval pening pressure Figh Reset Vales sticyfspings broke clearance inomect Replacrreset. Spray holes clogged, needle atch, poor pray Cieavrepace Cooingli oi eye fay ReciyHIGH EMISSION OVERHEATING (EXHAUST SMOKY) Probable Cause 7. OVERHEATING Catch pate worr-outfbuent eee Ronee Brakes cragsinai Pump nection timing ineoroct Readjust ‘Tyres under-inflated Inflate correctly Fill load course of delivery too high Recalibrate Exgine/veicle oveioaded Avid ovedoading Spray holes clogged, needle slicy, poor spray Cleaneplace Untimely gear shiting/unsteady driving Improve driving habits Engine compression poor/prtaly seizes Overhaul Engine idling 100 lng void Valves siky/Sorings broken/olearance incorrect Replace/reset Excessive carbon deposits in combustion chamber Decarborisn 6. HIGH EMISSION (EXHAUST SMOKY) Cooking! system fly Rectfy Probable cause Remedy Clutch slate woer-outfourt Replace Pump injection timing incorrect Readiust Brakes dragging/binding Readjust Excessive fuel device defective Rectiy Engine/rohicie overloaded ‘void verloading Pump dalvory vale stuck/pring broken Replace anc recalibrate Full loadfoourse of delivery too high Recalibrate Injection timer advance incorrect Ropair "Position of nozzle incorect (2 washers used) Reetiy ‘Opening pressure low Reset For further deta, contact: Department: SSE Nozzle stuck in open position/NH spring broken Replace Motor indnsinies Co: Eis PB. No, 9000, Hosur Road, Adugodi, Bangalore 660 080. Spray holes clogged, nesdle sticky, poor spray leanhroplace aE SE eer Sales Houses: New Delhi: Rishyamook, 85-A, Panchiuin Road, New Delti-110 001 Nozzle needle itt excessive Replace Ph: (01!) 484 6260/61/62/63, Fax: (011) 534 8264, Kolkata: PB, No, 9044, 91-A, Park Steet, Kokata-700 016, Ph: (039) 245 7471, 245 7475, Fax: (039) 245.7482, Air fiterfexhaust system clogged Clearvreplace Mumbai: 72, Dr. Annie Besant Road, Worl, Mumbai-400 018, Ph: (022) 499 2071, C Overhaul 4495 1631. Fax: (022) 497 3024. Chennal: PB, No. 6802, 22, Eira] Sali, Egmore, Ghenna-600 008. Phi (044) 827 9276,827 3981, Fax (044) B27 8350.