Indigo Problems. HELP!!!


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Hi there,
         We own Tata Indigo XL Grand Dicor, purchased on 03-05-2007 from 'Sterling Motors, Solapur'. It has crossed 63000+kms. The car since new is giving series of problems.
        1. In June 2007, the car met with an accident (A dog came in front of car and got killed), which cost about Rs.35000/-. (Odometer reading 8,500kms.)
        2. Again after 15 days, the coolant was leaking. So we showed to Sterling Motors (SM) from whom we purhcased. They replaced the Water Pump under warranty. (Odometer reading 9,740kms.)
        3. In August 2007, the car stalled in middle of road while driving. I tried to start the car but in vain. There was a bus stop ahead of our car. A person on bus stop said that the Diesel is leaking from under the car. (Thank God that we were in our Home City and not on a Highway when the car stalled.) Then I called the Manager (Mr. Nitin Patil) of 'SM' and told him about the incident. He sent the Road Assistance car for inspection with some necessary parts. The mechanic checked and said that the Main Fuel Line (it is made of Metal) which supplies fuel to the Engine has developed a crack. The fuel leaked from there and hence the Engine was not starting. The mechanic went back to bring that metal pipe from SM as he did not bring it before. He then replaced it. I was charged Rs.300/- against the Road Assistance provided. The pipe was replaced under warranty. (Dont remember the Odometer Reading).
        4. In February 2008, the car refused to start even if car was unlocked with Remote (Indigo XL comes with Factory-Fitted Engine Immobiliser). We tried unlocking the car with Remote 7-8 times but in vain. The 'LOCK' indicator on instrument panel was blinking continuously despite unlocking with Remote. The indicator was not turning OFF. It was night time and my Dad was at his friend's house which is 2-3 kms from our house. We parked and locked the car there safely and returned home. On next morning, a mechanic from Chavan Motors, Solapur (Tata Authorised Service Center) came and inspected the car. He interchanged the 60A fuse (not with a new one) but the 60A fuse present adjacent to it and tried to start the car. And what a surprise, the car started without any fuss. We brought the car to home. After 2 hours, again the car refused to unlock with Remote. Again the 'LOCK' indicator on instrument panel was refusing to go off. Again I interchanged the 60A fuse with its adjacent one. But still no sign to unlock. Again I interchanged both the 60A fuses and this time the car was unlocked with remote and the car started.
           We told SM (sterling Motors) about this. They inspected the car but could not find any problem.
           In March 2008, Mr. Nitin Patil (Sterling Motors) called me and said that the above problem of Remote Locking was detected in couple of other Indigo XLs also. So he told me to leave the car at their workshop and they will replace the Complete Remote Unlocking Kit with a New One. So I gave our car. They replaced the Complete Remote Unlocking Kit, the Timing Belt and the Pressure Plate (Both Timing Belt and Pressure Plate got wet with Engine Oil).All the three were replaced under warranty. (Odomter Reading 34,780kms.)
        5. Again in April 2008, the Auxillary Coolant Tank starting leaking and had to be replaced under warranty. (Odometer Reading 38,150kms.)
        6. Indigo Xl's Grand Variant comes with Electric Seats.
           In May 2008, the Front Passenger Seat refused to move 'To and Fro' (only back rest and height adjustment were able to be adjusted). Again I got it (Electric Adjustment Switch) replaced under warranty. (Odometer Reading 41,593kms.)
        7. Again in May 2008, the starter refused to start the car. After showing to SM, they repaired the starter under warranty. (Odometer Reading 42,758kms.)
        8. In September 2008, the AC Belt was replaced under Warranty. (odometer Reading 53,950kms.)
        9. Again in October 2008, the car suffered from Coolant Leakage and also the Temperature Guage showed that the Engine overheated, then the Engine shut off because of Overheating. This time Auxillary Coolant Tank was replaced under warranty. (Odometer Reading 57430kms.)
       10. In November 2008, again the Coolant Leakage Problem arosed. And this time the Temperature Guage on instrument panel showed that the car was overheating. The car This time SM replaced the Thermostat stating that the coolant was coming out of the Auxillary Tank's cap because of Back Pressure. Now still the Coolant Leakage is present
           Now I am thinking of going to Tata Motors Regional Office and tell them to sort the problem as I lost faith in Tata Motors Dealership.
           Also I will contact


 But when I emailed to on 20 March 2008 for some other problem, I received no feedback from ACI. Still waiting for the reply from Autocar India. There's a post of this topic (Please see topic of 20-25 March 2008 on this Forum).


        FRG (Manish), please Private Message me your Mobile Number. I want to call you and discuss about this series of Problems. And I know you will definitely help me in contacting ACI HelpDesk.
sudeepd2008-11-23 14:58:54
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You better contact helpline...

But The Helpline Does Not Have Time To Reply My Emails.

But then i think the dog accident triggered all these

              The dog hit the Front Bumper of the Car. That means the Condenser and in turn, the Radiator should get damaged. Then why "All other parts except Radiator" started to Leak the Coolant.


OK Now the Further Story=>>

On 24th November, when I asked the Service Manager,Mr. Nitin Patil at Sterling Motors, Solapur (Our Dealer) about why the coolant is coming out of the Auxillary Tank's cap with pressure, he said "The Head Gasket will have to be replaced with a new one. Also, after opening Head Block, the Injectors will also have to be replaced with new ones. The cost of replacing Head Gasket will be more than Rs.10,000/- plus the cost of injectors. The injectors of Common Rail Engine are VERY Expensive as compared to normal TDI Engine injectors."

  That means the cost will go in the range of Rs.15,000-20,000/- plus. I asked him I am ready to face that much cost if he can give me assurity that the coolant will not come out of Auxillary Tank's cap after replacing the Head Gasket (and Injectors). But he told me that he can not give assurity of the work carried out. Then I asked if he cannot give me assurity, then why should I expend Rs.15000-20000/-plus.
    My relative (he lives in USA) had come for some official work to India. He told me if Head Gasket is gone (if Head Gasket is faulty), the car will suffer from poor Pickup and poor Fuel Efficiency (Loss of Fuel Efficiency of about 20-30%). But our car does not face either of above problems (poor pickup or poor fuel efficiency). The Pickup is as it was when New and Fuel Efficiency also is good.

        The coolant comes out only after the temperature has reached the HALF Mark and the car is driven at speeds of 90-100kmph (5th Gear).i.e., Suppose the engine is Cool. Start driving the car and after sometime the Engine Temperature start rising and come to the HALF Mark. Now after coming to Half Mark, if the car is driven at speeds of 90-100kmph (5th Gear), the coolant comes out of Auxillary Tank's cap.         

        If the car is driven at speeds <=80kmph Even After Engine Temperature reaching Half Mark, the coolant does not come out. Then why only for 90-100kmph, the coolant comes out.


      On 25th November, I and my relative noticed that the Radiator Fan was not working and also the Heater was not blowing Hot Air (when I turned the AC Temperature Knob to RED Zone). I checked the Radiator Fuse (60A, for Radiator Fan not working) under bonnet, but it was OK and not blown.
     So on 26th, I went to a local garage to show the above problems of Radiator and Heater. But after travelling 7-8 kms distance to the garage in morning (10:15am), the Engine Temperature did not rise even to small extent. I told him to check that also. He checked the Temperature Sensor and told me to replace it. I replaced it. Then the Temperature Gauge showed Temperature of Engine.  
  As for Heater problem, he opened the Centre Console (not complete dashboard) and showed me that the cable connected to the AC Temperature Knob was jammed. He freed it. Then Hot Air started coming when the Knob was turned to RED Zone and Cool Air when the Knob was turned to BLUE Zone.
        For Radiator Fan not working, he checked the Radiator Fuse (60A) but it was OK. Then he checked Relay Unit Fuse (5A) under bonnet. That also was OK. Then he told me to take the car to TASS as the car was having Sensors, it can be checked on Laptop only (using software).
Then I went to our Dealer to check why the fan was not working.
 On the way after driving for 3-4 kms, the Engine Temperature Gauge started falling down slowly. It came down from HALF Mark (50%) to 25% while the car was moving (AND THAT TOO WITH RADIATOR FAN OFF). Again after 3-4 kms it came to 50%.
      The mechanic at our Dealer checked and said the Relay Unit Fuse (5A)was blown (this fuse was OK at the local garage). After replacing the fuse the Radiator Fan started working.



Can someone help me in this matter?
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Oh man!!..really thats lots of probs!!... smiley18.gif

Sudeep Buddy, send Aci help desk e-mails even if they don't hear, but they will have to hear you at one point of time! try to contact with them!

..n I agree to chirag that its even more better to contact TATA!....atleast they should know about this!...why don't you mail all these above probs to some tata official!?! sure even if doesn't hears about your problem, Tata will definately do something!..n its really very surprising that your car is not much old but still so many problem!! should take some action quickly for this!..and hope your probs get solved soon!All the best!smiley1.gif
vibhor2008-12-02 10:16:41
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quite a lot troubles here, you should contact the TATA motors and i dont think there is anyone else you must be looking for. almost all are electrical issues, which is really tough to troubleshoot and obviously need quite some experience. would suggest never contact local mechs for electrical issues.

anyways, where was the repair job done for the first accident, local dealer or Authorised?

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anyways' date=' where was the repair job done for the first accident, local dealer or Authorised?


at the Dealer from whom we bought the car.





And I am using the car with the speeds keeping below 80kmph.

Because if the car is driven above 80kmph the coolant comes out of the Auxillary Tank's cap and the car overheats. There's no problem (OF OVERHEATING OR COOLANT COMING OUT) if the car is driven upto the speed of 80kmph in 5th gear.
sudeepd2008-12-04 14:23:21
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  • 3 weeks later...

@ FRG You did not reply to my PM after 04-12-08. I replied you with my contact numbers so the ACI can contact me and take my Queries to TATA Motors.

    Anyways back to the topic.
     I took our Tata Indigo XL car which I mentioned in this thread to another Service Outlet Chavan Motors in our city which is TASS on Wednesday 17-12-08 and told the supervisor about the coolant coming out of the Aux. Tank when the car is driven at speeds of greater than 90-100kmph after the engine has attained the operating temperature (Half Mark as per Temp. Gauge). He came with me on a test drive to check the problem.
After driving 2-3 kms, the temp. gauge reached Half Mark.
 Then while driving it at speeds in excess of 90-100kmph, the temp gauge started falling down due to the Cold Wind flowing from front end which cooled the radiator. The Gauge reached to the 30-35% point.
    Then we took back the car at the TASS workshop. There we raised the engine at 3000-3500rpm in Neutral. After 2-3 mins., the coolant started spilling out of Auxillary Tank's cap. Then we came to know that the Radiator Fan was not working when the engine temp rised above Half Mark. Then he told a mechanic to see why the Fan was not working. The mechanic checked all the fuses in front of me but all were Ok. Then he removed the Air Filter and behind it there was a Sensor which activates the Radiator Fan when the Engine Temp. rises above Half Mark. The Sensor was Faulty hence the Radiator Fan was not working. The supervisor told me that he  will order the Sensor from Tata Motors, Pune. It will come by Monday. I will post what happens after replacing the Sensor.

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  • 2 weeks later...


          The problem of Coolant spilling out of Auxillary Tank's Cap has been solved. The reason of Overheating and the coolant spilling was that "Radiator Fan was not working when the Temperature Gauge tried to cross the Half Mark.

       Now I replaced the Radiator Fan Sensor which activates the Radiator Fan when the Temperature of the Engine tries to increase above Half Mark (>90 Degree C). Now the Fan gets activated when the Engine Temperature goes above 90 Degree C and cools the coolant.

            I did not have to replace the Head Gasket but only a Radiator Fan Sensor which cost me Rs.232/- only.



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well i too own INDIGO XL but havent faced any of the problems.... one thing which i would recommend is to go some other tata dealer and ask about the repair. also do ask about the garuntee. 


Now I dont have any problem with the vehicle.
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  • 1 month later...

I posting the picture of the Engine after the cap is removed.

There is no brown/cream coloured sludge.

So there is no any Head Gasket Problem. i.e., the HG is OK and no oil and coolant is mixing.

sudeepd2009-02-09 06:26:20

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Removing the thermostat will slow down the engine warm up, and you will pollute  (and consume) more while the engine warms up. This used to be a common trick 20-30 years ago when the thermostat was considered to be almost redundant and removed at the first sign of overheating and also on AC fitment.

One problem I had observed about 25 years ago in a Mustang was that on acceleration the bottom hose was being sucked closed due to the suction. Puttning a spring inside had fixed the problem. This should not be happening with standard hoses. That case was an import where spares were all 'jugad'.

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Do you have the valve with you? A very easy way to test it is to place it in a pan of water and boil it - the valve will open within 2 minutes of the water starting to bubble.

I carried out his experiment.

I put the valve in a steel bowl and filled water such that the valve will be fully immersed in water. Then I boiled water for 5 minutes (the boiling was done for 5 minutes and not heating).

 But I did not notice any change in valve other than the rod shown in below picture (on the right) come out about 0.5cm.

This picture shows the condition of valve before boiling.

This picture shows the condition of valve after boiling.

I have pointed the parts.

What do you say?

Should I fit a new thermostat valve?

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I am not able to post bigger pictures. I edited the photos in Paint and had pointed the parts and written their description (in above pics you can see the white boxes on left and right of both pics).

Please tell me how to post bigger pics so that you may be able to see the description clearly.

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The second picture shows the spindle quite a bit further back. This should indicate the valve opening properly. 

But sir, the spring (on the left) does not get depressed after boiling of water.

Please tell me after boiling of water or coolant, does the spring get depressed or not?

Means whether the Vertical Disc fitted to the spring should move to left after boiling of water because if I manually press the Vertical Disc to the left side, the disc moves and also the spring gets depressed.

Please solve my problem.

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