SUZUKI MARUTI 2005 1.G Owners Manual

Downloaded from www.Manualslib.com manuals search engine 9183K
INSPECTION AND MAINTENANCE
9-2
w ww w
w WARNING
MARUTI SUZUKI recommends that
maintenance on your MARUTI SUZUKI
vehicle should be performed by
MARUTI SUZUKI authorised Dealer/
Service Station.
CAUTION
Whenever it becomes necessary to
replace parts on your vehicle, it is
recommended that you use MARUTI
GENUINE PARTS (MGP) only.Periodic Maintenance Sched-
ule
“A” : Adjust
“C” : Clean
“R” : Replace or Change
“I” : Inspect, correct or replace if
necessary
“L” : Lubricate
“T” : Tighten to Specified Torque
“O” : Rotate
NOTE:
This table includes services as scheduled
up to 80,000 km mileage. Beyond 80,000
km, carry out the same services at the
same intervals respectively.

Downloaded from www.Manualslib.com manuals search engine 9283K
FREE INSPECTION PERIODIC MAINTENANCE AT COST
Interval: This interval should be judged by odometer km (x1000) 1 5 10 20 30 40 50 60 70 80
reading or months, whichever comes first.months 1 6 12 24 36 48 60 72 84 96
ENGINE
1-1. Water pump drive belt (Tension, Wear) Petrol-----I---R
1-2.Engine Coolant (Level, Leakage) I I I R I R I R I R
1-3. Engine oil and engine oil filter - - R RRRRRRR
1-4.Cooling system hoses and connections (Leakage and Damage)IIIIIIIIII
1-5.Engine bolts (All cylinder head and manifold fixings) - - T - T - T - T -
1-6.Engine Mounting (All cylinder head and manifold fixings) - - T - T - T - T -
1-7. Valve Cleanrance Petrol----I--I--
1-8.Exhaust System (Noise, Leakage etc.) - I - I-----I
1-9. Positive Crank Case Ventilation System
(Hoses, Connections and Valve)-I-I-----I
1-10.Exhaust Gas Recirculation Valve Diesel----C--C--
IGNITION
2-1.Ignition wiring (Damage, Deterioration) - - - I - I - I - I
2-2. Spark Plug (Clean and adjust the gap) Petrol-----R---R
FUEL
3-1. Air cleaner filter element Paved-road Petrol Clean after every 5,000 KM. Replace after every 40,000KM
Diesel Replace after every 20,000 KM. Cleaning not required
Dusty Condition Petrol Clean after every 2,500 KM. or as rquired. Replace after every 40,000KM
Diesel Replace after every 20,000 KM. Cleaning not required.
More frequent replacement if dust condition is severe.
3-2.
Fuel tank cap, fuel lines and connections (Leakage and Damage)
-I---I---I
3-3. Fuel Filter (Leakage) Petrol-----R---R
3-4. Fuel Filter and Water Draining Diesel I I I R I R I R I R
INSPECTION AND MAINTENANCE
9-3

Downloaded from www.Manualslib.com manuals search engine 9383K
FREE INSPECTION PERIODIC MAINTENANCE AT COST
Interval: This interval should be judged by odometer km (x1000) 1 5 10 20 30 40 50 60 70 80
reading or months, whichever comes first.months 1 6 12 24 36 48 60 72 84 96
CLUTCH AND TRANSMISSION
4-1. Clutch Pedal (Play) PetrolIIIIIIIIII
4-2.Clutch Fluid (Level, Leakage) Diesel I I I R I R I R I R
4-3. Clutch Slipping (Dragging or Excess Damage)IIIIIIIIII
4-4.
Manual Transmission/Transfer or Differential Oil (Level, Leakage)
I I IRIRIRIR
4.5. Automatic transmission Fluid (Level, Leakage) Replace at 1,65,000 KM or 11 years whichever comes first
4.6. Hose, Automatic transmission fluidIIIIIIIIII
DRIVE SHAFT
5-1. Drive shaft boot (boot damage) -IIIIIIIII
BRAKE
6-1. Brake Fluid (Level, Leakage) I I I R I R I R I R
6-2.Brake Pedal (pedal - wall clearance)IIIIIIIIII
6-3.Parking brake lever and cable (Play, damage)IIIIIIIIII
6-4.Brake disc and pad (Wear) -IIIIIIIII
6-5.Brake drum and shoes (Wear) - -IIIIIIII
6-6. Master cylinder/wheel cylinder/caliper (Oil leakage, boot cut)
IIIIIRIIIR
(replace piston and boot kits)
6-7.Brake hoses and pipes (Leakage, damage)IIIIIIIIII
WHEEL
7-1.Tyres (air pressure, abnormal wear, crack and rotation) I I&O I&O I&O I&O I&O I&O I&O I&O I&O
7-2. Wheels (Damage)IIIIIIIIII
7-3.Front/Rear wheel bearing (Loose, damage)IIIIIIIIII
FRONT / REAR SUSPENSION
8-1.Suspension strut (Oil leakage, damage)IIIIIIIIII
8-2. Suspension arms / Knuckle support (Loose, damage) -IIIIIIIII
8-3.Rear spring (Damage)IIIIIIIIII
8-4.Shock absorbers (Oil leakage, damage)IIIIIIIIII
8-5.All bolts and nuts (Loose) -TTTTTTTTT
8-6. Suspension arms and torsion rods -IIIIIIIII
INSPECTION AND MAINTENANCE
9-4

Downloaded from www.Manualslib.com manuals search engine 9483K
FREE INSPECTION PERIODIC MAINTENANCE AT COST
Interval: This interval should be judged by odometer km (x1000) 1 5 10 20 30 40 50 60 70 80
reading or months, whichever comes first.months 1 6 12 24 36 48 60 72 84 96
STEERING
9-1.Steering wheel (Play, loose)IIIIIIIIII
9-2. All rods and arms (Loose, damage, wear)IIIIIIIIII
ELECTRICAL
10-1.Battery electrolyte (Level, leakage)IIIIIIIIII
10-2. Wiring harness connection (Loose, damage) -IIIIIIIII
10-3. Lightening system (Operation, stains, damage)IIIIIIIIII
10-4.Horn (Operation)IIIIIIIIII
10-5.System Voltage -IIIIIIIII
BODY
11-1.All chassis bolts and nuts (Tighten) - ITTTTTTTT
11-2. All latches, hinges and locks (Function) I I&L I&L I&L I&L I&L I&L I&L I&L I&L
ROAD TEST
12-1.Operation of Brakes, gear shifting and speedometerIIIIIIIIII
12-2.Body and chassis noiseIIIIIIIIII
AIR CONDITIONER (if equipped)
13-1. Check belt tensionIIIIIIIIII
13-2.Tighten compressor mounting bolt -TTTTTTTTT
13-3. All hose joint (Check, tighten)IIIIIIIIII
13-4.Check functioning of Recirc flapIIIIIIIIII
13-5. Clean condensor with low pressure water - C C CCCCCCC
13-6. Check belt for frayed edgesIIIIIIIIII
13-7.Check all mounting boltsIIIIIIIIII
INSPECTION AND MAINTENANCE
9-5

Downloaded from www.Manualslib.com manuals search engine 9583KDrive Belt
w ww w
w WARNING
When the engine is running, keep
hands, hair, clothing, tools, etc. away
from the moving fan and drive belts.
(For Petrol Engine Model)
Make sure the drive belt tension is correct.
If the belt is too loose, insufficient battery
charging, engine overheating, poor power
steering, poor air conditioning, or excessive
belt wear can result. When you press the
belt with your thumb midway between the
pulleys, there should be a deflection
according to the following chart.
The belts should also be examined to
ensure that they are not damaged.
If you need to replace or adjust the belt
have it done by your MARUTI SUZUKI
dealer.
(For Diesel Engine Model)
The drive belts tension is adjusted auto-
matically.
Engine Oil and FilterSpecified Oil(For Petrol Engine Model)
(1) Preferred→: 100 N (10 kg, 22 lbs) press GE: Generator
DEF: Deflection AC: Air conditioner compressor
INSPECTION AND MAINTENANCE
9-6
83K-07-003
(For Diesel Engine Model)
83K-07-005
Be sure that the engine oil you use comes
under the quality classification of ACEA B3.
Select the appropriate oil viscosity according
to the above chart.
The recommended Engine Oil is CG
5W-40, API -CG4 or above.Oil Level Check(For Petrol Engine Model)
83K-07-006
(1) Preferred
83K-07-005
Be sure that the engine oil you use comes
under the quality classification of SG+.
The recommended Engine Oil is SG+
5W-30.

Downloaded from www.Manualslib.com manuals search engine 9683K
INSPECTION AND MAINTENANCE
9-7(For Diesel Engine Model)
83K-07-007
CAUTION
Failure to check the oil level regularly
could lead to serious engine trouble
due to insufficient oil.
(1) MIN
(2) MAX
(3) Engine oil dipstick
It is important to keep the engine oil at the
correct level for proper lubrication of your
vehicle’s engine. Check the oil level with the
vehicle on a level surface. The oil level
indication may be inaccurate if the vehicle
is on a slope. The oil level should be
checked either before starting the engine or
at least 5 minutes after stopping the engine.
The handle of the engine oil dipstick is col-
ored yellow for easy identification. Pull out
the oil dipstick, wipe oil off with a clean cloth,
insert the dipstick all the way into the engine,
then remove it again. The oil on the stick
should be between the upper and lower
limits shown on the stick. If the oil level
indication is near the lower limit, add enough
oil to raise the level to the upper limit.
83K-07-00883K-07-009
Refilling (Petrol)
Refilling (Diesel)Remove the oil filler cap and pour oil slowly
through the filler hole to bring the oil level
to the upper limit on the dipstick. Be careful
not to overfill. Too much oil is almost as
bad as too little oil. After refilling, start the
engine and allow it to idle for about a
minute. Stop the engine, wait about 5 min-
utes and check the oil level again.
Changing Engine Oil and FilterDrain the engine oil while the engine is still
warm.
83K-07-010
The engine oil temperature may be
high enough to burn your fingers
when the drain plug is loosened. Wait
until the drain plug is cool enough to
touch with your bare hands.
w ww w
w WARNING
1) Remove the oil filler cap.
2) Place a drain pan under the drain plug.
3) Using a wrench, remove the drain plug
and drain out the engine oil.

Downloaded from www.Manualslib.com manuals search engine 9783K
INSPECTION AND MAINTENANCE
9-8
83K-07-011
EXAMPLE For Petrol
For Diesel
EXAMPLETightening torque for drain plug (1):
Petrol Engine
35 Nm (3.5 kg-m, 25.5 lb-ft)
Diesel Engine
20 Nm (2.0 kg-m, 14.5 lb-ft)
NOTE:
Washer (2) should be replaced every time
when opened.
w ww w
w WARNING
New and used oil can be hazardous.
Children and pets may be harmed by
swallowing new or used oil. Keep new,
used oil and used oil filters away from
children and pets.
Continuous contact with used engine
oil may cause (skin) cancer.
Brief contact with used oil may irritate
skin.
To minimize your exposure to used
oil, wear a long-sleeve shirt and
moisture-proof gloves (such as dish-
washing gloves) when changing oil. If
oil contacts your skin, wash thor-
oughly with soap and water.
Launder any clothing or rags if wet
with oil.
Recycle or properly dispose of used
oil and filters.
4) Reinstall the drain plug and gasket.
Tighten the plug with a wrench to the
specified torque.Replace the Oil Filter1) Using an oil filter wrench, turn the oil fil-
ter counterclockwise and remove it.
2) Using a clean rag, wipe off the mount-
ing surface on the engine where the new
filter will be seated.3) Smear a little engine oil around the rub-
ber gasket of the new oil filter.
4) Screw on the new filter by hand until the
filter gasket contacts the mounting sur-
face.
(For Petrol Engine Model)
83K-07-012
83K-07-013
(1) Loosen
(2) Tighten
Tightening (viewed from filter top)
83K-07-014
(1) Oil filter
(2) 3/4 turn

Downloaded from www.Manualslib.com manuals search engine 9883K
INSPECTION AND MAINTENANCE
9-9(For Diesel Engine Model)
83K-07-015
CAUTION
To tighten the oil filter properly, it is
Important to accurately identify the
position at which the filter gasket first
contacts the mounting surface.
CAUTION
To prevent oil leakage, make sure that
the oil filter is tight, but do not over-
tighten it.
(1) Loosen
(2) Tighten
NOTE:
Replace ring along with the new filter never
use the old ring in the new filter.5) Tighten the filter specified turn from the
point of contact with the mounting sur-
face (or to the specified torque) using an
oil filter wrench.Tightening torque for oil filter
Petrol Engine
3/4 turn or
14 Nm (1.4 kg-m, 10.5 lb-ft)
Diesel Engine
3/4 turn or
25 Nm (2.5 kg-m, 18.1 lb-ft)
Refill with Oil and Check for Leaks1) Pour oil through the filler hole and install
the filler cap.
For the approximate capacity of the oil,
refer to the “CAPACITIES” item in the
“SPECIFICATIONS” section.
2) Start the engine and look carefully for
leaks at the oil filter and drain plug. Run
the engine at various speeds for at least
5 minutes.
3) Stop the engine and wait about 5 min-
utes. Check the oil level again and add
oil if necessary. Check for leaks again.
CAUTION
When replacing the oil filter, it is
recommended that you use a
MARUTI genuine replacement filter.
V VV V
V
CAUTION
V VV V
V Oil leaks from around the oil filter or
drain plug indicate incorrect installa-
tion or gasket damage. If you find
any leaks or are not sure that the
filter has been properly tightened,
have the vehicle inspected by your
MARUTI SUZUKI dealer.Engine Coolant(For Petrol Engine Model)
83K-07-016
EXAMPLE
EXAMPLE
83K-07-017

Downloaded from www.Manualslib.com manuals search engine 9983K
INSPECTION AND MAINTENANCE
9-10
(For Diesel Engine Model)
83K-07-018
CAUTION
To avoid damaging your cooling system:
Always use a high quality ethylene
glycol base non-silicate based
coolant diluted with distilled water
at the correct mixture concentration.
Make sure that the proper mix is 50/
50 coolant to distilled water (Diesel)
and 30/70 (For petrol). Concen-
trations other than this may cause
overheating conditions.
Neither use 100% coolant nor 100%
plain water.
Do not add extra inhibitors or addi-
tives. They may not be compatible
with your cooling system.
Do not mix different types of base
coolants. Doing so may result in
accelerated seal wear and/or the
possibility of severe overheating and
extensive engine damage.Coolant Level CheckCheck the coolant level at the reservoir
tank, not at the radiator. With the engine
cool, the coolant level should be between
the “FULL” and “LOW” marks.
Selection of CoolantTo maintain optimum performance and
durability of your engine, use MARUTI
Genuine Coolant or equivalent.
This type of coolant is best for your cooling
system as it:
Helps maintain proper engine tempera-
ture.
Gives proper protection against freezing
and boiling.
Gives proper protection against corrosion
and rust.
Failure to use the proper coolant can dam-
age your cooling system. Your MARUTI
SUZUKI authorized dealer can help you
select the proper coolant.
w ww w
w WARNING
It is hazardous to remove the reservoir
tank cap (degassing tank cap) for Diesel
engine when the water temperature is
high, because scalding fluid and steam
may be blown out under pressure. Wait
until the coolant temperature has
lowered before removing the cap.
Adding Coolant(For Petrol Engine Model)
If the coolant level is below the “LOW”
mark, more coolant should be added.Remove the reservoir tank cap and add
coolant until the reservoir tank level reaches
the “FULL” mark. Never fill the reservoir
tank above the “FULL” mark.
(For Diesel Engine Model)
If the coolant level is below the “LOW”
mark, more coolant should be added. When
the engine is cool, remove the degassing
tank cap by turning it anticlockwise slowly
to release any pressure. And add coolant
until the degassing tank level reaches the
“FULL” mark. Never fill the degassing tank
above the “FULL” mark.
The mixture you use should contain
50% concentration of antifreeze.
If the lowest ambient temperature in
your area is expected to be – 35°C
(–31°F) or below, use higher
concentrations up to 60% following
CAUTION
V VV V
V

Downloaded from www.Manualslib.com manuals search engine 10083K
INSPECTION AND MAINTENANCE
9-11
CAUTION
the instructions on the antifreeze
container.
When putting the cap on the reser-
voir tank, line up the arrow on the
cap and the arrow on the tank. Fail-
ure to follow this can result in cool-
ant leakage.
Engine coolant is harmful or fatal if
swallowed or inhaled. Do not drink
antifreeze or coolant solution. If swal-
lowed, do not induce vomiting. Imme-
diately contact a poison control center
or a physician. Avoid inhaling mist or
hot vapors; if inhaled, remove to fresh
air. If coolant gets in eyes, flush eyes
with water and seek medical attention.
Wash thoroughly after handling.
Solution can be poisonous to animals.
Keep out of the reach of children and
animals.
w ww w
w WARNING
V VV V
V
Coolant ReplacementCoolant Replacement work requires tech-
nical skill. Do not replace the coolant by
yourself. Trust this job to Maruti Suzuki
authorised Dealer Workshop or Service
Station.
Air Cleaner(For Petrol Engine Model)
83K-07-01983K-07-020
(For Diesel Engine Model)
If the air cleaner is clogged with dust, there
will be greater intake resistance, resultingin decreased power output and increased
fuel consumption.
Unclamp the side clamps or loosen the
screws, and remove the element from the
air cleaner case. If it appears to be dirty,
replace it with a new one.
Spark Plugs
83K-07-021