SUZUKI ALTO 2012 7.G CNG Manual

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
CONTENTSINTRODUCTION TO CNG............................................................................... ...... 1
SAFETY PRECAUTIONS (Do’s and Don’ts) ...................................................... 1
LAYOUT OF THE CNG SYSTEM..... ............................................................. ........ 2
FUEL MODES ....................................................................................................... 3
SELECTOR SWITCH POSITION ......................................................................... 3
PETROL MODE..................................................................................................... 3
AUTO MODE ........................................................................................................ 3
FORCED CNG MODE .......................................................................................... 4
CNG LEVEL INDICATOR .. ............................................................................ ....... 4
AUTOMATIC CHANGEOVER FROM CNG MODE TO PETROL MODE............. 4
CNG FILLER VALVE............................................................................................. 5
CNG CYLINDER.................................................................................................... 5
MANUAL SHUT-OFF VALVE ............................................................................... 6
LIST OF GOVERNMENT APPROVED CNG
CYLINDER TESTING STATIONS ........................................................................ 7
TYRE AND JACK REMOVAL ......... ............................................................. ........ 7
INSTRUMENT CLUSTER ..................................................................................... 8
CNG MALFUNCTION WARNING LAMP .......... ................................................... 8
KIT IDENTIFICATION ........................................................................................... 9
CNG WARNING LABEL....... ........................................................................... ...... 9
FUSE BOX ............................................................................................................ 9
PERIODIC MAINTENANCE SCHE DULE .................................................... ...... 10
SPECIFICATIONS............................................................................................... 11
FIRE EXTINGUISHER (if equipped) .................................................................. 12
PARTS DESCRIPTION .............................................................................................. 12
REMOVAL PROCEDURE (from front seat) .............................................................. 12
PROCEDURE OF OPERATION ......................................................................... 13
FITMENT PROCEDURE ..................................................................................... 13
REFILLING SCHEDULES .................................................................................. 13

1
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
INTRODUCTION TO CNG:
CNG (Compressed Natural Gas) is princi-
pally constituted by methane. CNG is con-
sidered as clean burning fuel. Due to low
density of CNG, it is compressed at a pres-
sure of around 200 bars to enhance the
vehicle on-board storage capacity.
SAFETY PRECAUTIONS (Do’s)
1. If any service or body repair is to becarried out, turn the manual shut off
valve on CNG cylinder valve to close
position prior to commencement of
there pair work.
2. Get the CNG cylinder checked every
three (3) years from the date of last
testing / retesting of cylinder by govern-
ment authorized CNG cylinder testing
agency.
3. If the vehicle does not changeover to CNG in AUTO MODE, then have your
vehicle checked by Maruti Suzuki
authorized workshop at the earliest.
4. Switch “OFF” engine while fuel filling
(CNG/Petrol).
5. After refueling CNG or Petrol, ensure that the fuel filler lid is closed. (Other-
wise vehicle cannot be started)
6. In AUTO MODE, It is programmed to start the vehicle in petrol and automati-
cally shift to CNG based on the engine
temperature etc. Do not press the
accelerator pedal to change from petrol
to CNG.
SAFETY PRECAUTIONS (Don’ts):
1. Do not change/modify the configura-tion, settings or the components from
CNG system.
2. The CNG cylinder should not be repaired under any circumstances, in
case of any problem, consult with
Maruti Suzuki authorized workshop.
3. Do not adjust se tting of CNG system.
4. Never install LPG or any other gas cyl-
inder in place of CNG cylinder.
5. Avoid carrying inflammable material near the CNG cylinder.
6. Do not fill any other type of gas other than CNG.
7. Do not press the accelerator pedal to
change from petrol to CNG MODE.
CAUTION
In case of any symptom of CNG leak-
age or releasing noise or any external
damage to CNG piping or during
accident, do not panic.
• Stop the vehicle and switch offthe engine, roll down the win-
dows and open all the doors
• Ensure to close manual shut off valve.
• Contact Maruti Suzuki authorized
workshop immediat ly for further
assistance.

2
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
LAYOUT OF THE CNG SYSTEM
1 Changeover switch
2 High pressure pipe
3 Receptacle
4 Fuel lid switch
5 CNG cylinder valve
6 CNG cylinder7 Vent hose
8 CNG controller
9 CNG injectors
10 Low pressure & temperature sensor
11 Engine
12 Pressure regulator53MHMC001
13 Water hose
14 High pressure sensor
15 High pressure gauge
16 Low pressure hose
17 CNG filter
9
6
7
5
2
10
11
13 1 43
1012
14
1516
17
8

3
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
FUEL MODES
There are three fuel modes in the vehicle
(Petrol, Auto and Forced CNG) which are
selectable by pressing the selector
switch(1) located on the right side of the
steering wheel on the dashboard.
NOTE:
• Do not press the accelerator pedal tochange-over from petrol to CNG mode.
• With ignition switch "ON" and engine not
running, blinking of CNG malfunction
warning lamp indicates that fuel lid is
open. Vehicle will not start in this condi-
tion.
SELECTOR SWITCH POSITION
53MHMC002
PETROL MODE
53MHMC003
In this mode vehicle starts in petrol and
continue running in petrol mode. In this
mode, petrol indicator is continuously dis-
played and CNG indicator will remain
“OFF”.
AUTO MODE
53MHMC004
In this mode engine starts in petrol mode
and then automatically changes to CNG
after reaching programmed warming up
condition. With ignition switch ON and
vehicle started in “AUTO MODE”, CNG
indicator blinks on the display and PET-
ROL indicator is displayed. After change-
over to CNG, CNG indicator will be
displayed and Petrol indicator will switch
OFF automatically.
NOTE:
• It is always recommended to start thevehicle in AUTO MODE or PETROL
MODE to enhance the engine life.
• The fuel changeover to CNG may not
happen if the vehicle is started when the
ambient / engine temperature is below
Zero Degree Celsius. In such a case,
run the engine in PETROL MODE till it
warms up and then try restarting the
engine to changeover to CNG.
WA R N I N G
Make sure that the parking brake is
applied fully and the transmission is
in Neutral before attempting to start
the engine.
CAUTION
• Stop turning the starter immedi- ately after the engine has started or
the starter system can be damaged.
• Do not crank the engine for more
than 15 seconds at a time. If the
engine doesn’t start on the first try,
wait about 15 seconds before try-
ing again.

4
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
FORCED CNG MODE
53MHMC005
This is emergency mode and may be used
in cases where there is no petrol in petrol
tank. In this mode vehicle starts in CNG
mode and continues running in CNG
mode.With ignition "ON" and engine not
running, press and hold the changeover
switch till only CNG indicator is displayed.
In this mode, CNG indicator is displayed
and Petrol indicator remains "OFF”.
NOTE:
• It is recommended to keep sufficientamount of petrol in the petrol tank.
• The vehicle may not start in Forced CNG
mode if the ambient / engine tempera-
ture is below Zero Degree Celsius. It is
recommended to start the vehicle in
Auto mode.
CNG LEVEL INDICATOR
53MHMC006
CNG level indicator (1) is built into the dis-
play. When the ignition switch is in the
“ON” position, this gauge gives an approxi-
mate indication of the q uantity of fuel in the
fuel tank. “F” stands for full and “E” stands
for empty.
If the CNG level meter indicator shows
only one segment to “E” refill the CNG tank
as soon as possible.
The mark (2) indicates that the fuel filler
door is located on the left side of the vehi-
cle.
AUTOMATIC CHANGEOVER FROM
CNG MODE TO PETROL MODE
If CNG is finished while the engine is run-
ning, vehicle will aut omatically changeover
from CNG mode to Petrol mode &CNG
malfunction warning lamp will start blink-
ing. Petrol indicator will be displayed con-
tinuously and CNG indicator will switch
OFF automatically.
To acknowledge this information, press the
changeover switch once. The CNG mal-
function warning lamp will stop blinking
after the changeover switch is pressed and
Petrol indicator will be displayed continu-
ously. However the CNG malfunction indi-
cator lamp will continue to blink after every
subsequent Ignition ON - Ignition OFF con-
dition until the vehicle is refilled with CNG.
NOTE:
• It is recommended to keep sufficient
amount of petrol in t he petrol tank to pre-
vent engine stalling while automatic
changeover from CNG mode to Petrol
mode.
• In case the CNG malfunction warning lamp does not stop blinking after press-
ing the changeover switch, take the vehi-
cle to the nearest MARUTI SUZUKI
dealer.(1) (2)

5
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
CNG FILLER VALVE
53MHMC007
The CNG filler valve is integrated in fuel
box next to petrol filling area.
CNG filler valve (1) can be uncovered by
pulling out the Filler valve cover (2) and it
can be covered by simply pushing it back.
Filling automatically gets cut off when the
cylinder pressure becomes equal to dis-
penser pressure. After CNG filling, ensure
that the filler valve cover (2) and fuel filler
lid (3) is closed.
NOTE:
• If the Fuel filler lid (3) is kept open, you
will not be able to start the vehicle.
• Engine will stop if the fuel filler lid (3)is
opened in vehicle stationary condition.
CNG CYLINDER
53MHMC008
CNG cylinder (1) is installed in the luggage
compartment.
CNG CYLINDER WARNING LABEL
53MHMC009
You may find this label on the CNG cylin-
der.
(1)
(3) (2)
CAUTION
Do not place any luggage or load
over cylinder as it may damage the
cylinder, pipe, hose, valve etc.
(1)
TO OBTAIN TESTING STATION INFORMATION
Visit the following internet / website address:
“www.peso.gov.in”

6
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
MANUAL SHUT-OFF VALVE
53MHMC010
Manual shut-off valve (2) is located on the
left hand side of the CNG cylinder.
MANUAL SHUT-OFF VALVE
OPERATION
53MHMC011
CNG supply can be switched off by closing
the manual shut-off valve.
Valve closing: Turn the knob completely
in clockwise direction to close the CNG
supply to Engine.
Valve opening: Turn the knob completely
in anti-clockwise direction to open the
CNG supply to Engine.
NOTE:
• If the manual shut-off valve is not
opened fully, then the engine may not
run properly.
• If the manual shut-off valve is in closed
condition, it is not possible to fill CNG
into the cylinder.
NOTE:
• As per Government regulation, CNG cyl- inder needs to be checked and certified
every three (3) years from the date of ini-
tial testing as mentioned on the CNG
cylinder identification plate.
• Customer has to present the vehicle to a government approved testing agency.
• Failure to test the cylinder may result in
denying of CNG filling by the CNG dis-
pensing stations or may result in confis-
cating the vehicle by enforcement
authorities.
• All the expenses for CNG cylinder test- ing has to be borne by the customer.
• As per Government regulation, CNG cyl- inder has to be discarded at 20 years
from the date of in itial testing as men- tioned in the CNG cylinder identification
plate.
• Customer has to discard the cylinder at his / her expense through government
approved scrap agencies.
• No person shall refill any cylinder, which has been repaired under sub-rule (2)
with any gas unless a full report on the
repairs and test carried out on the cylin-
der, accompanied by the repairer's certif-
icate of testing are furnished to the Chief
Controller and his permission is obtained
for its refilling.
OPENOMBCN G
onl yCLOSE(2)
12Open
Close
WA R N I N G
• Never remove the cylinder valve
from the cylinder assembly. For
any assistance consult Maruti
Suzuki authorized workshop.
• Never try to clean the cylinder. In case of any problem, contact
Maruti Suzuki au thorized work-
shop.
• Do not reuse the cylinder valve,
once it is replaced / removed from
cylinder assembly.
•Even if the CNG from the cylinder
is consumed till engine stops,
some amount of CNG will be left
out in the tank under pressure.

7
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
LIST OF APPROVED CNG CYLIN-
DERSTESTING STATIONS
To obtain testing stations information visit
the following internet website address
“www.peso.gov.in”
TYRE AND JACK REMOVAL
(For CNG vehicles)
53MHMC012
• Fold the rear seat by pulling the knob (1)and (2) together as shown, in order to
access the spare wheel.
53MHMC013
• Unscrew spare wheel screw in anticlock-wise direction.
• Remove spare wheel (3) from the front
side of vehicle as shown in the figure.
• Unscrew the jack from its holder and remove.
• Reverse the above procedure for fitting the spare wheel and jack.
NOTE:
• Spare wheel can only be removed from the front side of the vehicle.
• It is recommended to remove the spare wheel first before removing the jack.
( )
( )
( )

8
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
INSTRUMENT CLUSTER
Ty p e 1
53MHMC014
Ty p e 2
53MMMC001
CNG MALFUNCTION WARNING
LAMP
53MHMC015
When the ignition switch is turned "ON",
this CNG malfunction warning lamp comes
on briefly, to check that the CNG malfunc-
tion lamp is trouble free.
• If CNG malfunction warning lamp glows continuously, with ignition "ON" there is
some problem with the CNG system.
Immediately get your vehicle checked by
Maruti Suzuki authorized workshop.
• If CNG malfunction warning lamp blinks during engine running, it means there is
some problem in CNG system in which
vehicle cannot continue running in CNG-
MODE and automatically switchover to
petrol mode. Have y our vehicle checked
at Maruti Suzuki authorized workshop.
NOTE:
With ignition switch "ON" and engine not
running, blinking of CNG lamp indicates
that fuel lid is open. Vehicle will not start in
this condition. Close the lid in order to start
the vehicle.
( ) ( )
( )
( ) ( ) ( ) ( )( )
(1) Speedometer
(2) Odometer / Tripmeter
(3) Odometer / Tripmeter selector knob
(4) Fuel indica
tor (Petrol) (5) Fuel indicator (CNG)
(6) CNG malfunction warning Indicator lamp
(7) Other warning and indicator lamps
1
23 4
5 776( ) ( ) ( )
( )
( ) ( ) ( )( )

9
FOR VEHICLES FITTED WITH CNG FUEL SYSTEM
68PH0-74E
KIT IDENTIFICATION
53MHMC016
CNG cylinder identification number and
CNG kit installation date is located above
the fuel filling area.
53MHMC017
CNG WARNING LABEL
Front Driver Door
53MHMC018
53MHMC019
CNG warning label is located on front and
rear Right doors. FUSE BOX
53MHMC020
(9) CNG 7.5A
(21) CNG Valve 7.5A
For other fuses, refer "Inspection and
maintenance" section in the main owner's
manual.