SUZUKI BALENO 1999 1.G Service Manual
Manufacturer: SUZUKI, Model Year: 1999, Model line: BALENO, Model: SUZUKI BALENO 1999 1.GPages: 65, PDF Size: 3.28 MB
Page 41 of 65
60G-74E
INSPECTION AND MAINTENANCE
INSPECTION AND MAINTENANCE
Periodic Maintenance Schedule.. 9-2
Engine Oil and Filter 9-7
Gear OH 9-10
Engine Coolant 9-11
Windscreen Washer Fluid 9-13
Air Cleaner 9-13
Spark Plugs 9-14
Brakes 9-15
Steering 9-17
Power Steering (if equipped) 9-18
Clutch Pedal 9-18
Tyres... 9-19
Battery 9-22
Fuses 9-23
Bulb Replacement , 9-25
Wiper Blades 9-29
83
INSPECTION AND MAINTENANCE
60G-74E
70F-05-002
You should take extreme care when
working on your vehicle to prevent
accidental injury. Here are a few
precautions that you should be
especially careful to observe:
• Do not leave the engine running in
garages or other confined areas.
• When the engine Is running, keep
hands, clothing, tools, and other
objects away from the fan and water
pump belt. Even though the fan may
not be moving, it can automatically
turn on without warning. ^
When it is necessary to do service
work with the engine running, make
sure that the parking brake is applied
fully and the transmission is in
Neutral.
Do not touch ignition wires or other
ignition system parts when starting
the engine or when the engine is
running, or you could receive an
electric shock.
Be careful not to touch a hot engine,
exhaust manifold and pipes, muffler,
radiator and water hoses.
Do not allow smoking, sparks, or
flames around gasoline or the
battery. Flammable fumes are
present.
Do not get under your vehicle if it is
supported only with the portable
jack provided in your vehicle.
Be careful not to cause accidental
short circuits between the positive
and negative battery terminals.
Keep used oil, coolant, and other
fluids away from children and pets.
Dispose of used fluids properly;
never pour them on the ground, into
sewers, etc.
9-1
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Page 42 of 65
60G-74E
INSPECTION AND MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The following table shows when regular
maintenance on your vehicle is required. This
table shows in kilometres and months when
inspections, adjustments, lubrication and other
services should be performed.
Maruti recommends that maintenance
on your Maruti vehicle be performed by
Maruti 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).
85
9-2
INSPECTION AND MAINTENANCE
6OG-74E
PERIODIC MAINTENANCE SCHEDULE
A....Ad]ust. l....lnspect and correct or replace If necessary.
T....Tighten to specified torque. C....CIean.
R....Replace or change. O....Rotate
L....Lubrlcate.
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.
Interval: This interval should be judged
by odometer reading or months,
whichever comes first.
km (x 1,000)
months
ENGINE
1. Water pump drive belt (tension, wear)
2. Engine coolant (level, leakage)
3. Engine oil (API GRADE SF, SG, SH) & Oil filter
4. Cooling system hoses and connections (leakage, damage)
5. Engine bolts (All cylinder head and manifold fixings)
6. Engine mounting (loose, damage)
7. Valve clearance
8. Camshaft timing belt (damage, wear)
9. Exhaust system (noise, leakage or otherwise defective)
10. Positive crankcase ventilation System (Hoses, connections and valve;
IGNITION
1. Ignition wiring, (damage, deterioration)
2. Spark plugs (clean and adjust the gap)
FREE INSPECTIONS
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PERIODIC MAINTENANCE SERVICE AT COST
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Replace every 1,00,000 km
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60G-74E
INSPECTION AND MAINTENANCE
Interval: This interval should be Judged
by odometer reading or months,
whichever comes first.
km (x 1,000)
months
FUEL
1. Air cleaner Paved-road
Dusty condition
2. Accelerator cable and Throttle shafts
3. Fuel tank cap, fuel lines & connections(leakage,damage)
4. Fuel filter (leakage)
CLUTCH AND TRANSMISSION
1. Clutch pedal (play)
2. Clutch slipping (dragging or excessive damage)
3. Manual Transmission/Transfer and Differential oil (level, leakage)
DRIVE SHAFTS
1. Drive shafts boots (bent of boots damage)
BRAKE
1. Brake fluid (level, leakage)
2. Brake pedal (pedal-to-wall clearance)
3. Parking brake lever and cable (play, damage)
4. a. Brake discs and pads, (wear)
b. Brake drums & shoes
5. Master cylinder and wheel cylinder or calliper (oil leakage.boot kit)
6. Brake hoses and pipes (leakage, damage)
FREE
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INSPECTIONS
5
6
10
12
Clean every 5,000 km. F
PERIODIC MAINTENANCE
20
24
30
36
40
48
Replace every 40,000 krr
50
60
SERVICE
60
72
AT
70
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COST
80
96
Clean every 2,500 km or as required. Replace every 40,000 km. More frequent
replacement if dust condition is severe.
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9-4
INSPECTION AND MAINTENANCE
60G-74E
Interval: This Interval should be judged
by odometer reading or months,
whichever comes first
km (x 1,000)
months
WHEEL
1. Tyres (air pressure, abnormal wear, crack, ROTATION)
2. Wheels (damage)
3. Front wheel bearings (loose, damage)
4. Rear wheel bearings (loose, damage)
FRONT AND REAR SUSPENSION
1. Suspension strut (oil leakage, damage)
2. Suspension arms and knuckle supports (loose.damage)
3. Rear spring (damage)
4. Shock absorbers (oil leakage, damage)
5. All bolts and nuts (loose)
6. Suspension arms and Tension rods
STEERING
1. Steering wheel (play, loose)
2. Power steering fluid (level, leakage)/connections
3. All rods and arms (loose, damage, wear)
ELECTRICAL
1. Battery electrolyte (level, leakage)
2. Wiring harness connection (looseness, damage)
3. Lighting system (operation, stains, damage)
4. Horn (operation)
5. System voltage
BODY
1. All chassis bolts and nuts (tighten)
2. All Latches, Hinges & Locks (function)
FREE
1
1
INSPECTIONS
5
6
Rotate and
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PERIODIC
20
24
inspect every 5,000
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MAINTENANCE
40
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SERVICE
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9-5
88
Page 44 of 65
60G-74E
INSPECTION AND MAINTENANCE
Interval: This Interval should be judged
by odometer reading or months,
whichever comes first.
km (x 1,000)
months
ROAD TEST
1. Operation of Brakes, Gear shifting & speedometer
2. Body and Chassis noise
AIR CONDITIONER (if equipped)
1. Check belt tension
2. Check Receiver Drier bubbles.
3. Tighten compressor mounting bolts
4. Check all hose joints, tighten if necessary
5. Check functioning of Recirc flap .*
6. Clean condenser with low pressure water
7. Check belt for frayed edges, change if necessary
8. Check all mounting bolts
FREE
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INSPECTIONS
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The rear shock absorbers are filled with
high pressure gas. Never attempt to
disassemble it or throw it into a fire.
Avoid storing it near a heater or heating
device. When scrapping the absorber,
the gas must be released from the
absorber safely. Ask your dealer for
assistance.
89
9-6
INSPECTION AND MAINTENANCE
60G-74E
All maintenance should be carried
out with the Ignition switch in the
"OFF" position and the car parked
securely on the level ground unless
otherwise specified.
If you are In any way unsure of your
ability to undertake a task, then do
not start it but contact your Maruti
dealer to perform the work for you.
ENGINE OIL AND FILTER
Specified oil
Be sure that the engine oil you use comes
under the API classification of SF, SG or SH.
Select the appropriate oil viscosity according
to the above chart.
9-7
90
70F-07-004E
Page 45 of 65
60G-74E
INSPECTION AND MAINTENANCE
60G-09-002E
Oil Level Cheek
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.
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.
91
60G-09-003E
Refilling
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 for five minutes and check the oil level again.
Changing Engine Oil and Fitter
Drain the engine oil while the engine is still
warm.
1) Remove the oil filler cap.
2) Place a drain pan under the drain plug.
3) Using the correct spanner remove the
drain plug and drain out the engine oil.
60G-09-004
The engine oil temperature may be high
enough to burn your fingers when the
drain plug Is loosened. Watt until the
drain plug is cool enough to touch with
your bare hands.
9-8
INSPECTION AND MAINTENANCE
60G-74E
New and used oil can be hazardous.
Children and pets may be harmed by
swallowing new or used oil. Keep new
and used oil and used oil fitters away
from children and pets.
Continuous contact with used engine
oil has been found to cause (skin)
cancer in laboratory animals. Brief
contact with used oil may irritate skin.
To minimize your exposure to used oil,
wear a long-sleeve shirt and
moistureproof gloves (such 'as
dishwashing gloves) when changing
oil. If oil contacts your skin, wash
thoroughly 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 to a torque of
5.0 kg-m (36.5 Ib-ft).
70F-07-010
Replace the oil filter
1) Using an oil filter wrench, turn the oil filter
counterclockwise and remove it.
2) Using a clean rag, wipe off the mounting
surface on the engine where the new filter
will be seated.
3) Smear a little engine oil around the rubber
gasket of the new oil filter.
4) Screw on the new filter by hand until the
filter gasket contacts the mounting
surface.
60G-09-005
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.
5) Tighten the filter 3/4 turn from the point of
contact with the mounting surface, [or to
1.4 kg-m (10.5 Ib-ft)] using an oil filter
wrench.
9-9
92
Page 46 of 65
60G-74E
INSPECTION AND MAINTENANCE
GEAR OIL
CAUTION
To prevent oil leakage, make sure that
the oil filter is tight, but do not
overtighten it.
Refill with oil and check for leaks.
1) Pour 3.1 litres of oil through the filler hole
and install the filler cap.
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 for 5 minutes.
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 genuine
MARUTI replacement filter.
60G-09-006
CAUTION
Oil leaks from around the oil filter or
drain plug indicate incorrect
installation or gasket damage. If you
find any leaks or are not sure that the
fitter has been properly tightened, have
the vehicle inspected by your MARUTI
dealer.
70F-07-012E
Oil filler and level plug ©
Tightening torque: 2.1 kg-m (15.5 Ib-ft)
Specified Manual Transmission oil
When adding gear oil, use the appropriate
viscosity and grade as shown in the chart
below. We highly recommend you use API
GL-4 SAE 75W-90 gear oil.
Type of oil
Gear oil, API GL-4
93
9-10
INSPECTION AND MAINTENANCE
60G-74E
ENGINE COOLANT
70F-07-013E
Gear oil level check
To check the gear oil level, use the following
procedure:
1) Park the vehicle on a level surface with
the parking brake applied.
2) Clean casing around oil filler plug to
remove risk of any loose dirt or debris
entering oil filler plug hole. Remove the oil
filler plug ©.
3) Feel the inside of the hole with your finger.
If the oil level comes up to the bottom of
the plug hole, the oil level is correct. If so,
reinstall the plug.
4) If the oil level is low, add gear oil through
the filler plug hole © until the oil level
reaches the bottom of the filler hole, then
reinstall the plug.
After driving the vehicle, the
transmission oil temperature may be
high enough to burn you. Wait until the
oil filler plug is cool enough to touch
with your bare hands before inspecting
transmission oil.
CAUTION
When tightening the plug, apply sealing
compound to the plug threads to
prevent oil leakage.
Gear oil change
Since special procedures, materials and tools
are required, it is recommended that you trust
this job to your authorized MARUTI dealer.
60G-09-007
Coolant Level Check
Check 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.
Adding Coolant
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.
9-11
94
Page 47 of 65
60G-74E
INSPECTION AND MAINTENANCE
CAUTION
When adding or replacing coolant,
use a high quality ethylene glycol
antifreeze and anticorrosion (Non-
Amine type) diluted with distilled
water. If the lowest ambient
temperature in your area is expected
to be -15°C (5°F) or above, make the
antifreeze concentration of the
mixture you use at least 30% but no
more than 50%. If -16°C (3°F) or
below, make the concentration at
least 50%. If the 50% concentration
does not provide adequate
protection against freezing, follow
the instructions on the antifreeze
container to obtain the desired
freezing point.
When putting the cap on the
reservoir tank, line up the arrow on
the cap and the arrow on the tank,
or coolant can leak out.
70F-07-019E
Coolant Replacement
1) When the engine is cool, remove the
radiator cap by turning it slowly to the left
until a "stop" is felt. Do not press down
while turning the cap. Wait until any
pressure is released, then press down on
the cap and continue turning it
anticlockwise.
60G-09-039E
It is dangerous to remove the radiator
cap when the water temperature is
high, because scalding fluid and steam
may be blown out under pressure. Watt
until the coolant temperature has
lowered before removing the cap.
2) Remove the reservoir tank cap. Remove
the reservoir by lifting it up, and drain the
reservoir completely by pouring the
coolant in to a suitable container.
95
9-12
INSPECTION AND MAINTENANCE
60G-74E
WINDSCREEN WASHER FLUID
AIR CLEANER
60G-09-008
3) Loosen the drain plug attached to the
lower part of the radiator and drain the
coolant into a suitable container.
4) Tighten the drain plug on the radiator, fill
the radiator with coolant and install the
radiator cap.
5) Refit the reservoir and fill it with the correct
coolant to the "FULL" line. Refit the
reservoir tank cap, ensuring the arrows are
correctly aligned.
CAUTION
The coolant must be replaced with the
vehicle on level ground.
63B-09-001
Check that there is washer fluid in the tank.
Refill it if necessary. Use a good quality
windscreen washer fluid, diluted with water as
necessary.
Do not use "antifreeze" solution in the
windscreen washer reservoir.This can
severely impair visibility when sprayed
on the windscreen, and can also
damage your vehicle's paint.
CAUTION
Damage may result if the washer motor
is operated whilst the fluid or fluid
nozzles are frozen or with no fluid in
the washer tank.
6OG-09-009
If the air cleaner is clogged with dust, there
will be greater intake resistance, resulting in
decreased power output and increased fuel
consumption.
Take out the air cleaner element after
unhooking the clamps shown in the illustration.
Blow off dust on air cleaner element by
compressed air. If the air cleaner element
appears to be dirty, replace it with a new one.
9-13
96
Page 48 of 65
60G-74E
INSPECTION AND MAINTENANCE
SPARK PLUGS
60G-09-010E
CAUTION
The air cleaner element should be
replaced every 40,000 km. More
frequent replacement is necessary
when you drive under dusty conditions.
60G-09-011E
You should inspect spark plugs periodically
for carbon deposits. When carbon
accumulates on a spark plug, a strong spark
may not be produced. Remove carbon
deposits with a wire or pin and adjust the spark
plug gap.
60G-09-012E
CAUTION
When disconnecting the spark plug
cables, pull on the boot, not on the
cable itself. Pulling on the cable can
damage it.
When installing the spark plugs,
screw them in with your fingers to
avoid stripping the threads.Tighten
with a torque wrench to 2.0-3.0 kgm
(20.0-30.0 N-m, 15.0-22.0 Ib-ft). Do
not allow contaminants to enter the
engine through the spark plug holes
when the plugs are removed.
Never use spark plugs with the
wrong thread size or length.
97
9-14
INSPECTION AND MAINTENANCE
60G-74E
BRAKES
70F-07-026E
CAUTION
When replacing spark plugs, you
should use the brand and type
specified for your vehicle. For the
specified plugs, refer to the
"SPECIFICATIONS" section at the end
of this book.
60G-09-013E
NOTE:
If you experience some firing problem of spark
plugs, such as, hard engine-starting, misfire
etc., the cause may be located not only on
spark plugs but also on deteriorated ignition
wiring (generally, used for more than 80,000
km or five years). If spark plug replacement
does not solve the problem, have the ignition
wiring and other ignition system inspected by
your MARUTI dealer.
60Q-09-014E
Brake Fluid
Check the brake fluid level by looking at the
reservoir in the engine compartment. Check
that the fluid level is between the "MAX" and
"MIN" lines. If the brake fluid level is near the
"MIN" line, fill it up to the "MAX" line with SAE
J1703 or DOT-3 brake fluid.
Failure to follow the guidelines below
can result in personal injury or serious
damage to the brake system.
• If the brake fluid in the reservoir
drops below a certain level, the brake
warning light on the instrument
9-15
98
Page 49 of 65
60G-74E
INSPECTION AND MAINTENANCE
70F-07-029
Do not use any fluid other than SAE
J1703 or DOT-3 brake fluid. Do not
use reclaimed fluid or fluid that has
been stored in old or open
containers. It is essential that foreign
particles and other liquids are kept
out of the brake fluid reservoir.
CAUTION
The brake fluid should be replaced
every two years or 20,000 km.
panel will come on (the engine must
be running with the parking brake
fully disengaged). Should the light
come on, immediately ask your
MARUTI dealer to inspect the brake
system.
A rapid fluid loss Indicates a leak in
the brake system which should be
inspected by your MARUTI dealer
immediately.
Brake fluid can harm your eyes and
damage painted surfaces. Use
caution when refilling the reservoir.
NOTE:
With disc brakes, the fluid level can be
expected to gradually fall as the brake pads
wear.
99
70F-07-030
Brake Pedal
Check if the brake pedal stops at the regular
height without "spongy" feeling when you
depress it. If not, have the brake system
inspected by your MARUTI dealer. If you doubt
the brake pedal for the regular height, check
it as follows:
With the engine running, measure the distance
between the brake pedal and floor wall when
the pedal is depressed with approximately 30
kg (66 lbs) of force. The minimum distance
required is 80 mm (3.1 in). Since your vehicle's
brake system is self-adjusting, there is no need
for pedal adjustment. If the pedal to floor wall
distance as measured above is less than the
minimum distance required, have your vehicle
inspected by your MARUTI dealer.
9-16
INSPECTION AND MAINTENANCE
60G-74E
STEERING
60G-09-015E
NOTE:
When measuring the distance between the
brake pedal and floor wall, be sure not to
include any floor covering in the measurement.
If you experience any of the following
problems with your vehicle's brake
system, have the vehicle inspected
immediately by your MARUTI dealer.
Poor braking performance
Uneven braking (Brakes not working
uniformly on all wheels.)
Excessive pedal travel
Brake dragging
Excessive noise
Pedal pulsation (Pedal pulsates
when depressed.)
63B-09-00SE
Parking brake
Check the parking brake for proper adjustment
by counting the number of clicks made by the
ratchet teeth as you slowly pull up on the
parking brake lever to the point of full
engagement. The parking brake lever should
stop between the 3rd and 5th ratchet tooth
and the rear wheels should be securely locked.
If the parking brake is not properly adjusted
or the brakes drag after the lever has been
fully released, have the parking brake
inspected and/or adjusted by your MARUTI
dealer.
60G-09-016
Check the play of the steering wheel by gently
turning it from left to right and measuring the
distance that it moves before you feel slight
resistance. The play should be between 0 -
30
mm
(0.0 -1.2 in).
Check that the steering wheel turns easily and
smoothly without rattling by turning it all the
way to the right and to the left while driving
very slowly in an open area. If the amount of
free play is outside the specification or you
find anything else to be wrong, an inspection
must be performed by your MARUTI dealer.
9-17
100
Page 50 of 65
60G-74E
INSPECTION AND MAINTENANCE
POWER STEERING (if equipped)
CLUTCH PEDAL
60G-09-017
Check the steering box case, vane pump and
hose connections for leaks or damage.
Power steering fluid
Check the fluid level by looking at the reservoir
in the engine compartment when the fluid is
cold (about room temperature).
Check that the fluid level is between the
"UPPER" and "LOWER" lines. If the fluid level
is near the "LOWER" line, fill it up to the
"UPPER" line with an automatic transmission
fluid equivalent to DEXRON»-IIE or
DEXRON'-III. Do not overfill.
63B-09-00SE
Power steering belt
The tension of the belt should be such that
there is a deflection of 8-10mm (0.31 -0.39 in.)
when you press your thumb midway between
the pulleys.
The belt should also be examined to ensure
that it is not damaged. If necessary, have the
belt adjusted or replaced by your MARUTI
dealer.
70F-07-034
Measure the clutch pedal piay by moving the
clutch pedal with your hand and measuring
the distance it moves until you feel slight
resistance. The play in the clutch pedal should
be between 15-20 mm (0.6 - 0.8 in). If the
play is more or less than the above, or clutch
dragging is felt with the pedal fully depressed,
have the clutch inspected by your MARUTI
dealer.
101
9-18
INSPECTION AND MAINTENANCE
60G-74E
TYRES
60G-09-018
The front and rear tyre pressure specifications
for your vehicle are listed on the Tyre Inflation
Pressure Label and in the "SPECIFICATIONS"
section at the end of this book. Both the front
and rear tyres should have the specified tyre
pressure.
Tyre Inspection
Inspect your vehicle's tyres periodically by
performing the following checks:
1) Measure the air pressure with a tyre
gauge. Adjust the pressure if necessary.
Air pressures should be checked
when the tyres are cold or you may
get inaccurate readings.
Check the inflation pressure from
time to time while inflating the tyre
gradually, until the specified
pressure is obtained.
Never underinf late or overinf late the
tyres.
Underinflation can cause unusual
handling characteristics or can
cause the rim to slip on the tyre
bead, resulting in an accident or
damage to the tyre or rim.
Overinflation can cause the tyre to
burst, resulting in personal injury.
Overinflation can also cause
unusual handling characteristics
which may result In an accident.
70F-07-037E
2) Check that the depth of the tread groove
is more than 1.6 mm (0.06 in). To help you
check this, the tyres have moulded in tread
wear indicators in the grooves. When the
indicators appear on the tread surface, the
remaining depth of the tread is 1.6 mm
(0.06 in) or less and the tyre should be
replaced.
3) Check for abnormal wear, cracks and
damage. Any tyres with cracks or other
damage should be replaced. If any tyres
show abnormal wear, have them inspected
by your MARUTI dealer.
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102