warning SUZUKI MARUTI 2005 1.G Repair Manual

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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.
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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

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INSPECTION AND MAINTENANCE
9-13
CAUTION
fied for your vehicle. For the specified
spark plugs, refer to the “SPECIFI-
CATIONS” section at the end of this
book. It is recommended to trust this
job on your MARUTI SUZUKI dealer.
83K-07-026
NOTE:
If your engine is equipped with the high-
tension cord type ignition wiring and 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
wirings (generally, used for more than 80000
km or five years). If spark plug replacement
does not solve the problem, have theEXAMPLEV VV V
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ignition wiring and other ignition system
inspected by your MARUTI SUZUKI dealer.Gear OilTransmission OilWhen adding gear oil, use gear oil with the
appropriate viscosity and grade.
We highly recommend you use:
API GL-4 SAE 75W-90.
83K-07-027
Gear Oil Level Check
(1) Oil filler and level plug
(for petrol engine model)
(2) Oil filler and level plug
(for diesel engine model)
To check the gear oil level, use the follow-
ing procedure:
1) Park the vehicle on a level surface withthe parking brake applied. Then, stop the
engine.
2) Remove the oil filler plug.
3) Feel the inside of the hole with your fin-
ger. If the oil level comes up to the bot-
tom 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 oil filler plug hole (1) until
the oil level reaches the bottom of the
filler hole, then reinstall the plug.
Tightening torque (1):
21 Nm (2.1 kg-m, 15.5 lb-ft)
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After driving the vehicle, the trans-
mission oil temperature may be high
enough to burn your skin. 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 the
following sealing compound or
equivalent to the plug threads to pre-
vent oil leakage.
Manual transmission sealant:
SUZUKI Bond No. “1217G”

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hot weather, or if the vehicle has been
pulling a trailer. Wait until the fluid cools
down (about 30 minutes), or the fluid level
indication will not be correct.
83K-07-029A
INSPECTION AND MAINTENANCE
9-152) Park your vehicle on level ground.
3) Apply the parking brake and then start
the engine in “P” (Park). Let it idle for
two minutes and keep it running during
the fluid level check.
4) With your foot on the brake pedal, move
the gearshift lever through each range,
pausing for about three seconds in each
range. Then move it back to the “P”
(Park) position.Be sure to depress the brake pedal
when moving the gearshift lever, or
the vehicle can move suddenly.
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83K-07-029B
5) The handle of the A/T fluid dipstick is
colored red or orange for easy identi-
fication.
Remove the dipstick, clean it and push
it back in until the cap seats. Then pull
out the dipstick.
6) Check both sides of the dipstick, and
read the lowest level. The fluid level
should be between the two marks in the
“HOT” range on the dipstick.(1) FULL HOT
(2) LOW HOT
(3) The lowest point = Fluid level
7) Add just enough specified fluid through
the dipstick hole to fill the transaxle to
the proper level.
83K-07-029C
EXAMPLE
NOTICE
After checking or adding oil, be sure
to insert the dipstick securely.Changing OilSince special procedures, materials, and
tools are required to change the automatic
transaxle oil, it is recommended that you
trust this job to your authorized d MARUTI
SUZUKI dealer.
EXAMPLE
EXAMPLE

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INSPECTION AND MAINTENANCE
9-17BrakesBrake FluidCheck 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 Maruti Genuine brake fluid.
83K-07-031
EXAMPLEFailure to follow the guidelines below
can result in personal injury or seri-
ous damage to the brake system.
If the brake fluid in the reservoir
drops below a certain level, the
brake warning light on the instru-
ment panel will come on (the engine
must be running with the parking
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Vbrake fully disengaged). If the light
comes on, immediately contact your
MARUTI SUZUKI dealer to inspect
the brake system.
A rapid fluid loss indicates a leak in
the brake system which should be
inspected by your MARUTI SUZUKI
dealer immediately.
Brake fluid can harm your eyes and
damage painted surfaces. Use cau-
tion when refilling the reservoir.
Do not use any fluid other than
specified brake fluid. Do not use
reclaimed fluid or fluid that has
been stored in old or open contain-
ers. It is essential that foreign parti-
cles and other liquids are kept out
of the brake fluid reservoir.
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Brake fluid is harmful or fatal if swal-
lowed, and harmful if it comes in con-
tact with skin or eyes. If swallowed,
do not induce vomiting. Immediately
contact a poison control center or a
physician. If brake fluid gets in eyes,
flush eyes with water and seek medi-
cal attention. Wash thoroughly after
handling. Solution can be poisonous
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Vto animals. Keep out of the reach of
children and animals.NOTE:
With disc brakes, the fluid level can be
expected to gradually fall as the brake pads
wear.Brake PedalCheck if the brake pedal stops at the regu-
lar height without “spongy” feeling when you
depress it. If not, have the brake system
inspected by your MARUTI SUZUKI dealer.
If you doubt the brake pedal for the regular
height, check it as follows:
83K-07-032
Pedal to wall minimum distance “a”:
85 mm (3.3 in.)
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INSPECTION AND MAINTENANCE
9-18
With the engine running, measure the dis-
tance between the brake pedal and floor
carpet when the pedal is depressed with
approximately 30 kg (66 lbs) of force. The
minimum distance required is as specified.
Since your vehicle’s brake system is self-
adjusting, there is no need for pedal
adjustment.
If the pedal to floor wall distance as mea-
sured above is less than the minimum dis-
tance required, have your vehicle inspec-ted
by your MARUTI SUZUKI dealer.NOTE:
When measuring the distance between the
brake pedal and floor wall, be sure not to
include the floor mat or rubber on the floor
wall in your measurement.
83K-07-033
Parking Brake
Ratchet tooth specification “b”:
4th – 9th
Lever pull force (1):
200 N (20 kg, 44 lbs)
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If you experience any of the following
problems with your vehicle’s brake
system, have the vehicle inspected
immediately by your MARUTI SUZUKI
dealer.
Poor braking performance
Uneven braking (Brakes not working
uniformly on all wheels.)
Excessive pedal travel
Brake dragging
Excessive noise
83K-07-034
EXAMPLE
Check the parking brake for proper adjust-
ment 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 specified ratchet
teeth 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 SUZUKI dealer.Steering
EXAMPLE
Steering wheel play “c”:
0 – 30 mm (0.0 – 1.2 in.)
Check the play of the steering wheel by
gently turning it from left to right and mea-
suring the distance that it moves before you
feel slight resistance. The play should be
between the specified values.
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
83K-07-035

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INSPECTION AND MAINTENANCE
9-19driving very slowly in an open area. If the
amount of free play is outside the specifi-
cation or you find anything else to be
wrong, an inspection must be performed by
your MARUTI SUZUKI dealer.TyresThe front and rear tyre pressure specifica-
tions for your vehicle are listed on the Tyre
Information Label. Both the front and rear
tyres should have the specified tyre pres-
sure.
83K-07-036
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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 pres-
sure is obtained.
Never underinflate or overinflate the
tyres.
Underinflation can cause unusual
handling characteristics or can
cause the rim to slip on the tire
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.
EXAMPLE
83K-07-037
EXAMPLE
Tyre Inspection
Inspect your vehicle’s tyres at least once a
month by performing the following checks:
1) Measure the air pressure with a tire
gauge. Adjust the pressure if necessary.
Remember to check the spare tyre, too.(1) Tread wear indicator
(2) Indicator location mark
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 molded-
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 s hould be replaced. If any tyres
show abnormal wear, have them inspected
by your MARUTI SUZUKI dealer.
Hitting curbs and running over rocks
can damage tyres and affect wheel
alignment. Be sure to have tyres and
wheel alignment checked periodically
by your MARUTI SUZUKI dealer.
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4) Check for loose wheel nuts.
5) Check that there are no nails, stones or
other objects sticking into the tyres.
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Your MARUTI SUZUKI is equipped
with tyres which are all the same
type and size. This is important to
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INSPECTION AND MAINTENANCE
9-20
ensure proper steering and handling
of the vehicle. Never mix tyres of
different size or type on the four
wheels of your vehicle. The size and
type of tyres used should be only
those approved by MARUTI SUZUKI
as standard or optional equipment
for your vehicle.
Replacing the wheels and tyres
equipped on your vehicle with cer-
tain combinations of aftermarket
wheels and tyres can significantly
change the steering and handling
characteristics of your vehicle.
Therefore, use only those wheel and
tyre combinations which are
approved by MARUTI SUZUKI for
your vehicle.
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Replacing the original tyres with tyres
of a different size may result in false
speedometer or odometer readings.
Check with your MARUTI SUZUKI
dealer before purchasing replacement
tyres that differ in size from the
original tyres.V VV V
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Tire RotationTo avoid uneven wear of your tyres and to
prolong their life, rotate the tyres as
illustrated. Tyres should be rotated as rec-
ommended in the periodic maintenance
schedule. After rotation, adjust front and
rear tyre pressures to the specification listed
on your vehicle’s Tyre Information Label.Wheel BalancingIf the vehicle vibrates abnormally on smooth
road, have the wheels balanced at Maruti
Suzuki authorized workshop.Wheel AlignmentIn case of abnormal tyre wear or pulling
towards one side, have the wheel aligned
at Maruti Suzuki authorized workshop.
Tubeless Tyres (If equipped)
The vehicle is equipped with Tubeless Tyres.
In tubeless tyre, a thin layer of butyl rubber
83K-07-038
is used for lining the inside of the tubeless
tyre. This layer is to prevent air loss and
fulfilling the purpose of tube. The air pressure
is maintained by the sealing between tyre
bead and wheel rim. Tubeless tyres are
having advantage of slow air loss and
preventing sudden deflation while driving.Care and maintenance tips for tube-
less tyres1. Always maintain recommended inflation
pressure. Driving continously at low
inflation pressure can lead to tyre damage.
2. In case any leakage is found, check for
any nail penetration/valve core damage
or rim bent. Damaged wheel must not
be used.
3. In case tyre has run at low pressue, it
must be inspected for any defect.
4. Whenver new tyre is fitted, replace the
valve.
5. If continous high speed driving is
required, increase tyres pressure by 5
psi over recommended inflation pressure.
6. Never run the tyre beyond TWI (Tread
wear indicator). The tyre is recommen-ded
to be replaced when the remaining tread
has worn to this point. The indicators are
spaced across the tread around the tyre
marked by a triagular symbol (TWI).
7. Always prefer tubeless tyre mounting
machine. In case of manual mounting-
tyre/wheel rim damage may occur.

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INSPECTION AND MAINTENANCE
9-21
83K-07-039
8. In case of any problem, please get in
touch with MARUTI SUZUKI authorised
dealer.Full Wheel Cover (if equipped)
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Batteries produce flammable hydro-
gen gas. Keep flames and sparks
away from the battery or an explosion
may occur. Never smoke when
working in the vicinity of the battery.
When checking or servicing the
battery, disconnect the negative
cable. Be careful not to cause a
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short circuit by allowing metal
objects to contact the battery posts
and the vehicle at the same time.
To avoid harm to yourself or dam-
age to your vehicle or battery, fol-
low the jump starting instructions in
the “EMERGENCY SERVICE” section
of this manual if it is necessary to
jump start your vehicle.V VV V
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Petrol
83K-07-040-41
EXAMPLE
The level of the battery solution must be
kept above the line between MAX and MIN.
If the level is found to be below the line,
add distilled water to bring level above line.
You should periodically check the battery,
battery terminals, and battery hold down
bracket for corrosion. Remove corrosion
using a stiff brush and ammonia mixed with
water, or baking soda mixed with water.
After removing corrosion, rinse with clean
water.If your vehicle is not going to be
driven for a month or longer, disconnect the
cable from the negative terminal of the
battery to help prevent discharge.
EXAMPLE
TYPE-1TYPE-2Insert a piece of cloth between the spokes
of the wheel cover and try to pull the cover
outward (as shown in figure). Take out the
detached wheel cover from the wheel rim. For
installation first match the slot at the wheel
cover with the air filling nozzle of the wheel.
Apply equal pressure at the circumference of
the wheel cover to fix it in the wheel rim.Battery
TYPE-1
83K-07-42
EXAMPLEDiesel
TYPE-2

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INSPECTION AND MAINTENANCE
9-24
(18) 15A Front fog light fuse
(19) 30A Ignition switch fuse
(20) 50APower window, Ignition,
Wiper, Starter
(21)100A All Electrical Load
(22)100A ABS, MIL, Front fog
(23)100AEPS, Radiator Fan,
Heater, Starter Motor
(24) 50ALamp
(25)100A Glow
(26) 30A Blank
(27) 30A Blank
(28) – Blank
(29) 20A FI fuse
(30) – Blank
(31) 10A FI3 fuseThe main fuse, primary fuses and some of
the individual fuses are located in the
engine compartment. If the main fuse blows,
no electrical component will function. If a
primary fuse blows, no electrical component
in the corresponding load group will
function. When replacing the main fuse, a
primary fuse or an individual fuse, use a
MARUTI genuine replacement.
To remove a fuse, use the fuse puller pro-
vided in the fuse box. The amperage of
each fuse is shown in the back of the fuse
box cover.
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If the main fuse or a primary fuse
blows, be sure to have your vehicle
inspected by a MARUTI SUZUKI
authorized dealer. Always use a Maruti
Genuine replacement. Never use a
substitute such as a wire even for a
temporary repair, or extensive
electrical damage and a fire can result.NOTE:
Make sure that the fuse box always carries
spare fuses and fuse puller.EXAMPLEFuses under the Dash Board
83K-07-04983K-07-050
EXAMPLE
83K-07-048

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INSPECTION AND MAINTENANCE
9-25(1) – Blank
(2) 15A Ignition coil
(3) 10A Back-up light
(4) 10A Meter
(5) 15A Accessory 1
(6) 15A Accessory 2
(7) 30A Power window
(8) 15A Wiper / Washer
(9) 10A IG1 SIG
(10) 15A Air bag
(11) 10A Anti-lock brake system
(12) 10ATail light
(13) – Blank
(14) 20A Door lock
(15) – Blank
(16) 10A ST SIG
(17) 10A Immobilizer
(18) 10A IG2 SIG
(19) 15A Rear fog light
(20) 15ARadio
(21) 20A Rear defogger
(22) 15A Horn / Hazard
(23) – Blank
(24) – BlankMAIN FUSE/PRIMARY FUSE
83K-07-051
The fuse box is located under the driver’s
side of the dashboard.
Remove the fuse box cover by pushing in
at both ends and pulling off the cover.
To remove a fuse, use the fuse puller pro-
vided in the fuse box.
83K-07-052
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Always be sure to replace a blown
fuse with a fuse of the correct amper-
age. Never use a substitute such as
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aluminum foil or wire to replace a
blown fuse. If you replace a fuse and
the new one blows in a short period
of time, you may have a major electri-
cal problem. Have your vehicle
inspected immediately by your
MARUTI SUZUKI authorized dealer.V VV V
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Bulb Replacement Light bulbs can be hot enough to
burn your finger right after being
turned off. This is true especially for
halogen headlight bulbs. Replace the
bulbs after they become cool
enough.
The headlight bulbs are filled with
pressurized halogen gas. They can
burst and injure you if they are hit
or dropped. Handle them carefully.
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The oils from your skin may cause a
halogen bulb to overheat and burst
when the lights are on. Grasp a new
bulb with a clean cloth.
CAUTION