FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

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

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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 lowdensity of CNG, it is compressed at a pres-sure of around 200 bars to enhance thevehicle on-board storage capacity.

SAFETY PRECAUTIONS (Do’s)

1. If any service or body repair is to becarried out, turn the manual shut offvalve on CNG cylinder valve to closeposition prior to commencement ofthere pair work.

2. Get the CNG cylinder checked everythree (3) years from the date of lasttesting / retesting of cylinder by govern-ment authorized CNG cylinder testingagency.

3. If the vehicle does not changeover toCNG in AUTO MODE, then have yourvehicle checked by Maruti Suzukiauthorized workshop at the earliest.

4. Switch “OFF” engine while fuel filling(CNG/Petrol).

5. After refueling CNG or Petrol, ensurethat the fuel filler lid is closed. (Other-wise vehicle cannot be started)

6. In AUTO MODE, It is programmed tostart the vehicle in petrol and automati-cally shift to CNG based on the enginetemperature etc. Do not press theaccelerator pedal to change from petrolto CNG.

SAFETY PRECAUTIONS (Don’ts):

1. Do not change/modify the configura-tion, settings or the components fromCNG system.

2. The CNG cylinder should not berepaired under any circumstances, incase of any problem, consult withMaruti Suzuki authorized workshop.

3. Do not adjust setting 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 externaldamage to CNG piping or duringaccident, do not panic.• Stop the vehicle and switch off

the engine, roll down the win-dows and open all the doors

• Ensure to close manual shut offvalve.

• Contact Maruti Suzuki authorizedworkshop immediatly for furtherassistance.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

LAYOUT OF THE CNG SYSTEM

1 Changeover switch2 High pressure pipe3 Receptacle4 Fuel lid switch5 CNG cylinder valve6 CNG cylinder

7 Vent hose8 CNG controller9 CNG injectors10 Low pressure & temperature sensor11 Engine12 Pressure regulator

53MHMC001

13 Water hose14 High pressure sensor15 High pressure gauge16 Low pressure hose17 CNG filter

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6

75210

1113

1

43

10 12 14

1516

17

8

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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 areselectable by pressing the selectorswitch(1) located on the right side of thesteering wheel on the dashboard.

NOTE:• Do not press the accelerator pedal to

change-over from petrol to CNG mode.• With ignition switch "ON" and engine not

running, blinking of CNG malfunctionwarning lamp indicates that fuel lid isopen. Vehicle will not start in this condi-tion.

SELECTOR SWITCH POSITION

53MHMC002

PETROL MODE

53MHMC003

In this mode vehicle starts in petrol andcontinue running in petrol mode. In thismode, petrol indicator is continuously dis-played and CNG indicator will remain“OFF”.

AUTO MODE

53MHMC004

In this mode engine starts in petrol modeand then automatically changes to CNGafter reaching programmed warming upcondition. With ignition switch ON andvehicle started in “AUTO MODE”, CNGindicator blinks on the display and PET-ROL indicator is displayed. After change-over to CNG, CNG indicator will bedisplayed and Petrol indicator will switchOFF automatically.

NOTE:• It is always recommended to start the

vehicle in AUTO MODE or PETROLMODE to enhance the engine life.

• The fuel changeover to CNG may nothappen if the vehicle is started when theambient / engine temperature is belowZero Degree Celsius. In such a case,run the engine in PETROL MODE till itwarms up and then try restarting theengine to changeover to CNG.

WARNING

Make sure that the parking brake isapplied fully and the transmission isin Neutral before attempting to startthe engine.

CAUTION

• Stop turning the starter immedi-ately after the engine has started orthe starter system can be damaged.

• Do not crank the engine for morethan 15 seconds at a time. If theengine doesn’t start on the first try,wait about 15 seconds before try-ing again.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

FORCED CNG MODE

53MHMC005

This is emergency mode and may be usedin cases where there is no petrol in petroltank. In this mode vehicle starts in CNGmode and continues running in CNGmode.With ignition "ON" and engine notrunning, press and hold the changeoverswitch till only CNG indicator is displayed.In this mode, CNG indicator is displayedand Petrol indicator remains "OFF”.

NOTE:• It is recommended to keep sufficient

amount 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 isrecommended to start the vehicle inAuto 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 quantity of fuel in thefuel tank. “F” stands for full and “E” standsfor empty.If the CNG level meter indicator showsonly one segment to “E” refill the CNG tankas soon as possible.The mark (2) indicates that the fuel fillerdoor 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 automatically changeoverfrom CNG mode to Petrol mode &CNGmalfunction warning lamp will start blink-ing. Petrol indicator will be displayed con-tinuously and CNG indicator will switchOFF automatically.To acknowledge this information, press thechangeover switch once. The CNG mal-function warning lamp will stop blinkingafter the changeover switch is pressed andPetrol indicator will be displayed continu-ously. However the CNG malfunction indi-cator lamp will continue to blink after everysubsequent Ignition ON - Ignition OFF con-dition until the vehicle is refilled with CNG.

NOTE:• It is recommended to keep sufficient

amount of petrol in the petrol tank to pre-vent engine stalling while automaticchangeover from CNG mode to Petrolmode.

• In case the CNG malfunction warninglamp does not stop blinking after press-ing the changeover switch, take the vehi-cle to the nearest MARUTI SUZUKIdealer.

(1) (2)

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

CNG FILLER VALVE

53MHMC007

The CNG filler valve is integrated in fuelbox next to petrol filling area.

CNG filler valve (1) can be uncovered bypulling out the Filler valve cover (2) and itcan be covered by simply pushing it back.

Filling automatically gets cut off when thecylinder pressure becomes equal to dis-penser pressure. After CNG filling, ensurethat the filler valve cover (2) and fuel fillerlid (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 luggagecompartment.

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 loadover cylinder as it may damage thecylinder, pipe, hose, valve etc.

(1)

TO OBTAIN TESTING STATION INFORMATIONVisit the following internet / website address:“www.peso.gov.in”

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

MANUAL SHUT-OFF VALVE

53MHMC010

Manual shut-off valve (2) is located on theleft hand side of the CNG cylinder.

MANUAL SHUT-OFF VALVE OPERATION

53MHMC011

CNG supply can be switched off by closingthe manual shut-off valve.

Valve closing: Turn the knob completelyin clockwise direction to close the CNGsupply to Engine.

Valve opening: Turn the knob completelyin anti-clockwise direction to open theCNG supply to Engine.

NOTE:• If the manual shut-off valve is not

opened fully, then the engine may notrun properly.

• If the manual shut-off valve is in closedcondition, it is not possible to fill CNGinto the cylinder.

NOTE:• As per Government regulation, CNG cyl-

inder needs to be checked and certifiedevery three (3) years from the date of ini-tial testing as mentioned on the CNGcylinder identification plate.

• Customer has to present the vehicle to agovernment approved testing agency.

• Failure to test the cylinder may result indenying of CNG filling by the CNG dis-pensing stations or may result in confis-cating the vehicle by enforcementauthorities.

• 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 yearsfrom the date of initial testing as men-

tioned in the CNG cylinder identificationplate.

• Customer has to discard the cylinder athis / her expense through governmentapproved scrap agencies.

• No person shall refill any cylinder, whichhas been repaired under sub-rule (2)with any gas unless a full report on therepairs and test carried out on the cylin-der, accompanied by the repairer's certif-icate of testing are furnished to the ChiefController and his permission is obtainedfor its refilling.

OPEN

OMBCNG

onl yCLO

SE(2)

1 2Open Close

WARNING

• Never remove the cylinder valvefrom the cylinder assembly. Forany assistance consult MarutiSuzuki authorized workshop.

• Never try to clean the cylinder. Incase of any problem, contactMaruti Suzuki authorized work-shop.

• Do not reuse the cylinder valve,once it is replaced / removed fromcylinder assembly.

• Even if the CNG from the cylinderis consumed till engine stops,some amount of CNG will be leftout in the tank under pressure.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

LIST OF APPROVED CNG CYLIN-DERSTESTING STATIONS

To obtain testing stations information visitthe 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 toaccess the spare wheel.

53MHMC013

• Unscrew spare wheel screw in anticlock-wise direction.

• Remove spare wheel (3) from the frontside of vehicle as shown in the figure.

• Unscrew the jack from its holder andremove.

• Reverse the above procedure for fittingthe 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.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

INSTRUMENT CLUSTER

Type 1

53MHMC014

Type 2

53MMMC001

CNG MALFUNCTION WARNING LAMP

53MHMC015

When the ignition switch is turned "ON",this CNG malfunction warning lamp comeson briefly, to check that the CNG malfunc-tion lamp is trouble free.• If CNG malfunction warning lamp glows

continuously, with ignition "ON" there issome problem with the CNG system.Immediately get your vehicle checked byMaruti Suzuki authorized workshop.

• If CNG malfunction warning lamp blinksduring engine running, it means there issome problem in CNG system in whichvehicle cannot continue running in CNG-MODE and automatically switchover topetrol mode. Have your vehicle checkedat Maruti Suzuki authorized workshop.

NOTE:With ignition switch "ON" and engine notrunning, blinking of CNG lamp indicatesthat fuel lid is open. Vehicle will not start inthis condition. Close the lid in order to startthe vehicle.

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(1) Speedometer(2) Odometer / Tripmeter(3) Odometer / Tripmeter selector knob(4) Fuel indicator (Petrol)

(5) Fuel indicator (CNG)(6) CNG malfunction warning Indicator lamp(7) Other warning and indicator lamps

1

2 345

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

KIT IDENTIFICATION

53MHMC016

CNG cylinder identification number andCNG kit installation date is located abovethe fuel filling area.

53MHMC017

CNG WARNING LABEL

Front Driver Door

53MHMC018

53MHMC019

CNG warning label is located on front andrear Right doors.

FUSE BOX

53MHMC020

(9) CNG 7.5A (21) CNG Valve 7.5AFor other fuses, refer "Inspection andmaintenance" section in the main owner'smanual.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

PERIODIC MAINTENANCE SCHEDULE

Kms (1 x 1000)Month

11

56

1012

2024

3036

4048

5060

6072

7084

8096

90108

100120

All Joints (Gas leakage) I I I I I I I I I I I I

Coolant Hoses(Leakage, Damage) I I I I I I I I I I I I

All Fasteners Torque values T T T T T T T T T T T T

CNG low pressure filtercartridge with O-Ring - - - R - R - R - R - R

CNG cylinder leak testing andcertification Every 3 years from the date of initial testing by govt. approved testing agency

CNG filler receptacle O-Ring Replace every 4 years or 300,000 Km, whichever comes earlier

T ........Tighten to Specified Torque I ........ Inspect and correct or replace if necessaryR ....... Replace

NOTE:• This table includes services as scheduled up to 100,000 km mileage. Beyond 100,000 km, carry out the same services at the same

intervals respectively.• For other maintenance details refer “Inspection & Maintenance” section in main Owner’s Manual.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

SPECIFICATIONSMass (Weight) (Kgs)

Kerb Weight 810-812 Kgs

Gross Weight 1185 Kgs

Seating Capacity 4 persons

Fuel Capacity (litres)

Petrol 35 L

CNG (Water Filling Capacity 60 L

NOTE:Specifications are subject to change without notice.

NOTE:1) It is recommended to run the vehicle on petrol mode for 5~10 kms after every 300~500 km run in CNG mode to keep fuel system in

good condition.2) Always keep minimum 5 litres of petrol in your petrol tank.

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

FIRE EXTINGUISHER (if equipped) Do's and Don'ts

53MHMC021

Do's1. Check pressure gauge periodically.

Max charging pressure is 15Kgf/cm2 (ingreen zone (2)).

2. When pressure drops, indicator nee-dle(1) will shift to the red zone(3).Immediately contact the fire extin-guisher manufacturer as per the infor-mation provided on the fireextinguisher.

3. Get the fire extinguisher serviced onlythrough the manufacturer service cen-tre.Refer the information provided onthe fire extinguisher to locate the near-est service centre.

4. Ensure that the Fire extinguisher isalways kept at its prescribed position inthe vehicle.

5. Refill the fire extinguisher immediatelyafter use.

Don't• Do not use water for cleaning fire extin-

guisher. (Use clean cloth for removingdust)

• Do not rely on used or discharged fireextinguisher.

LOCATION

53MHMC023

Fire extinguisher is located below co pas-senger's seat.

PARTS DESCRIPTION

53MHMC024

(1) Fire extinguisher cylinder(2) Seal(3) Safety Pin(4) Lever(5) Nozzle

REMOVAL PROCEDURE (from front seat)

53MHMC025

Lift Lever (1) of fire extinguisher slightlyupwards and pull the fire extinguisher inthe direction as shown in the figure, inorder to disengage it from clamps (2).

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FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

68PH0-74E

PROCEDURE OF OPERATION

53MHMC026

1. Hold the fire extinguisher (1) upright.2. Break seal (2) by rotating the safety

pin(3).

53MHMC027

3. Pull Safety pin (3)4. Squeeze lever (4) and direct the jet

from nozzle (5) towards the near edgeof the fire with a rapid (fast) sweepingmotion.

53MHMC028

5. Drive the fire towards the far edge untilflames are extinguished.

NOTE:Fire extinguisher is only meant for smallfire caused in vehicle by external sourceonly.

FITMENT PROCEDURE

53MHMC029

Insert the body of fire extinguisher (1) in tothe clamps (3) and place the nozzle(2)carefully downwards, on the clamp.

NOTE:Ensure that the nozzle of fire extinguisheris properly seated on the clamp.

REFILLING SCHEDULES

1. Refilling is necessary after every use.2. Fire extinguisher needs refilling after

every 3 years even if it is not used.( )

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