Maruti 800 LPG - Manual

7/26/2019 Maruti 800 LPG - Manual

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TABLE OF CONTENTS 1MAINTENANCE SERVICE RECORD2WARRANTY POLICY

3BEFORE DRIVING

4STEERING COLUME CONTROLS

5INSTRUMENT PANEL

6OTHER CONTROLS AND EQUIPMENT

7OPERATING YOUR VEHICLE

8DRIVING TIPS AND SAFE DRIVING

9INSPECTION AND MAINTENANCE

10EMERGENCY SERVICE

11BODY WORK CARE

12GENERAL INFORMATION13FOR LPG KIT FITTED VEHICLE

14SPECIFICATION


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MODIFICATION WARNING

wwwww WARNING

Do not modify this vehicle. Modifica-tion could adversely affect safety,

handling, performance, or durabilityand may contravene regulations. Inaddition, damage or performanceproblems resulting from modification

may not be covered under warranty.

Copying, quoting or reproduction of anypart of this manual is not permittedwithout explicit approval by MARUTISUZUKI INDIA LIMITED.

0-2

wwwww WARNING

Your vehicle has monocoque bodyconstruction which provides for

certain crumple zones in the bodywhich absorbs larger part of impact

energy in the event of a front collisionand protects the occupants fromimpact. Do not use any fitmentssuch as crash guards. These

fitments will increase the risk to theoccupants because of the shockdirectly getting transmitted to theoccupants.

CAUTIONImproper instllation of moblecommunication euipment such ascellular talephones or CB (Citizen'sBand) radios may cause electronic

interference with your vehicle'signition system, resulting in vehicleperformance problems. Consult yourMARUTI SUZUKI dealer or qualified

service technician for advice oninstalling such mobilecommunication equipment.844-00-001

The circle with a slash in this manual

means Dont do this or Dont let thishappen.


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1MAINTENANCE SERVICE RECORD

IMPORTANT INFORMATION TO CUSTOMER

Dear CustomerFor any assistance with regard to our product, please contact

General Manager/Works Manager at any of our Dealer orAuthorised Service Station. For additional enquiry you maycontact our Regional office or Service Department. TheAddresses and Phone nos. are given in Service Networkbooklet provided along with vehicle.

MODEL CHASSIS NO. ENGINE NO. DATE OF MILEAGE BATTERYDELIVERY MAKE SR. NO/BATCH CODE

km.

OWNERS NAME & ADDRESS ____________________________________________________________________________

_____________________________________________________________________ TEL. NO. _________________________

ADDRESS/STAMP OF SELLING DEALER SELLING DEALER CODE

SHOWROOM

WORKSHOP

MAINTENANCE SERVICE RECORD

1-1


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F....free Service P....Paid Service W....Warranty. A....Accident

MAINTENANCE SERVICE RECORD

DATE OF KIND OF MILEAGE DESCRIPTION OF JOB NAME OF SERVICING JOB CARD MECHANICS

SERVICE SERVICE km DEALER/MASS NO. SIGNATURE

1-2


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Maruti Suzuki offers the Emission Warranty on all Maruti Suzuki vehicles (apart from the Regular warranty and will run parallelto the regular product warranty) only in four metropolitan cities (New Delhi, Kolkata, Mumbai and Chennai) with effect fromJuly 1st, 2001.

Terms:

The Emission Warranty will be applicable for 80,000 kms or 3 years (Which ever comes earlier) from the date of delivery to

the first owner. The remaining warranty terms will be valid in case of any change in ownership provided the production of allvalid document.

Conditions:

1. Under Emission Warranty, Warranty claims will be admitted for a prima facie examination, in case vehicle fails to meet to theEmission Standard as specified in sub rule (2) of rule no. 115 of Central Motor Vehicles Rules (CMVR), 1989.

2. The warranty claims will only be accepted after examination carried out by Maruti Suzuki or it's dealer which leads to firm conclusionsthat the

a) Original settings have not been tempered in any case.

b) Part (as given in Annexure-A) has a manufacturing defect.

c) Vehicle is unable to meet the Emission Standards (as given in 1.), inspite of the vehicle having been maintained and usedin accordance with the instructions as specified in Owner's Manual and Service Booklet and the used fuel and different oils (Engine

oil, Transmission oil, Brake oil etc.) are also as per specification.

3. The method of examination for deciding the warranty of the parts will be at the sole discretion of Maruti Suzuki and it's dealer

and results of the examination will be final and binding. If after examination, the warrantable condition is not established, MarutiSuzuki and it's dealer has has the right to charge all, or part of the cost of such examination.

4. Under Emission Warranty, the parts (as given in Annexure-A) will be changed free of cost, but the consumables will be charged

as per actual.

5. If the part covered under Emission Warranty or the associated parts, are not independently replaceable, on account of these beingintegral parts a complete assembly, Maruti Suzuki and it's dealer will have the sole discretion to replace entire assembly or byusing some of the parts of the system through suitable repair or modifications.

EMISSION WARRANTY

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6. Any consequential repairs or replacement of parts which may be found necessary to establish compliance of Emission Warranty,will not be considered under warranty, unless the same is under product warranty. The consumable will be charged as per actualunder such repair or replacement.

7. Maruti Suzuki will not be responsible for the cost of transportation of the vehicle to the nearest Maruti Suzuki dealer workshopor any loss due to non-availability of the vehicle during the period of lodging of a warranty claim and examination and/or repairby Maruti Suzuki dealer.

8. Maruti Suzuki will not be responsible for any penalty that may be charged by statutory authorities on account of failure to complywith the EMISSION STANDARDS.

9. Emission Warranty will not be affected on the change of owner, provided all the documents are available.

10. All maintenance actions (as specified in the Owner's Manual and Service Booklet) need to be followed and recorded in the manualfor emission warranty.

11. The customer needs to produce the PUC (Pollution Under Control) certificate valid for the period preceding the test during which

the failure is discovered. The receipts (for the maintenance of the vehicle as per specification in Owner's Manual and ServiceBooklet from the date of original purchase of the vehicle) will also be required.

Condition Under which the Emission Warranty is not APPLICABLE

1. In the absence of valid PUC certificate.

2. Vehicle not serviced from Maruti Suzuki authorised workshop as per the schedule specified in the Owner's Manual.

3. Vehicle subjected to abnormal use (accident, motor race, rallies or for the purpose of establishing the records etc.)

4. Use of non MGP (Maruti Genuine Part).

5. Vehicle tempered in an unauthorised manner.

6. Tampering with odometer so that the actual kilometer reading can not be read.

7. Use of adulterated fuel and/or unspecified oils (Engine oil, Transmission oil and Brake oil etc.)

EMISSION WARRANTY

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Annexure-A

List of parts covered under Emission Warranty

1. Fuel injection Assembly, Pressure Regulator, Throttle Body Assembly.

2. Electronic Control Module (ECM).

3. Intake Manifold.

4. EGR valve.

5. Distributor and internal parts.

6. Ignitions coil.

7. Canister Assembly.

8. Vapour Liquid Separator.

9. Fuel Tank and Filler Cap.

10. PCV (Positive Crankcase Ventilation) Valve.

11. Oil Filler Cap.12. Catalytic Convertor.

13. Exhaust manifold.

14. All fuel injection System related SENSORS.

15. Maniverter

EMISSION WARRANTY

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BEFORE DRIVING

BEFORE DRIVING

Fuel Recommendation .......................................................................................3-1

Keys ......................................................................................................................3-2Immobilizer Key (if equipped) .........................................................................3-2

Door Locks ..........................................................................................................3-3

Windows ............................................................................................................... 3-4

Mirrors ...................................................................................................................3-4

Front Seat Adjustment ......................................................................................3-5

Adjustable Head Restraints (if equipped) ....................................................3-6

Seat Belts ............................................................................................................3-6


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BEFORE DRIVING

FUEL RECOMMENDATION

Be careful not to spill fuel containingalcohol while refuelling. Fuelscontaining alcohol can cause paintdamage, which is not covered underWarranty.

Use of leaded fuel in vehicle equippedwith catalytic converter is prohibited,because lead deactivates the pollutantreducing components of catalyticconverter and may result in permanentdamage to catalytic converter.

CAUTION

CAUTION

Petrol/Ethanol BlendsBlends of unleaded petrol and ethanol (grain

alcohol), also known as gasohol, arecommercially available in some areas.

Blends of this type may be used in yourvehicle if they are no more than 5%ethanol. Make sure this petrol-ethanol blendhas octane ratings no lower than thoserecommended for petrol.

Petrol/Methanol BlendsBlends of unleaded petrol and methanol(wood alcohol) are also commerciallyavailable in some areas. DO NOT USEfuels containing more than 5% methanolunder any circumstances. Fuel system

damage or vehicle performance problemsresulting from the use of such fuels are notthe responsibility of MARUTI SUZUKI andmay not be covered under Warranty.

Fuels containing 5% or less methanol maybe suitable for use in your vehicle if theycontain cosolvents and corrosion inhibitors.

NOTE:If you are not satisfied with the driveability

or fuel economy of your vehicle when youare using a petrol/alcohol blend, you shouldswitch back to unleaded petrol containing no

alcohol.

CAUTION

The fuel tank has an air space toallow for fuel expansion in hotweather. If you continue to add fuelafter the filler nozzle has automaticallyshut off or an initial blowback occurs,the air chamber will become full.Exposure to heat when fully fuelled inthis manner will result in leakage dueto fuel expansion. To prevent suchfuel leakage, stop filling after the fillernozzle has automatically shut off, orwhen using an alternative nonautomatic system, initial ventblowback occurs.


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3-2

Your vehicle comes with a pair of identicalkeys. Keep the spare key in a safe place.One key can open all of the locks on thevehicle.

The key identification number is stamped ona metal tag provided with the keys. Keepthe tag in a safe place. If you lose yourkeys, you will need this number to havenew keys made. Write the number downand keep it in a safe accessible place awayfrom the vehicle.

KEYS

wwwwwWARNING

Do not use locally made key. Should you require a duplicate key,

place your order with a MARUTISUZUKI dealer only.

Note:Keep the spare key very carefully. When itis lost, consult your dealer by quoting key

number.

Key No. :

IMMOBILIZER KEYS (if equipped)

844-03-001 844-03-002


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DOOR LOCKS

To lock a front door from outside thevehicle:a) Insert the key fully and turn the top of

the key toward the front of the vehicle,or

b) Push in the lock lever and hold the doorhandle up as you close the door.

To unlock a front door from outside the

vehicle, insert the key fully and turn the topof the key toward the rear of the vehicle.

To lock a rear door from outside the

vehicle, push in the lock lever and close thedoor.

IMMOBILIZER SYSTEM (if equipped)

NOTE: If you lose your Immobilizer ignition key,

contact your MARUTI SUZUKI dealer assoon as possible to have the lost onedeactivated, then have the new keymade by them.

I f you own other vehic les wi thimmobilizer keys, keep those keys awayfrom the ignition switch when using your

vehicle, or the engine may not bestarted because they may interfere withyour vehicles immobilizer system.

CAUTIONIn case of attaching any metal objectsto the immobilizer key, it may notstart the engine.The immobilizer key is a sensitiveelectronic instrument. To avoiddamaging the immobilizer key: Do not expose it to impacts,

moisture or high temperature suchas by leaving it on the dashboardunder direct sunlight.

Keep the immobilizer key away from

magnetic objects.

This system is designed to help preventvehicle theft by electronically disabling theengine starting system.

The engine can be started only with your

vehicles original immobilizer ignition keywhich has an electronic identification codeprogrammed into it. The key communicatesthe identification code to the vehicle when

the key is turned to the ON position. Ifyou need to make spare keys, contact yourMARUTI SUZUKI dealer. The vehicle mustbe programmed with the correct identifica-tion code for the spare keys. A key madeby an ordinary locksmith will not work.

If the Immobilizer system light (1) blinkswhen the ignition switch is in the ONposition, there may be something wrong

with your key or with the immobilizer sys-tem. Contact your MARUTI SUZUKI dealerto inspect the system.

3-3

BEFORE DRIVING

844-03-003

844-03-004


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3-4

To lock a door from inside the vehicle, pushin the lock lever. Pull out the lock lever tounlock the door.

Always lock all doors when driving.Locking the door prevents occupantsfrom being thrown from the vehicle inthe event of an accident. It also helpsprevent unintentional opening of thedoors.

wwwwwWARNING

Do not use the key to lift up the lid,or the key may break off in the lock.

CAUTIONHatchbackTo unlock insert the key fully in to the lockknob and turn it anticlockwise and to lockturn it clockwise. Hatchback can be openedby pushing in the lock knob and lifting hook-shaped grip.

Always make sure that the hatchbackis closed and latched securely.Completely closing it helps keepexhaust gases from entering the car.Completely closing the hatchback lidalso helps prevent occupants frombeing thrown from the vehicle in theevent of an accident.

wwwwwWARNING

844-03-005 844-03-006


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WINDOWS

Raise or lower the door windows by turningthe handle located on the door panel.

MIRRORS

Inside Rearview MirrorTo adjust the interior rearview mirror, movethe mirror up, down, or sideways to obtainthe best view.

Outside Rearview MirrorAdjust the outside rearview mirror so youcan just see the side of your vehicle in themirror.

Be careful when judging the size ordistance of a vehicle or other objectseen in the side convex mirror (ifequipped). Be aware that objects looksmaller and appear farther away thanwhen seen in a flat mirror.

wwwwwWARNING

844-03-007 844-03-008 844-03-009


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3-7

ADJUSTABLE HEAD RESTRAINTS(if equipped)

wwwwwWARNING

Never drive the vehicle with thehead restraints removed.

Do not attempt to adjust the headrestraint while driving.

Head restraints are designed to help reducethe risk of neck injuries in the case of anaccident. Adjust the head restraint to theposition which places the middle of the headrestraint closest to the top of your ears.

There are two height positions for the headrestraints. To raise the head restraint, pull

upward on the restraint until it clicks. Tolower the restraint, push down on therestraint while holding in the lock lever. Ifa head restraint must be removed (forcleaning, replacement, etc.), push in thelock lever and pull the head restraint all the

way out.

Wear Your Seat Belts at All Times.

There are two types of seat belt "Automaticretracting type" and "3-point, non retractortype".

To fasten the seat belt, pull the buckletongue attached to the seat belt across yourbody and slide it into the buckle catch slot

on the opposite side until you hear a click.

wwwwwWARNING

SEAT BELTS

844-03-012 844-03-013 844-03-014


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3-point non-retractor typeAdjust the shoulder portion of the belt so

that it is slightly slack. To shorten thebelt, pull the free end in the direction of

the arrow as illustrated. To lengthen thebelt, grab it at the shoulder anchor andpull it in the direction of the arrow, atright angles to the anchor. The shoulderportion should have just enough slack sothat a clenched fist can be inserted

between the belt and your chest asillustrated. Too much slack at the

shoulder portion makes the beltineffective in accidents. The shoulderportion should be worn on the outsideshoulder only, and never under the arm.

Inspect all seat belts after anycollision. Any automatic retractingtype belt which was in use at thetime of collision and subjected tostress must be replaced.

Any automatic retracting type beltnot in use at the time of collisionshould be carefully inspected andthe static operation checked. If thereis any doubt whatsoever in the

operation or condition of the belt, itmust be replaced. Non retractor type belts with any

form of damage or abrasion to anypart of the belt must be replaced.

wwwwwWARNINGAfter use, always rehang the belt on thehook provided near the upper anchorage

point.

844-03-018 844-03-019 844-03-020


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844-74ESTEERING COLUMN CONTROLS

4-1

IGNITION SWITCH

The ignition switch has the following fourpositions:

Do not use any locally made key. Should you require duplicate key,

place your order with MARUTISUZUKI dealer only.

LOCKThis is the normal parking position. It is the

only position in which the key can beremoved.

The LOCK position locks the ignition, andprevents normal use of the steering wheelafter the key is removed.

To release the steering lock, fully insert the

key and turn it clockwise to one of the otherpositions. If you have trouble turning thekey to unlock the steering, try turning the

steering wheel slightly to the right or leftwhile turning the key.

To avoid possible injury, do notoperate controls by reaching throughthe steering wheel.

wwwwwWARNING

wwwwwWARNING

844-04-001 844-04-002 844-04-003


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844-74EINSTRUMENT PANEL

5-1

1. Instrument cluster2. Ignition switch

3. Lighting switch/Turn signal anddimmer switch

4. Windscreen wiper and washerswitch

5. Hazard warning switch6. Other switches (if equipped)

7. Heater control panel8. Cigarette lighter (if equipped)9. Ashtray (if equipped)

10. Bonnet release

11. Center ventilator12. Side ventilator13. Side defroster14. Glove box

15. Fuse box

INSTRUMENT PANEL

1. Speedometer2. Odometer3. Fuel Gauge4. Temperature gauge5. Warning and indicator lights

INSTRUMENT CLUSTER

844-05-001

844-05-002


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5-3

If you operate the engine with thislight on, severe engine damage canresult.

Do not rely on the Oil PressureLight to indicate the need to add oil.Be sure to periodically check theengine oil level (see pages 9-7 and9-8).

CAUTION Charging LightThis light comes on when the ignition switch

is turned on, and goes out when the engineis started. The light will come on andremain on if there is something wrong withthe battery charging system. If the lightcomes on when the engine is running, thecharging system should be inspected

immediately by your MARUTI SUZUKIdealer.

Do not continue driving long with thecharging light ON as this will drain thebattery 'dead'.

CAUTION

Malfunction Indicator LightYour vehicle has a computer-controlledemission control system. A Malfunction

Indicator light is provided on the instrumentpanel to indicate when it is necessary tohave the emission control system serviced.The Malfunction Indicator light comes on

when the ignition switch is turned to ON

and goes out when the engine is started.If the Malfunction Indicator light comes on

when the engine is running, there is aproblem with the emission control system.Take the vehicle to your MARUTI SUZUKIdealer to have the problem corrected.

Continuing to drive the vehicle whenthe Malfunction Indicator light is on

can cause permanent damage to thevehicles emission control system, andcan affect fuel economy anddriveability.

CAUTION

844-05-005 844-05-006

844-05-007


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844-74E INSTRUMENT PANEL

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Turn Signal IndicatorsWhen you turn on the left or right turnsignals, the corresponding green arrow onthe instrument panel will flash along with therespective turn signal lights. When you turnon the hazard warning switch, both arrowswill flash along with all of the turn signallights.

Main Beam (High Beam) Indicator LightThis indicator comes on when headlightmain beams (high beams) are turned on.

SPEEDOMETER/ODOMETER

1 Speedometer2 Odometer

The speedometer indicates vehicle speed inkm/h. The odometer records the totaldistance the vehicle has been driven.

Keep track of your odometer readingand check the maintenance scheduleregularly for required services.Increased wear or damage to certainparts can result from failure toperform required services at theproper mileage intervals and yourwarranty rights may be affected.

CAUTION

When the ignition switch is turned to theON position, this light comes on to let youknow the light is working. If this light blinks

with the ignition switch turned to ON, theremay be something wrong with the immobi-lizer system. Contact your MARUTI SUZUKIdealer to have the system inspected.

Immobilizer System Light (if equipped)

844-05-008 844-05-009

844-05-011

844-05-010


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Description of ControlsFunction selector 1: This selector is used

to select one of the functions describedbelow:

DEFROST & VENTILATION 2:Temperature-controlled air comesout of the center and side outletsof instrument panel, windshielddefroster outlet and side defrosteroutlets.

VENTILATION 3: Temperature-controlled air comes out of thecenter and side air outlets.

BI-LEVEL 4 : Temperature-

controlled air comes out of thefloor outlets and cooler air comesout of the center and side outlets.When the temperature controllever is in the fully COOLposition or fully HOT position,however, the air from the flooroutlets and the air from the centerand side outlets will be the sametemperature.

HEAT 5: Temperature-controlledair comes out of the floor outlets.

HEAT & DEFROST 6: Temp-erature-controlled air comes out

of the floor outlets, thewindscreen defroster outlets, andthe side defroster outlets.

DEFROST 7 : Temperature-controlled air comes out of thewindscreen defroster outlets andthe side defroster outlets.

Air Intake Lever8: This lever is used toselect between circulating outside air

(FRESH AIR) or recirculating inside air(RECIRCULATED AIR).

Temperature Control Dial9: This dial is

used to control the temperature of the airthat comes out of the air outlets.

Fan switch0: This switch is used to turnon the fan and to select fan speed. Thereare four positions: OFF, LOW, MEDIUM andHIGH.

Natural VentilationMove the function selector to

VENTILATION, the air intake lever toFRESH AIR, The temperature control dialto the desired temperature position, and the

fan switch to OFF. Fresh air will flowthrough the vehicle when it is moving.

SYSTEM OPERATING INSTRUCTIONS

844-05-020

844-05-026

844-05-021

844-05-022

844-05-023

844-05-025

844-05-024


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AIR CONDITIONING SYSTEM(if equipped)

SYSTEM OPERATING INSTRUCTIONS

The air conditioning system can be used toprovide cooling and dehumidifying, as

described below. To turn on the airconditioning system, push in the A/C buttonand move the fan switch to a position otherthan OFF. An indicator light will come onwhen the air conditioning system is on. Toturn off the air conditioning system, push

the A/C button again.

During operation of the air conditioner, youmay notice slight changes in engine speed.

These changes are normal, the system isdesigned so that the compressor turns onor off to maintain the desired temperature.Less operation of the compressor results inbetter fuel economy.

Normal Cooling (using outside air)push in the A/C button, move the function

selector to VENTILATION, the air intakelever to FRESH AIR, the temperaturecontrol dial to the COOL position, and thefan switch to the desired fan speed position.Moving the fan switch to a higher fan speedposition increases cooling efficiency.

844-05-033 844-05-034


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Quick Cooling (Using recirculated air)The lever settings are the same as for

normal cooling except you move the airintake lever to RECIRCULATED AIR. Ifyou use this cooling method for a extendedperiod of time, the air in the vehicle canbecome contaminated. Therefore, youshould occasionally move the air intake

lever to FRESH AIR.

NOTE:If your vehicle has been left in the sun withthe windows closed, it will cool faster if you

open the windows briefly while you operatethe air conditioner with the air intake leverat FRESH AIR and the fan at high speed.

DehumidifyingPush in the A/C button, move the function

selector to the desired function position, theair intake lever to FRESH AIR, thetemperature control dial to the desiredtemperature position, and the fan switch tothe desired fan speed position.

NOTE:

Because the air conditioner dehumidifies theair, turning it on will help keep the windowsclear, even when blowing heated air usingthe DEMIST or HEATER & DEMIST

functions.

NOTE:There are two types of air conditioning

systems used in MARUTI SUZUKI vehicles.One type uses refrigerant CFC-12, commonlycalled R-12; the other type uses the newrefrigerant HFC-134a, commonly called R-

134a. For each system, the correctrefrigerant must be used. To identify thesystem, a label that states "R134a" or"HFC134a" is stuck on the front side of theengine compartment.

Using the wrong refrigerant maydamage the air conditioning system.Use correct refrigerant only. Do notmix the two refrigerants.

CAUTION

844-05-035 844-05-036 844-05-037


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844-74E OTHER CONTROLS AND EQUIPMENT

6

OTHER CONTROLS AND EQUIPMENT

Parking Brake Lever ..........................................................................................6-1

Pedals ...................................................................................................................6-2

Gear Lever ...........................................................................................................6-2

Fuel Filler Cap ....................................................................................................6-3

Folding Rear Seats ............................................................................................6-4

Sun Visor .............................................................................................................6-5

Interior Light Switch ..........................................................................................6-5

Assist Grips ........................................................................................................6-5

Bonnet ...................................................................................................................6-6

Tyre Changing Tools .........................................................................................6-7

High Mount Stop Lamp (if equipped) ........................................................... 6-7


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PEDALS

Do not ride the brakes by applyingthem continuously or resting your footon the pedal. This will result inoverheating of the brakes which couldcause unpredictable braking action,longer stopping distances, orpermanent brake damage.

Accelerator Pedal 33333This pedal controls the speed of theengine. Depressing the accelerator pedal

increases power output and speed.

Clutch Pedal 11111The clutch pedal is used to disengage the

drive to the wheels when starting theengine, stopping, or shifting the transmissionlever. Depressing the pedal disengages theclutch.

Do not drive with your foot resting onthe clutch pedal. It could result inexcessive clutch wear, clutch damage,or unexpected loss of engine braking.

Brake Pedal 22222Your MARUTI SUZUKI vehicle is equippedwith front disc brakes and rear drum brakes.Depressing the brake pedal applies bothsets of brakes.

You may hear occasional brake squealwhen you apply the brakes. This is a

normal condition caused by environmentalfactors such as cold, wet, snow, etc.

If brake squeal is excessive andoccurs each time the brakes areapplied, you should have the brakeschecked by your MARUTI SUZUKI

dealer.

wwwwwWARNING

CAUTION

wwwwwWARNING

GEAR LEVER

Your vehicle is equipped with either a 4-speed or 5-speed manual transmission.The

gear change pattern for each transmissionis shown in the illustration. For details onhow to use the transmission, refer toUSING THE TRANSMISSION in theOPERATING YOUR VEHICLE section (Seepage 7-3).

4 SPEED TRANSMISSION

844-06-003 844-06-004


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SUN VISOR INTERIOR LIGHT SWITCH

The sun visors can be pulled down to blockglare coming through the wind screen, orthey can be unhooked and turned to theside to block glare coming through the sidewindow.

When unhooking and hooking a sunvisor, be sure to handle it by the hardplastic parts or the sun visor can bedamaged.

This light switch has three positions whichfunction as described below:

1 The light remains off even when thedoor is opened.

2 The light comes on when the door isopened.

3 The light comes on and stays onregardless of whether the door is open

or closed.

NOTE:Only front doors are involved in lighting

operation of interior light.

CAUTION

ASSIST GRIPS

Assist grips are provided for passengerconvenience.

Do not hang items on the assist grips.They could obstruct the drivers view,resulting in an accident, or could bethrown about in an accident or abruptmanoeuvre, causing injury.

wwwwwWARNING

844-06-010 844-06-011 844-06-012


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BONNET

To open the bonnet:

1) Pull the bonnet release handle located

on the outboard side of the drivers sideof the instrument panel. This willdisengage the bonnet lock halfway.

2) Push the under-bonnet release leverupwards with your finger, as shown inthe illustration. While pushing the lever,lift up the bonnet.

3) Continue to lift up the bonnet until it ishigh enough to support with the proprod.

Make sure the bonnet is fully closedand latched before driving. If it is not,it can fly up unexpectedly duringdriving, obstructing your view andresulting in an accident.

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TYRE CHANGING TOOLS

The jack, wheel wrench and jack handle arestowed in the luggage compartment behindthe rear seat.

To remove the jack, turn its shaftcounterclockwise and pull the jack out of thestorage bracket. To stow the jack, place itin the storage bracket and turn the shaftclockwise until the jack is securely held in

place.

The jack should be used only to

change wheels. It is important to readthe jacking instructions in theEMERGENCY SERVICE section of thismanual before attempting to use thejack.

After using the jack, jack handle, andwheel wrench, be sure to stow them

securely or they can cause injury if anaccident occurs.

wwwwwWARNING

wwwwwWARNING

HIGH MOUNT STOP LAMP(if equipped)

High mount stop lamp is provided with yourvehicle and is fitted on back door. The stoplamp will glow as when the brake pedal willbe depressed.To change the bulb of the stop lamp,remove the clips at both sides of the cover,

by pressing the inner pin inside so that theclip gets loose and remove the bulb onturning it anticlock-wise.The rating of bulb is 16W/12V. There areone bulb in high mount stop lamp.

844-06-016 844-06-017 844-06-018


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844-74E OPERATING YOUR VEHICLE

7

OPERATING YOUR VEHICLE

Exhaust Gas Warning .......................................................................................7-1

Daily Inspection Checklist ................................................................................7-1

Starting the Engine ...........................................................................................7-2

Using the Transmission .................................................................................... 7-3

Braking ................................................................................................................. 7-4

Running-in ............................................................................................................7-4

Catalytic Converter ............................................................................................7-5

Improving Fuel Economy .................................................................................7-6

Trailer Towing .....................................................................................................7-6


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EXHAUST GAS WARNING

with the engine running, make surethe air intake lever is set to FRESHAIR and the fan is at high speed.

Avoid operating the vehicle with thehatchback open. If it is necessary tooperate the vehicle with hatchbackopen, make sure all the windows areclosed, and the fan is at high speedwith the air intake lever set toFRESH AIR.

To allow proper operation of yourvehicles ventilation system, keepthe air inlet grille in front of thewindscreen clear of snow, leaves, or

other obstructions at all times. Keep the exhaust tailpipe area clear

of snow and other material to helpreduce the buildup of exhaust gasesunder the vehicle. This isparticularly important when parkedin blizzard conditions.

Have the exhaust system inspectedperiodically for damage and leaks.Any damage or leaks should be

repaired immediately.

DAILY INSPECTION CHECKLIST

wwwwwWARNING

wwwwwWARNING

Before driving:1) Make sure that windows, mirrors, lights,

and reflectors are clean and unobstructed.

2) Check the tyres.3) Look for fluid and oil leaks.

NOTE :It is normal for water to drip from the airconditioning system after use.4) Adjust the seat/head restraint

5) Check the brake pedal and the parkingbrake lever.

6) Adjust the mirrors.

7) Make sure that you and passengershave properly fastened your seat belts.

8) Make sure that all warning lights comeon as the key is turned to the ON orSTART position.

9) Check all gauges.10)Make sure that the brake fluid level

warning light is off after restarting theengine.

Avoid breathing exhaust gases.

Exhaust gases contain carbonmonoxide, a potentially lethal gas thatis colourless and odourless. Sincecarbon monoxide is difficult to detectby itself, be sure to take the followingprecautions to help prevent carbonmonoxide from entering your vehicle. Do not leave the engine running in

garages or other confined areas. Do not park with the engine running

for a long period of time, even in anopen area. If it is necessary to sitfor a short time in a parked vehicle

V

V

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844-07-001

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STARTING THE ENGINE

Before starting the engine:1) Make sure the parking brake is applied

fully.2) Shift into N (neutral) and depress the

clutch pedal all the way to the floor. Holdit while starting the engine.

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

Stop turning the starter immediately

after the engine has started or thestarter system can be damaged.

Do not crank the engine for morethan 15 seconds at a time. If theengine doesnt start on the first try,wait about 15 seconds before tryingagain.

wwwww WARNING

Starting a Cold/Warm Engine

For Electronic fuel injection models

With your foot off the accelerator pedal,

crank the engine by turning the ignitionkey to START. Release the key whenthe engine starts.

If the engine does not start after 15seconds of cranking, wait about 15seconds, then press down theaccelerator pedal to 1/3 of its travel andtry cranking the engine again. Releasethe key and accelerator pedal when theengine starts.

If the engine still does not start, try

holding the accelerator pedal all the wayto the floor while cranking. This shouldclear the engine if it is flooded.

Once a week, or each time you fill your fueltank, perform the following under-bonnet

checks:

1) Engine oil level.2) Coolant level.

3) Brake fluid level.4) Windscreen washer fluid level.5) Battery solution level.6) Bonnet latch operation.

Pull the bonnet release handle inside thevehicle. Make sure that you can notopen the hood all the way withoutreleasing the secondary latch. Be sureto close the hood securely after checkingfor proper operation. See "All Latches,

Hinges & Locks" of "PERIODICMAINTENANCE SCHEDULE" in the"INSPECTION AND MAINTENANCE"

section for lubrication schedule.

Make sure the bonnet is fully closedand latched before driving. If it is not,it can fly up unexpectedly duringdriving, obstructing your view andresulting in an accident.

wwwww WARNING

CAUTION


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7-5


CATALYTIC CONVERTER

The purpose of the catalytic converterinstalled on your vehicle is to convertexhaust pollutants to harmless water vapour,

carbon dioxide, and nitrogen. Use of leadedfuel in vehicles equipped with catalyticconverters is prohibited, because leaddeactivates the pollutant-reducingcomponents of the catalyst system.

It is very important to keep the engineproperly tuned. Engine misfiring, which canresult from an improperly tuned engine, maycause overheating of the catalyst. This mayresult in permanent heat damage to thecatalyst and other vehicle components.

To minimize the possibility of catalystor other vehicle damage: Maintain the engine in the proper

operating condition. In the event of an engine

malfunction, particularly oneinvolving engine misfire or otherapparent loss of performance, havethe vehicle serviced promptly.

Do not turn off the engine orinterrupt the ignition when thetransmission is in gear and thevehicle is in motion.

Do not try to start the engine by

pushing or towing the vehicle, orcoasting down a hill.

Do not idle the engine with anyspark plug wires disconnected orremoved, such as during diagnostictesting.

Do not idle the vehicle forprolonged periods if idling seemsrough or there are othermalfunctions.

Do not allow the fuel tank to getnear the empty level.

CAUTION

Be careful where you park and drive;

the catalytic converter and otherexhaust components can get very hot.As with any vehicle, do not park oroperate this vehicle in areas wherecombustible materials such as drygrass or leaves can come in contactwith a hot exhaust system.

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844-74E DRIVING TIPS AND SAFE DRIVING

8

DRIVING TIPS AND SAFE DRIVING

High Speed Driving ...........................................................................................8-1

Driving on Hills ..................................................................................................8-1

Driving on Slippery Roads ..............................................................................8-1Driving on Wet Roads ...................................................................................... 8-2

Dos and Donts for Safe Driving ..................................................................8-3


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8-1


Wear Your Seat Belts at All Times.

The driver and passengers shouldbe properly restrained at all times,using the seatbelts provided. Referto the SEATBELTS section forinstructions on proper use of theseat belts.

Never drive while under theinfluence of alcohol or other drugs.Alcohol and drugs can seriouslyimpair your ability to drive safely,

greatly increasing the risk of injuryto yourself and others. You shouldalso avoid driving when you aretired, sick, irritated, or under stress.

HIGH-SPEED DRIVING

When driving at a high-speed, pay attentionto the following:

Stopping dis tance progressivelyincreases with vehicle speed. Apply thebrakes far enough ahead of the stopping

point to allow for the extra stoppingdistance.

On rainy days, Aquaplaning can occur.Aquaplaning is the loss of directcontact between the road surface andthe vehicles tyres due to a water filmforming between them. Steering orbraking the vehicle while Aquaplaningcan be very difficult, and loss of control

can occur. Keep speed down when the

road surface is wet.

At high speeds, the vehicle may beaffected by side winds. Therefore, reducespeed and be prepared for unexpectedbuffeting, which can occur at the exitsof tunnels, when passing by a cut of ahill, or when being overtaken by largevehicles, etc.

DRIVING ON HILLS When climbing steep hills, the car may

begin to slow down and show a lack ofpower. If this happens, you shouldchange to a lower gear so that the

engine will again be operating in its

normal power range. Change rapidly toprevent the car from losing momentum.

When driving down a hill, the engineshould be used for braking by shifting tonext lower gear.

Try not to hold the brake pedal downtoo long or too often while goingdown a steep or long hill. This couldcause the brakes to overheat,resulting in reduced braking efficiency.Failure to take this precaution couldresult in loss of vehicle control.

When descending a down hill, NEVERturn the ignition key to the OFFposition. Emission control systemdamage may result.

DRIVING ON SLIPPERY ROADSUnder wet road conditions you should driveat a lower speed than on dry roads due topossible slippage of tyres during braking.

When driving on icy, snowcovered, ormuddy roads, reduce your speed and avoidsudden acceleration, abrupt braking, orsharp steering movements.

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CAUTION

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Night time driving1. Drive more slowly at night than in the

daytime, for the visual range is restricted

at night.2. Dont overtake other vehicles at night.

Darkness bothers your sense of speedand hinders your judgement on thevehicle-to-vehicle distance.

3. Dont use the high headlight beamunless its use is inevitable. Its dazzlemay blitz the driver of the oncomingvehicle, thus causing an accident.

4. Always keep the window glasses clean.Dont operate the windshield wiper whenthe windshield glass is dry or the wiperblade and glass may get damaged.

MARGIN FOR SAFETY

It is important to allow yourself a margin forsafety during driving so that you can cope

with erroneous or unexpected driving ofother drivers. For that, observe the

following. Drive at a safe speed. Maintain a sufficient distance between

your vehicle and the vehicle ahead. Dont force yourself to overtake other

vehicles. Dont make quick start, hard steering or

sudden stops. Al low an ample t ime in the driv ing

schedule.

Observe traffic rules and regulations.

CONCLUSION

A perfect driver does not exist. Theendeavour of every motorist should be tostrive for perfection. Safety consciousnessnot only ensures your safety and the safety

of other road users, it also helps reduce thewear and tear on your vehicle, prolongs itslife, gives more mileage and ensures acomfortable driving experience.

Follow the dos and donts listed, anddriving will never be the same again.

844-08-007 844-08-008

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844-74E INSPECTION AND MAINTENANCE

9

INSPECTION AND MAINTENANCE

Periodic Maintenance Schedule ......................................................................... 9-1

Drive Belt ..............................................................................................................9-6

Engine Oil and Filter ............................................................................................9-6Gear Oil ................................................................................................................. 9-9

Engine Coolant ...................................................................................................9-11

Windscreen Washer Fluid .................................................................................9-12

Air Cleaner ..........................................................................................................9-12

Spark Plugs ........................................................................................................9-13

Brakes ................................................................................................................. 9-14

Steering ...............................................................................................................9-16

Clutch Pedal ....................................................................................................... 9-16

Tyres ................................................................................................................... 9-17

Battery ................................................................................................................. 9-20

Fuses ................................................................................................................... 9-20

Bulb Replacement ..............................................................................................9-22

Wiper Blades ...................................................................................................... 9-25


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You should take extreme care whenworking on your vehicle to preventaccidental injury. Here are a fewprecautions 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 otherobjects away from the fan and waterpump belt. Even though the fan maynot be moving, it can automaticallyturn on without warning.

When it is necessary to do servicework with the engine running, makesure that the parking brake isapplied fully and the transmission isin Neutral.

Do not touch ignition wires or otherignition system parts when startingthe engine or when the engine isrunning, or you could receive anelectric shock.

Be careful not to touch hot exhaustcomponents such as the manifold,

pipes, and mufflers.

Do not allow smoking, sparks, orflames around gasoline or thebattery. Flammable fumes arepresent.

Do not get under your vehicle if itis supported only with the portablejack provided in your vehicle.

Be careful not to cause accidentalshort circuits between the positiveand negative battery terminals.

Keep used oil, coolant, and otherfluids away from children and pets.Dispose of used fluids properly;never pour them on the ground, into

sewers, etc.


9-1

wwwwwWARNING wwwwwWARNING

V

V

PERIODIC MAINTENANCE SCHEDULE

The following table shows when regularmaintenance on your vehicle is required.

This table shows in kilometres and monthswhen inspections, adjustments, lubricationand other services should be performed.

Maruti Suzuki recommends thatmaintenance on your Maruti Suzukivehicle be performed by Maruti SuzukiAuthorised Dealer/Service Station.

Whenever it becomes necessary toreplace parts on your vehicle, it is

recommended that you use MARUTIGENUINE PARTS (MGP).

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CAUTION


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9-2

A....Adjust. I....Inspect and correct or replace if necessary.T....Tighten to specified torque. C....Clean.R....Replace or change. O....RotateL....Lubricate.

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 FREE INSPECTIONS PERIODIC MAINTENANCE SERVICE AT COST

by odometer reading or months, km (x 1,000) 1 5 10 20 30 40 50 60 70 80

whichever comes first. months 1 6 12 24 36 48 60 72 84 96

ENGINE

1. Water pump drive belt (tension, wear) A I I I I I I R A I

*1-1Water pump drive belt (tension, wear) A I I I I R A I I R

2. Engine coolant (level, leakage) I I I R I R I R I R

3. Engine oil (API GRADE SF, SG, SH) & Oil filter R I R R R R R R R R

4. Cooling system hoses and connections (leakage, damage) I I I I I I I I I I

5. Engine bolts (All cylinder head and manifold fixings) T T T T

6. Engine mounting (loose, damage) T T T T

7. Valve clearance A A A A A

8. Camshaft timing belt (damage, wear) I I I IReplace every 1,00,000 km

9. Exhaust system (noise, leakage or otherwise defective) I I I I I

10. Positive crankcase ventilation System (Hoses, connections and valve) I I I I I

IGNITION

1. Ignition wiring, (damage, deterioration) I I I I2. Distributor cap and rotor (wear, deterioration)* I I I I

3. Spark plugs (clean and adjust the gap) I R I R I R I R

*Item 1-1 is applicable for vehicle equipped with F8B engine only.


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Interval: This interval should be judged FREE INSPECTIONS PERIODIC MAINTENANCE SERVICE AT COST

by odometer reading or months, km (x 1,000) 1 5 10 20 30 40 50 60 70 80

whichever comes first. months 1 6 12 24 36 48 60 72 84 96

WHEEL1. Tyres (air pressure, abnormal wear, crack, ROTATION) I I&O I&O I&O I&O I&O I&O I&O I&O I&O

2. Wheels (damage) I I I I I I I I I I

3. Front wheel bearings (loose, damage) I I I I I I I I I

4. Rear wheel bearings (loose, damage) I I I I I I I I I

FRONT AND REAR SUSPENSION1. Suspension strut (oil leakage, damage) I I I I I I I I I I

2. Suspension arms and knuckle supports (loose,damage) I I I I I I I I I

3. Rear spring (damage) I I I I I I I I I

4. Shock absorbers (oil leakage, damage) I I I I I I I I I I

5. All bolts and nuts (loose) T T T T T T T T T

6. Suspension arms and Tension rods I I I I I I I I I

STEERING

1. Steering wheel (play, loose) I I I I I I I I I I2. All rods and arms (loose, damage, wear) I I I I I I I I I I

ELECTRICAL1. Battery electrolyte (level, leakage) I I I I I I I I I I

2. Wiring harness connection (looseness, damage) I I I I I I I I I

3. Lighting system (operation, stains, damage) I I I I I I I I I I

4. Horn (operation) I I I I I I I I I I

5. System voltage I I I I I I I I I

BODY

1. All chassis bolts and nuts (tighten) I T T T T T T T T

2. All Latches, Hinges & Locks (function) I I&L I&L I&L I&L I&L I&L I&L I&L I&L


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9-7

Oil Level Check

It is important to keep the engine oil at thecorrect level for proper lubrication of your

vehicles engine. Check the oil level with thevehicle on a level surface. The oil levelindication may be inaccurate if the vehicleis on a slope. The oil level should bechecked either before starting the engine orat least five minutes after stopping theengine.

Pull out the oil dipstick, wipe oil off with aclean cloth, insert the dipstick all the wayinto the engine, then remove it again. Theoil on the stick should be between the

upper and lower limits shown on the stick.If the oil level indication is near the lowerlimit, add enough oil to raise the level tothe upper limit.

RefillingRemove the oil filler cap and pour oil slowlythrough the filler hole to bring the oil level

to the upper limit on the dipstick. Be carefulnot to overfill. Too much oil is almost asbad as too little oil. After refilling, start theengine and allow it to idle for about aminute. Stop the engine, wait for five

minutes and check the oil level again.Changing Engine Oil and FilterDrain the engine oil while the engine is stillwarm.

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.

Tightening torque:5.0 kg-m (36.5 lb-ft)

The engine oil temperature may behigh enough to burn your fingerswhen the drain plug is loosened. Waituntil the drain plug is cool enough totouch with your bare hands.

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WARNING

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9-8

New and used oil can be hazardous.Children and pets may be harmed byswallowing new or used oil. Keep newand used oil and used oil filters away

from children and pets.Continuous contact with used engineoil has been found to cause (skin)cancer in laboratory animals.Brief contact with used oil may irritateskin.To minimize your exposure to usedoil, wear a long-sleeve shirt andmoistureproof gloves (such asdishwashing gloves) when changingoil. If oil contacts your skin, washthoroughly with soap and water.Launder any clothing or rags if wetwith oil.Recycle or properly dispose of usedoil and filters.

4) Reinstall the drain plug and gasket.

Tighten the plug to a torque of5.0 kg-m (36.5 lb-ft).

Replace the oil filter1) Using an oil filter wrench, turn the oil

filter counterclockwise and remove it.

2) Using a clean rag, wipe off the mountingsurface 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 thefilter gasket contacts the mountingsurface.

wwwww WARNING

Tightening torque: 1.4 kg-m (10.5 lb-ft)

To tighten the oil filter properly, it isimportant to accurately identify theposition at which the filter gasketfirst contacts the mounting surface.

5) Tighten the filter 3/4 turn from the point

of contact with the mounting surface. [orto 1.4 kg-m (10.5 lb-ft)] using an oil filterwrench.

To prevent oil leakage, make sure thatthe oil filter is tight, but do notovertighten it.

CAUTION

CAUTION

844-09-007 844-09-008


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9-14

Note :If you experience some firing problem ofspark plugs, such as, hard engine-starting.

Misfire etc., the cause may be located notonly on spark plugs but also on deterioratedignition wiring (generally, used for more than80,000 km or five years). If spark plugreplacement does not solve the problem

have the ignition wiring and other ignitionsystem inspected by your MARUTI SUZUKIdealer.

BRAKES

wwwwwWARNING

Brake FluidCheck the brake fluid level by looking at thereservoir in the engine compartment. Check

that the fluid level is between the MAXand MIN lines. If the brake fluid level isnear the MIN line, fill it up to the MAXline with MARUTI GENUINE brake fluid.

Failure to follow the guidelines belowcan result in personal injury orserious damage to the brake system. If the brake fluid in the reservoir

drops below a certain level, thebrake warning light on theinstrument panel will come on (theV

0.8 - 0.9 mm

844-09-020 844-09-022 844-09-023

844-09-021


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9-18

Replacing the wheels and tyresequipped on your vehicle with certaincombinations of aftermarket wheelsand tyres can significantly change thesteering and handling characteristicsof your vehicle. Therefore, use onlythose wheel and tyre combinationsapproved by MARUTI SUZUKI asstandard or optional equipment foryour vehicle.

Replacing the original tyres with tyresof a different size may result in false

speedometer or odometer readings.

Tyre RotationTo avoid uneven wear of your tyres and to

prolong their life, rotate the tyres as

illustrated. Tyres should be rotated asrecommended in the periodic maintenanceschedule. After rotation, adjust front and reartyre pressures to the specification listed onyour vehicles Tyre Inflation Pressure Label.

Hitting curbs and running over rockscan damage tyres and affect wheelalignment. Be sure to have tyres andwheel alignment checked periodicallyby your MARUTI SUZUKI dealer.

4) Check for loose wheel nuts.5) Check that there are no nails, stones,

or other objects sticking into the tyres.

Your MARUTI SUZUKI is equippedwith tyres which are all the same typeand size. This is important to ensureproper steering and handling of thevehicle. Never mix tyres of differentsize or type on the four wheels ofyour vehicle. The size and type oftyres used should be only thoseapproved by MARUTI SUZUKI asstandard or optional equipment foryour vehicle.

wwwwwWARNING

wwwwwWARNING

wwwwwWARNING

CAUTION

Wheel BalancingIf the vehicle vibrates abnormally on smoothroad, have the wheels balanced at MarutiSuzuki authorized workshop.

Wheel Alignment

In case of abnormal tyre wear or pullingtowards one side, have the wheel alignedat Maruti Suzuki authorized workshop.

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9-22

BULB REPLACEMENT

Interior LightPull down on the rear part of lens toremove. To install it, hook its front end inand push it up.

The bulb can be removed by simply pullingit out. When replacing the bulb, make surethat the contact springs are holding the bulbsecurely.

wwwwwWARNING

Light bulbs can be hot enough toburn your finger right after beingturned off. This is true especially forhalogen headlight bulbs. Replace thebulbs after they become coolenough.

The headlight bulbs are filled withpressurized halogen gas. They canburst and injure you if they are hitor dropped. Handle them carefully.

The oils from your skin may cause ahalogen bulb to overheat and burst

when the lights are on. Grasp a newbulb with a clean cloth.

Frequent replacement of a bulbindicates the need for an inspection ofthe electrical system. This should becarried out by your MARUTI SUZUKIdealer.

CAUTION

CAUTION

844-09-039 844-09-041

844-09-040


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9-24

Front clearance lightOpen the bonnet and support it with theprop rod.

Front turn signal lightUndo the two screws and remove the lens.Side turn signal lightRemove the lens by using a plain screw

driver covered with a soft cloth.

Rear combination light (tail, stop, turnsignal, etc.)Undo the screws that secure the housing

and remove the housing.

844-09-045 844-09-046 844-09-048

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10

EMERGENCY SERVICE

Jacking Instructions ........................................................................................10-1

Jump Starting Instructions ............................................................................10-2

Towing ................................................................................................................10-4

Emergency Remedies ......................................................................................10-4

Warning triangle ...............................................................................................10-5

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10-1

JACKING INSTRUCTIONS

Do not put the jack head on to thelateral rod (if equipped), or the lateralrod will be damaged.

6) Continue to raise the jack slowly and

smoothly until the tyre clears the ground.Do not raise the vehicle more thannecessary.

Use the jack only to change wheels. Never jack up the vehicle on an

inclined surface. Never raise the vehicle with the jack

in a location other than the placespecified in the illustration near thewheel to be changed.

Make sure that the jack is raised atleast 2 inches (51 mm) before itcontacts the vehicle. Use of the jackwhen it is within 2 inches of beingfully collapsed may result in failure

of the jack.

1) Park the vehicle securely on hard levelground.

2) Choke the front and rear wheeldiagonally opposite the wheel to bechanged.

3) Switch on the hazard warning flasher ifyour vehicle is in or near traffic.

4) Slacken but do not remove wheel nuts

on the wheel to be changed.5) Position the jack vertically and raise the

jack by turning the jack handle clockwiseuntil the jack head fits the front

suspension arm or the rear axle asshown overleaf.

CAUTION wwwwwWARNING

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10-3

To avoid harm to yourself ordamage to your vehicle or battery,follow the jump starting instructionsbelow precisely and in order. If you

are in doubt, call for qualified roadservice.

Vehicle equipped with electronic fuelinjection system will not start bypushing or towing as the fuel pumpwill not work in this condition. Thisstarting method could also result inpermanent damage to the catalytic

converter. Use jump leads to starta vehicle with a weak or flat battery.

When jump starting your vehicle, use thefollowing procedure:1) Use only a 12 volt battery to jump start

your vehicle. Position the good 12V

battery close to your vehicle so that thejump leads wil l reach both batteries.When using a battery installed onanother vehicle, DO NOT LET THE

VEHICLES TOUCH. Apply the parkingbrakes fully on both vehicles.

2) Turn off all vehicle accessories, exceptthose necessary for safety reasons (for

example, headlights or hazard lights).

3) Make jump lead connections as follows:

a) Connect one end of the first jumplead to the positive (+) terminal of theflat battery.

b) Connect the other end to the positive

(+) terminal of the booster battery.

c) Connect one end of the second jumplead to the negative (-) terminal ofthe booster battery.

d) Make the final connection to anunpainted, heavy metal part of theengine of the vehicle with the flatbattery.

Never connect the jump lead directly

to the negative (-) terminal of thedischarged battery, or an explosionmay occur.

4) If the booster battery you are using is

fitted to another vehicle, start the engineof the vehicle with the booster battery.Run the engine at moderate speed.

5) Start the engine of the vehicle with theflat battery.

6) Remove the jump leads in the exactreverse order in which you connectedthem.

wwwwwWARNING

wwwwwWARNING

V

CAUTION

844-10-005


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Remove the warning triangle carefullyfrom the box as shown by arrow 1.

Open both the reflector arms as shown

by arrow and lock the arms with eachother with the clip provided in the rightarm. Open the botton stand in counterclock-wise direction as shown by arrow

3. Position the warning triangle behind thevehicle on a plain surface.

Reverse the removal procedure forkeeping inside the box.

10-6

844-10-008 844-10-009

844-74E


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844-74E BODY WORK CARE


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BODY WORK CARE

Corrosion Prevention .......................................................................................11-1

Vehicle Cleaning ...............................................................................................11-2


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11-3

Cleaning the Exterior

It is important that your vehicle bekept clean and free from dirt. Failureto keep your vehicle clean may resultin fading of the paint or corrosion tovarious parts of the vehicle body.

Washing

Never attempt to wash and wax yourvehicle with the engine running.

When cleaning the underside of thebody and fender, where there maybe sharp-edged parts, you should

wear gloves and a longsleeved shirtto protect your hands and armsfrom being cut.

After washing your vehicle, carefullytest the brakes before driving tomake sure they have maintainedtheir normal effectiveness.

When washing the vehicle, follow theinstructions below:

1) Flush the underside of body and wheelhousings with pressurized water toremove mud and debris. Use plenty ofwater.

When washing the vehicle, avoiddirecting steam or hot water of morethan 800C (1760F) on plastic parts.

2) Remove dirt and mud from the bodyexterior with running water. You may use

a soft sponge or brush. Do not use hardmaterials which can scratch the paint.

3) Wash the entire exterior with a mild

detergent or car wash soap using asponge or soft cloth. The sponge orcloth should be frequently soaked in thesoap solution.

When using a commercial car washproduct, observe the cautionsspecified by the manufacturer. Neveruse strong household detergents or

soaps.

wwwwwWARNING

CAUTION

4) Once the dirt has been completelyremoved, rinse off the detergent with

running water.5) After rinsing, wipe off the vehicle body

with a wet chamois or cloth and allowit to dry in the shade.

6) Check carefully for damage to painted

surfaces. If there is any damage,Touchup the damage following the

procedure below:

a) Clean all damaged spots and allow

them to dry.b) Stir the paint and touchup the

damaged spots lightly using a smallbrush.

c) Allow the paint to dry completely.

WaxingAfter washing the vehicle, waxing andpolishing are recommended to furtherprotect and beautify the paint. Only use waxes and polishes of good

quality. When using waxes and polishes,

observe the precautions specified by the

manufacturers.

CAUTION

CAUTION

844-74E GENERAL INFORMATION


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GENERAL INFORMATION

Vehicle Identification .......................................................................................12-1


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844-74E

FOR LPG KIT FITTED VEHICLE


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13

(LIQUID PETROLEUM GAS)

Location of LPG system and Major components .............................................. 13-1

Introduction to LPG ................................................................................................. 13-2

Safety Precautions (Do's and Dont's) .................................................................. 13-2

Vehicle Starting Modes ........................................................................................... 13-4

Manual shut off valve.............................................................................................. 13-4

LPG Level indicator ................................................................................................. 13-4

Auto Mode ................................................................................................................. 13-5

Petrol Mode ............................................................................................................... 13-5

Forced LPG Mode .................................................................................................... 13-6

Spare Wheel Location ............................................................................................. 13-6

Spare Wheel Removal Procedure .......................................................................... 13-6

LPG Filling ................................................................................................................. 13-7Petrol tank capacity ............................................................................................... 13-7

Periodic maintenance schedule ............................................................................. 13-7

Maintenance (Fuse) .................................................................................................. 13-9

Kit Identification........................................................................................................ 13-9

Scrapping of LPG Tanks After Expiry Date ..................................................... 13-10

844-74ELIQUID PETROLEUM GAS (LPG)

LOCATION OF LPG SYSTEM AND MAJOR COMPONENTS


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1. LPG Switch 7. Pressure Regulator 13 LPG Ventilation Hose2. LPG Controller 8. High Pressure pipe joint 14. LPG Ventilation Duct

3. LPG Filter cum Solenoid Valve 9. Filler Valve 15. High Pressure Pipe4. Stepper Motor 10. Multivalve 16. Wiring Harness

5. Low Pressure Hose 11. Gas Tight Housing 17. LPG Filling Pipe6. Coolant Hose 12. LPG Tank

13-1

SIDE VIEW


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SAFETY PRECAUTIONS (Dont's)

LIQUID PETROLEUM GAS (LPG)


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It is recommended to run the vehicle onPetrol for 5-10 Kilometers after every

300-500 Kilometers run in LPG mode tokeep the fuel system in good condition.

In case of any symptom of LPG leakage:1. Stop the vehicle and switch off the

Engine.

2. Ensure to close Manual Shut-Offvalve which is located on the

multivalve assembly on the LPGcylinder.

3. Do not run the vehicle in LPGmode.

4. Cal l the nearest Marut i Suzukiauthorized workshop for assistance.

Note: It is recommended to carry twonumbers of government certified dry powder

fire extinguisher (1 Kg. each) in yourvehicle.

Do not use Domestic LPG in yourvehicle.

Never install any other gas cylinder inplace of LPG.

Never install CNG or any other gascylinder in place of LPG.

Never adjust setting of the LPG System.

The Auto LPG cylinder should never berepaired under any circumstances,incase of any problem, consult withMaruti Suzuki authorized workshop.

Never carry inflammable material near

Auto LPG cylinder. Never handle LPG system components.

In case of replacement of anycomponent, always contact Maruti Suzuki

authorized workshop.

Avoid frequent change over from LPGmode to petrol mode and petrol modeto LPG mode to avoid engine missingand back fire.

Do not try to fill more then 19 Ltrs ofLPG.

Note : Always maintain some amount ofpetrol in petrol tank

13-3

844-74E

VEHICLE STARTING MODES

LIQUID PETROLEUM GAS (LPG)

MANUAL SHUT OFF VALVE LPG LEVEL INDICATOR


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Selector switch is installed on thedashboard, on the right hand side of thesteering wheel. One can choose the typeof mode by gentle push on the switch (2).

This switch has three modes i.e. Auto,Petrol and Forced LPG. Each mode isindicated by LED (light) on the switch.

In Ignition switch ON condition, beforecranking the engine, if :

GREEN light (3) blinking & ORANGElight (1) glowing - indicates Auto mode

ORANGE light (1) glowing - indicatesPETROL mode

GREEN light (3) Glowing - indicatesForced LPG mode

13-4

Manual shut off valve (A) is located onMultivalve, mounted on the Auto LPGcylinder. The valve should always be inopen position to allow the flow of LPG to

engine. In the close position, LPG supplyto the engine is stopped. The shut off valvemust be closed in case of any repair in thecylinder or any symptoms of LPG leakage.

TURN CLOCKWISE - CLOSE

TURN ANTICLOCKWISE - OPEN

1 Orange LED - Petrol

2 LPG Changeover switch

3 Green LED - LPG

4 Level Indicators

LED for indicating LPG quantity in thecylinder is installed on the dashboard, onthe right-hand side of steering wheel. AutoLPG cylinder also houses a level indicator

on the Multivalve. All four green LED (4) willglow when the tank is filled to 80% of themaximum capacity. With reducing level ofLPG in the tank, number of LED (lights)

glowing will reduce.

RED LED (5) glows, when LPG in the tankis in reserve condition. LPG refilling shouldbe done in this condition, immediatly. Do notrun the vehicle till the fuel tank is completlyempty.

Note : Numbers of LEDs (Green) glowingis only indicative display of residual LPG.


STARTING MODES OF THE VEHICLE


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Auto Mode : Vehicle when started in automode will get started in Petrol with GREENlight (3) blinking & ORANGE light (1) glowsuntil coolant temperature and engine RPM

reaches certain predefined value and thenthe system will automatically shift to LPGmode (during deceleration). At this stage theGREEN LED (3) will start glowing

continuously, which indicate that the vehicleis running in LPG.

13-5

Note : It is recommended to start thevehicle in Auto mode/Petrol mode.

Note: In auto mode engine will start withpetrol. Engine will switch to LPG

automatically when coolant temperaturereaches around 40oC.

In warmed up condition, changeover frompetrol to LPG will happen after around 5seconds of starting the engine.

Petrol Mode : Vehicle can be started inPetrol mode with ignition switch ON and

selecting Petrol Mode by gently pressing themode selector switch (2) till ORANGE LED

(1) glows. At this stage vehicle will start andrun on petrol only.

When the vehicle is running in LPG mode,

it can be shifted to petrol mode by pressingthe mode switch (2). At this stage ORANGELED (1) will start glowing and the vehiclewill start running in petrol mode. At thisstage no green LED will glow.

Note : If the vehicle is switched OFF inPetrol mode, then next time it will start in

Petrol mode only.

Auto Mode Petrol Mode

844-74E LIQUID PETROLEUM GAS (LPG)

SPARE WHEEL LOCATION SPARE WHEEL REMOVALPROCEDURE


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Forced LPG Mode : In case of emergency,vehicle can be started in Forced LPG modewith ignition switch ON and pressing themode selector switch (2) for more then 8

seconds till the GREEN LED (3) & (4) glowscontinuously. At this stage the LED's (4) willcontinuously glow, indicating the quantity ofLPG in the cylinder.

13-6

Spare wheel is mounted on the LPG tankand secured tightly with the help of sparewheel screw.

To remove the spare wheel, unscrew sparewheel screw in anti-clockwise direction usingwheel wrench as show in the figure.

Reverse the above procedure for fitting the

spare wheel.

Note : During fitment of spare wheel,

position of the air filler nozzle should befacing upward and towards rear seat.

Forced LPG Mode

CAUTIONIt is not recommended to start thevehicle in Forced LPG mode unlessthere is no petrol in the vehicle

Note: In forced LPG mode, vehicle will not

switch to Auto/Petrol mode. In case youwant to changeover, switch OFF and startvehicle in required mode.


LPG FILLING PETROL TANK CAPACITY

Note : The interval should be judged by

PERIODIC MAINTENANCE SCHEDULE


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LPG filler Valve (1) is installed on left handside of your vehicle. LPG Filling will stopautomatically once cylinder is filled upto80% of the capacity. The cylinder fitted in

your vehicle is of 24 liters water capacity.When filling an empty cylinder, it is advisedto fill maximum 19 liters of LPG in the tankof your vehicle. Incase, filling is being done

after removal and/or fitment of Auto LPGcylinder, have the joints checked for LPGleakage by applying soap solution on all the

joints.

Do not fill more than 19 liters of LPGin tank.

CAUTION

Your vehicle is fitted with petrol tank of 28litres capacity.

Note : The tank should always havesufficient quantity of petrol.

Note : The interval should be judged byodometer reading. Over and above the

regular maintenance schedule described inthe main owner's manual (supplied with thevehicle) following has to be checked onlyby Maruti Suzuki authorized workshop.Check Auto LPG cylinder every five years

at Maruti Suzuki authorized workshop. Forperiodic maintenance refer next page.

PETROL

TANK

LI D

844-74E LIQUID PETROLEUM GAS (LPG)

PERIODIC MAINTENANCE SCHEDULE FOR LPG KIT PARTS


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Kms (1 X 1000) 1 5 10 20 30 40 50 60 70 80 90 100

Month 1 6 12 24 36 48 60 72 84 96 108 120

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

LPG Filter with O rings C C R R R R R R R R R R

Gas Solenoid Valve Plunger - - C C C C I C C C C C

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

Drain Oil from Regulator - - - C - C - C - C - C

Low Pressurre Regulator Overhauling & - - - - - R - - - R - -Diaphragm Replacement

All Bolts and Nuts of LPR, LPG Tank,Solenoid Valve.

T T T T T T T T T T T T

Idle RPM, Idle CO/HC, Idle screw settingin Gas mode

I I I I I I I I I I I I

Ignition Wiring (Damage, Deterioration) I - I I I I I I I I I ISpark plugs (Clean & Adjust the Gap) I - I R I R I R I R I R

Tappet Clearance - I I I I I I I I I I I

T.......Tighten to specified torque.

I.......Inspect and correct or replace if necessary.

C......Clean

R......Replace


LPG KIT IDENTIFICATIONMAINTENANCE (FUSE)


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LPG kit Identification plate (1) is locatedabove t

Documents

Maruti 800 LPG - Manual