59K,76G,844-74E
MAINTENANCE SERVICE RECORD TABLE OF CONTENTS 1 WARRANTY POLICY 2 BEFORE DRIVING 3 STEERING COLUME CONTROLS 4 INSTRUMENT PANEL 5 OTHER CONTROLS AND EQUIPMENT 6 OPERATING YOUR VEHICLE 7 DRIVING TIPS AND SAFE DRIVING 8 INSPECTION AND MAINTENANCE 9 EMERGENCY SERVICE 10 BODY WORK CARE 11 GENERAL INFORMATION 12 FOR LPG KIT FITTED VEHICLE 13 SPECIFICATION 14
1 59K,76G,844-74E
2 59K,76G,844-74E
FOREWORD IMPORTANT This manual is an essential part of your MARUTI SUZUKI INDIA LIMITED believes WARNING/CAUTION/NOTE vehicle and should be kept with the vehicle in conservation and protection of Earth's Please read this manual and follow its at all times. Please read this manual natural resources. instructions carefully. To emphasise special carefully and review it from time to time. It To that end, we encourage every vehicle information, the words WARNING, contains important information on owner to recycle, trade in, or properly CAUTION, and NOTE have special maintenance. It is especially important that dispose of, as appropriate, used motor oil, meanings. Information following these signal this manual remain with the vehicle at the coolant, and other fluids; batteries; and words should be carefully reviewed. time of resale. The next owner will need this tyres. information also. w WARNING You are invited to avail the three free MARUTI SUZUKI INDIA The personal safety of the driver, inspection services as described in this LIMITED passengers, or bystanders may be manual. Three free inspection coupons are involved. Disregarding this information attached to this manual. Please show thisAll information in this manual is could result in their injury or death. manual to your dealer when you take yourbased on the latest product vehicle for any Service. information available at the time of CAUTION To prolong the life of your vehicle andpublication. Due to improvements or other changes, there may be reduce mainte These instructions point out special discrepancies between information maintenance must be carried out according service procedures or precautions nance costs, the periodicin this manual and your vehicle. to the "PERIODIC MAINTENANCE that must be followed to avoid MARUTI SUZUKI reserves the right damaging the vehicle. SCHEDULE" described in "INSPECTIONto make changes at any time AND MAINTENANCE" section of withoutthis notice. NOTE : manual. Periodic maintenance is essentialThis vehicle may not comply with This provides special information to make for preventing trouble and accidentsstandards to or regulations of other maintenance easier or important instructions ensure your satisfaction and safety.countries. Before attempting to clearer. Daily Inspection and Care as per register"DAILY this vehicle in any other INSPECTION CHECKLIST" describedcountry, in the check all applicable "INSPECTION AND MAINTENANCE"regulations and make any section of this Manual is essentialnecessary for modifications. prolonging the operating life of the vehicle 3 0-1 and for safe driving. 59K,76G,844-74E
MODIFICATION WARNING w WARNING CAUTION Do not modify this vehicle. Modifica- Improper instllation of moble tion could adversely affect safety, communication euipment such as handling, performance, or durability cellular talephones or CB (Citizen's and may contravene regulations. In Band) radios may cause electronic addition, damage or performance interference with your vehicle's problems resulting from modification ignition system, resulting in vehicle may not be covered under warranty. performance problems. Consult your MARUTI SUZUKI dealer or qualified service technician for advice on w WARNING installing such mobile communication equipment. 844-00-001 Your vehicle has monocoque body The circle with a slash in this manual construction which provides for means “Don’t do this” or Don’t let this certain crumple zones in the body happen”. which absorbs larger part of impact energy in the event of a front collision and protects the occupants from impact. Do not use any fitments such as crash guards. These fitments will increase the risk to the occupants because of the shock directly getting transmitted to the occupants.
Copying, quoting or reproduction of any part of this manual is not permitted without explicit approval by MARUTI SUZUKI INDIA LIMITED. 0-2 4 59K,76G,844-74E MAINTENANCE SERVICE RECORD
MAINTENANCE SERVICE RECORD 1 MODEL CHASSIS NO. ENGINE NO. DATE OF MILEAGE BATTERY DELIVERY MAKE SR. NO/BATCH CODE
km.
OWNER’S NAME & ADDRESS ______
______TEL. NO. ______
ADDRESS/STAMP OF SELLING DEALER SELLING DEALER CODE
SHOWROOM
IMPORTANT INFORMATION TO CUSTOMER
Dear Customer WORKSHOP For any assistance with regard to our product, please contact General Manager/Works Manager at any of our Dealer or Authorised Service Station. For additional enquiry you may contact our Regional office or Service Department. The Addresses and Phone nos. are given in Service Network booklet provided along with vehicle.
5 1-1 MAINTENANCE SERVICE RECORD 59K,76G,844-74E
DATE OF KIND OF MILEAGE DESCRIPTION OF JOB NAME OF SERVICING JOB CARD MECHANIC’S SERVICE SERVICE km DEALER/MASS NO. SIGNATURE
F....free Service P....Paid Service W....Warranty. A....Accident
1-2 6 59K,76G,844-74E WARRANTY POLICY
WARRANTY POLICY Maruti Suzuki India Limited (hereinafter called “Maruti Suzuki”), (4) Limitation: warrants that each new Maruti Suzuki vehicle distributed in India This warranty shall not apply to: 2 by Maruti Suzuki and sold by an authorised Maruti Suzuki dealer (a) normal maintenance service required other than the three will be free, under normal use and service, from any defects in free services, including without limitation, oil and fluid material and workmanship at the time of manufacture SUBJECT changes, headlight aiming, fastener retightening, wheel TO THE FOLLOWING TERMS AND CONDITIONS: balancing, wheel alignment and tyre rotation, cleaning of injectors, adjustments of carburettor, ignition timing, clutch (1) Qualification: and valve clearance. To qualify for this warranty: (b) the replacement of normal wear parts including without (a) The Maruti Suzuki vehicle must be delivered by Maruti limitation, bulbs, battery, tyres and tubes, spark plugs, belts, Suzuki authorised dealer and set-up, serviced by Maruti hoses, filters, wiper blades, brushes, contact points, fuses, Suzuki authorised dealer/service station. clutch disc, brake shoes, brake pads, cable and all rubber parts (except oil seal and glass run). (b) The warranty registration card in respect of each vehicle (c) any vehicle which has been used for competition or racing. must be completed by the dealer at the time of delivery (d) any repairs or replacement required as a result of accidents of the vehicle and dealer should retain the same. or collision. (e) any defects caused by misuse, negligence, abnormal use (2) Term: or insufficient care. The term of the warranty shall be twenty four (24) months (f) any vehicle which has been modified or altered, including or 40,000 kilometers (whichever occurs first) from the date without limitation, the installation of performance of delivery to the first owner. accessories. (g) any vehicle on which parts or accessories not approved (3) Maruti Suzuki Warranty Obligation: by Maruti Suzuki have been used. If any defect(s) should be found in a Maruti Suzuki vehicle within (h) any vehicle which has not been operated in accordance the term stipulated above, Maruti Suzuki only obligation is to repair with the operating instructions in the Maruti Suzuki Owner’s or replace at its sole discretion any part shown to be defective, Manual. with a new part or the equivalent at no cost to the owner for (i) any vehicle which has not received, during the warranty parts or labour, when Maruti Suzuki acknowledges that such a term, the service inspections prescribed in the Maruti defect is attributable to faulty material or workmanship at the time Suzuki Owner’s Manual. of manufacture. The owner is responsible for any repair or (j) any vehicle which has been assembled, disassembled, replacements which are not covered by this warranty. adjusted or repaired by other than an Maruti Suzuki 7 2-1 WARRANTY POLICY 59K,76G,844-74E
authorised dealer/service station. (a) make certain that the warranty registration/PDI card was (k) any vehicle which has been used for purposes other than completed at the time of delivery of the vehicle; what it was designed for. (b) have performed, at his own expenses, by an Maruti Suzuki (l) any damage or deterioration caused by industrial pollution authorised dealer/service station all the service inspections and bird droppings. specified in the Maruti Suzuki “Owner’s Manual and Service (m) insignificant defects which do not affect the function of the Booklet” and maintain adequate proof that such service vehicle including without limitation, sound, vibration and fluid inspections have been performed. seep. (c) make certain that the Maruti Suzuki authorised dealer/ (n) any natural wear and tear including without limitation, aging servise station performing the service inspection has etc. certified the work on the “Maintenance Service Record” page in the “Owner’s Manual and Service Booklet” and For Maruti Suzuki Air-Conditioned Vehicles (d) present the Maruti Suzuki “Owner’s Manual and Service (o) V-belts, hoses and gas leaks. Booklet” to the authorised Maruti Suzuki dealer whenever requesting service inspections or warranty service. (5) Extent of Warranty: If the “Owner’s Manual and Service Booklet” should be lost or This warranty is the entire written warranty given by Maruti for destroyed the owner should consult the authorised Maruti Suzuki Maruti Suzuki vehicles and no dealer or its or his agent or dealer from whom the vehicle was purchased for instructions employee is authorised to extend or enlarge this warranty and concerning replacement of the “Owner’s Manual and Service no dealer or its or his agent or employee is authorised to make Booklet”. any oral warranty on Maruti Suzuki behalf. Maruti Suzuki reserves the right to add any improvements or (8) Disclaimer of Consequential Damage: change the design of any model at any time with no obligation Maruti Suzuki assumes no responsibility for loss of vehicle, loss to make the same changes on units previously sold. of time, inconvenience or any other indirect incidental or consequential damage resulting from the vehicle not being (6) Warranty Service: available to the owner because of any defect covered by this To obtain warranty service, the complete vehicle must be warranty. presented at the owner’s expenses to any authorised Maruti Suzuki dealer. (9) Change of Owner Even if ownership of the vehicle changes, the remaining (7) Owner’s Warranty Responsibilities: warranty period is effective for the new owner. It is responsibility of each owner to:
2-2 8 59K,76G,844-74E EMISSION WARRANTY
Maruti Suzuki offers the Emission Warranty on all Maruti Suzuki vehicles (apart from the Regular warranty and will run parallel to the regular product warranty) only in four metropolitan cities (New Delhi, Kolkata, Mumbai and Chennai) with effect from July 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 all valid document. Conditions: 1. Under Emission Warranty, Warranty claims will be admitted for a prima facie examination, in case vehicle fails to meet to the Emission 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 conclusions that 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 used in 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, Maruti Suzuki 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 being integral parts a complete assembly, Maruti Suzuki and it's dealer will have the sole discretion to replace entire assembly or by using some of the parts of the system through suitable repair or modifications.
9 2-3 EMISSION WARRANTY 59K,76G,844-74E
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 actual under 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 workshop or any loss due to non-availability of the vehicle during the period of lodging of a warranty claim and examination and/or repair by 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 comply with 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 manual for 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 Service Booklet 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.)
2-4 10 59K,76G,844-74E EMISSION WARRANTY
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
11 2-5 EMISSION WARRANTY 59K,76G,844-74E
12 844-74E BEFORE DRIVING
BEFORE DRIVING
Fuel Recommendation ...... 3-1 3 Keys ...... 3-2 Immobilizer 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
MARUTI 800 DOMESTIC 13 BEFORE DRIVING 844-74E
FUEL RECOMMENDATION
CAUTION Petrol/Ethanol Blends CAUTION Blends of unleaded petrol and ethanol (grain Use of leaded fuel in vehicle equipped alcohol), also known as gasohol, are Be careful not to spill fuel containing with catalytic converter is prohibited, commercially available in some areas. alcohol while refuelling. Fuels because lead deactivates the pollutant Blends of this type may be used in your containing alcohol can cause paint reducing components of catalytic vehicle if they are no more than 5% damage, which is not covered under converter and may result in permanent ethanol. Make sure this petrol-ethanol blend Warranty. damage to catalytic converter. has octane ratings no lower than those recommended for petrol. Petrol/Methanol Blends CAUTION Blends of unleaded petrol and methanol The fuel tank has an air space to (wood alcohol) are also commercially allow for fuel expansion in hot available in some areas. DO NOT USE weather. If you continue to add fuel fuels containing more than 5% methanol after the filler nozzle has automatically under any circumstances. Fuel system shut off or an initial blowback occurs, damage or vehicle performance problems the air chamber will become full. resulting from the use of such fuels are not Exposure to heat when fully fuelled in the responsibility of MARUTI SUZUKI and this manner will result in leakage due may not be covered under Warranty. to fuel expansion. To prevent such Fuels containing 5% or less methanol may fuel leakage, stop filling after the filler be suitable for use in your vehicle if they nozzle has automatically shut off, or contain cosolvents and corrosion inhibitors. when using an alternative non
automatic system, initial vent MARUTI 800DOMESTIC NOTE: blowback occurs. If you are not satisfied with the driveability or fuel economy of your vehicle when you are using a petrol/alcohol blend, you should switch back to unleaded petrol containing no alcohol.
3-1 14 844-74E BEFORE DRIVING
KEYS IMMOBILIZER KEYS (if equipped)
844-03-001 844-03-002 Your vehicle comes with a pair of identical w WARNING keys. Keep the spare key in a safe place. One key can open all of the locks on the • Do not use locally made key. vehicle. • Should you require a duplicate key, place your order with a MARUTI The key identification number is stamped on SUZUKI dealer only. a metal tag provided with the keys. Keep the tag in a safe place. If you lose your keys, you will need this number to have Note: new keys made. Write the number down Keep the spare key very carefully. When it and keep it in a safe accessible place away is lost, consult your dealer by quoting key from the vehicle. number.
Key No. :
MARUTI 800 DOMESTIC 15 3-2 BEFORE DRIVING 844-74E
IMMOBILIZER SYSTEM (if equipped) DOOR LOCKS
This system is designed to help prevent NOTE: vehicle theft by electronically disabling the • If you lose your Immobilizer ignition key, engine starting system. contact your MARUTI SUZUKI dealer as The engine can be started only with your soon as possible to have the lost one vehicle’s original immobilizer ignition key deactivated, then have the new key which has an electronic identification code made by them. programmed into it. The key communicates • If you own other vehicles with the identification code to the vehicle when immobilizer keys, keep those keys away the key is turned to the “ON” position. If from the ignition switch when using your you need to make spare keys, contact your vehicle, or the engine may not be MARUTI SUZUKI dealer. The vehicle must started because they may interfere with be programmed with the correct identifica- your vehicle’s immobilizer system. tion code for the spare keys. A key made 844-03-004 by an ordinary locksmith will not work. CAUTION To lock a front door from outside the In case of attaching any metal objects vehicle: to the immobilizer key, it may not a) Insert the key fully and turn the top of start the engine. the key toward the front of the vehicle, The immobilizer key is a sensitive or electronic instrument. To avoid b) Push in the lock lever and hold the door damaging the immobilizer key: handle up as you close the door. • Do not expose it to impacts, To unlock a front door from outside the 844-03-003 moisture or high temperature such If the Immobilizer system light (1) blinks vehicle, insert the key fully and turn the top
as by leaving it on the dashboard MARUTI 800DOMESTIC of the key toward the rear of the vehicle. when the ignition switch is in the “ON” under direct sunlight. position, there may be something wrong • Keep the immobilizer key away from To lock a rear door from outside the with your key or with the immobilizer sys- magnetic objects. vehicle, push in the lock lever and close the tem. Contact your MARUTI SUZUKI dealer door. to inspect the system.
3-3 16 844-74E BEFORE DRIVING
844-03-005 844-03-006 To lock a door from inside the vehicle, push Hatchback CAUTION in the lock lever. Pull out the lock lever to To unlock insert the key fully in to the lock unlock the door. knob and turn it anticlockwise and to lock Do not use the key to lift up the lid, turn it clockwise. Hatchback can be opened or the key may break off in the lock. w WARNING by pushing in the lock knob and lifting hook- shaped grip. Always lock all doors when driving. Locking the door prevents occupants w from being thrown from the vehicle in WARNING the event of an accident. It also helps Always make sure that the hatchback prevent unintentional opening of the is closed and latched securely. doors. Completely closing it helps keep exhaust gases from entering the car. Completely closing the hatchback lid also helps prevent occupants from being thrown from the vehicle in the event of an accident.
MARUTI 800 DOMESTIC 17 3-4 BEFORE DRIVING 844-74E
WINDOWS MIRRORS
844-03-007 844-03-008 844-03-009 Raise or lower the door windows by turning Inside Rearview Mirror Outside Rearview Mirror the handle located on the door panel. To adjust the interior rearview mirror, move Adjust the outside rearview mirror so you the mirror up, down, or sideways to obtain can just see the side of your vehicle in the the best view. mirror. w WARNING Be careful when judging the size or distance of a vehicle or other object seen in the side convex mirror (if
equipped). Be aware that objects look MARUTI 800DOMESTIC smaller and appear farther away than when seen in a flat mirror.
3-5 18 844-74E BEFORE DRIVING
FRONT SEAT ADJUSTMENT
w WARNING Never attempt to adjust the driver’s seat or seatback while driving. The seat or seatback could move unexpectedly, causing loss of control. Make sure that the driver’s seat and seatback are properly adjusted before you start driving.
844-03-010 844-03-011 Adjusting Seat Position Adjusting Seatbacks The adjustment lever for each front seat is The seatbacks can be adjusted to different located under the front of the seat, on the angles. To adjust the seatback angle, pull inboard side. To adjust the seat position, up the lever on the outboard side of the pull up on the adjustment lever and slide seat, move the seatback to the desired the seat forward or rearward. After position, and release the lever to lock the adjustment, try to move the seat forward seatback in place. and rearward to ensure that it is securely latched. w WARNING w Seatbacks should always be in an WARNING upright position when driving, or seat To avoid excessive seat belt slack, belt effectiveness may be reduced. which reduces the effectiveness of the Seat belts are designed to offer seat belts as a safety device, make maximum protection when seatbacks sure that the seats are adjusted before are in the fully upright position. the seat belts are fastened.
MARUTI 800 DOMESTIC 19 3-6 BEFORE DRIVING 844-74E
ADJUSTABLE HEAD RESTRAINTS SEAT BELTS (if equipped)
844-03-012 844-03-013 844-03-014 w WARNING There are two height positions for the head w WARNING restraints. To raise the head restraint, pull • Never drive the vehicle with the upward on the restraint until it clicks. To Wear Your Seat Belts at All Times. head restraints removed. lower the restraint, push down on the • Do not attempt to adjust the head restraint while holding in the lock lever. If There are two types of seat belt "Automatic restraint while driving. a head restraint must be removed (for retracting type" and "3-point, non retractor cleaning, replacement, etc.), push in the type". Head restraints are designed to help reduce lock lever and pull the head restraint all the the risk of neck injuries in the case of an way out. To fasten the seat belt, pull the buckle accident. Adjust the head restraint to the tongue attached to the seat belt across your position which places the middle of the head body and slide it into the buckle catch slot MARUTI 800DOMESTIC restraint closest to the top of your ears. on the opposite side until you hear a “click”.
3-7 20 844-74E BEFORE DRIVING
844-03-015 844-03-016 844-03-017 To reduce the risk of sliding under the belt To unfasten the belt, press the release To Adjust the Belt during a collision, position the lap portion button on the buckle catch. • Automatic retracting type of the belt across your lap as low on your Pull the shoulder portion of the belt hips as possible and adjust the belt to a upwards through the tongue plate. snug fit using the proper method described below. Make sure that the belt is not The length of the diagonal shoulder strap twisted. adjusts itself to allow freedom of movement. The seat belt has an emergency locking retractor (ELR), which is designed to lock the seat belt only during a sudden stop or impact. w WARNING No modifications or additions of any sort should be made to the seat belt or its operating mechanism.
MARUTI 800 DOMESTIC 21 3-8 BEFORE DRIVING 844-74E
844-03-018 844-03-019 844-03-020 • 3-point non-retractor type After use, always rehang the belt on the w WARNING Adjust the shoulder portion of the belt so hook provided near the upper anchorage that it is slightly slack. To shorten the point. • Inspect all seat belts after any belt, pull the free end in the direction of collision. Any automatic retracting the arrow as illustrated. To lengthen the type belt which was in use at the belt, grab it at the shoulder anchor and time of collision and subjected to pull it in the direction of the arrow, at stress must be replaced. right angles to the anchor. The shoulder • Any automatic retracting type belt portion should have just enough slack so not in use at the time of collision should be carefully inspected and that a clenched fist can be inserted MARUTI 800DOMESTIC between the belt and your chest as the static operation checked. If there illustrated. Too much slack at the is any doubt whatsoever in the shoulder portion makes the belt operation or condition of the belt, it ineffective in accidents. The shoulder must be replaced. portion should be worn on the outside • Non retractor type belts with any shoulder only, and never under the arm. form of damage or abrasion to any part of the belt must be replaced.
3-9 22 844-74E BEFORE DRIVING
w w w V
WARNING WARNING V WARNING
• Never allow persons to ride in the pockets or on your clothing. If an • Infants and small children should cargo area of a vehicle. In the event accident occurs, objects such as never be transported unless they are of an accident, there is a much glasses, pens, etc. under the seat properly restrained. Restraint greater risk of injury for persons belt can cause injury. systems for infants and small who are not riding in a seat with • Never use the same seat belt on children can be purchased locally their seat belt securely fastened. more than one occupant and never and should be used. Make sure that • Seat belts should always be attach a seat belt over an infant or the system you purchase meets adjusted so the lap portion of the child being held on an occupant’s applicable safety standards. Read belt is worn low across the pelvis, lap. Such seat belt use could cause and follow all the directions not across the waist. Shoulder serious injury in the event of an provided by the manufacturer. straps should be worn on the accident. • Avoid contamination of seat belt outside shoulder only, and never • Pregnant women should use seat webbing by polishes, oils, under the arm. Seat belts should belts, although specific recommen- chemicals, and particularly battery never be worn with the straps dations about restraint use should acid. Cleaning may safely be carried twisted and should be adjusted as be made by the woman’s medical out using mild soap and water. tightly as is comfortable to provide advisor. • For children, if the shoulder belt the protection for which they have • Periodically inspect seat belt irritates the neck or face, move the been designed. A slack belt will assemblies for excessive wear and child closer to the center of the provide less protection than one damage. Seat belts should be vehicle. which is snug. replaced if webbing becomes frayed, • Make sure that each seat belt buckle contaminated, or damaged in any is inserted into the proper buckle way. It is essential to replace the catch. entire seat belt assembly after it has • Do not wear your seat belt over been stressed in an impact, even if hard or breakable objects in your damage to the assembly is not obvious. V V
MARUTI 800 DOMESTIC 23 3-10 844-74E
MEMO
24 844-74E STEERING COLUMN CONTROLS
STEERING COLUMN CONTROLS
Ignition Switch ...... 4-1 Lighting/Turn Signal Control Lever ...... 4-2 Hazard Warning Switch ...... 4-3 4 Windscreen Wiper and Washer Lever ...... 4-4 Horn...... 4-5
MARUTI 800 DOMESTIC 25 STEERING COLUMN CONTROLS 844-74E
IGNITION SWITCH
844-04-001 844-04-002 844-04-003 w WARNING The ignition switch has the following four LOCK positions: This is the normal parking position. It is the To avoid possible injury, do not only position in which the key can be operate controls by reaching through w WARNING removed. the steering wheel. • Do not use any locally made key. The “LOCK” position locks the ignition, and • Should you require duplicate key, prevents normal use of the steering wheel place your order with MARUTI after the key is removed. SUZUKI dealer only. To release the steering lock, fully insert the
key and turn it clockwise to one of the other MARUTI 800DOMESTIC positions. If you have trouble turning the key to unlock the steering, try turning the steering wheel slightly to the right or left while turning the key.
4-1 26 844-74E STEERING COLUMN CONTROLS
LIGHTING/TURN SIGNAL CONTROL LEVER ACC CAUTION Accessories such as the radio can operate, but the engine is off. • Do not use the starter motor for more than 15 seconds at a time. If ON the engine does not start; wait 15 This is the normal operating position. All seconds before trying again. If the electrical systems are on. engine does not start after several START attempts, check the fuel and ignition This is the position for starting the engine systems or consult your MARUTI using the starter motor. The key should be SUZUKI dealer. released from this position as soon as the • Do not leave the ignition switch in engine starts. the “ON” position if the engine is not running as the battery will 844-04-004 w discharge. WARNING This control lever is located on the outboard • Never remove the ignition key while side of the steering column. Operate the the vehicle is moving. The steering lever as described below. wheel will lock and you will not be Lighting Operation able to steer the vehicle. To turn the lights on or off, twist the knob • Do not leave children alone in a on the end of the lever. There are three parked vehicle. Unattended children positions: in the “OFF” position all lights are could cause accidental movement of off; in the middle position the front parking the vehicle, which could result in lights, tail-lights, registration plate light, and severe personal injury. instrument lights are on, but the headlights • Always remove the key when parked are off; in the third position the headlights to prevent unintentional operation of come on in addition to the other lights. the vehicle and to improve security.
MARUTI 800 DOMESTIC 27 4-2 STEERING COLUMN CONTROLS 844-74E
HAZARD WARNING SWITCH
844-04-005 844-04-006 844-04-007 With the headlights on, push the lever Turn Signal Operation Pull up the hazard warning switch to forward to switch to the high beams (main With the ignition switch in the “ON” position, activate the hazard warning lights. All four beams) or pull the lever toward you to move the lever clockwise until it clicks to turn signal lights and both turn signal switch to the low beams. When the high signal a right turn or anticlockwise to signal indicators will flash simultaneously. To turn beams (main beams) are on, a light on the a left turn. When the turn is completed, the off the lights, push down switch. instrument panel will come on. To flash the signal will cancel and the lever will return Use the hazard warning lights to warn other high beams (main beams) pull the lever to its normal position. traffic during emergency parking or when slightly towards you and release it. your vehicle could otherwise become a traffic hazard. MARUTI 800DOMESTIC
4-3 28 844-74E STEERING COLUMN CONTROLS
WINDSCREEN WIPER AND WASHER LEVER Windscreen Washer CAUTION To spray windscreen washer fluid, pull the lever toward you. The windscreen wipers To help prevent damage to the will automatically turn on at low speed if windscreen wiper and washer system they are not already on and the “INT” components, you should take the position is equipped. following precautions: • Do not continue to hold in the lever w WARNING when there is no windscreen washer • To prevent windscreen icing in cold fluid being sprayed or the washer weather, turn on the defroster to motor can be damaged. heat the windscreen before and • Do not attempt to remove dirt from during windscreen washer use. a dry windscreen with the wipers or 844-04-008 • Do not use radiator antifreeze in the you can damage the windscreen and Windscreen Wipers windscreen washer reservoir. It can the wiper blades. Always wet the To turn the windscreen wipers on, twist the severely impair visibility when windscreen with washer fluid before knob on the end of the lever to one of the sprayed on the windscreen, and can operating the wipers. three operating positions. In the “INT” also damage your vehicle’s paint. • Clear ice or packed snow from the position (if equipped), the wipers operate wiper blades before using the intermittently. The “INT” position is very wipers. convenient for driving in mist or light rain. • Check the washer fluid level In the “LOW” position, the wipers operate regularly. Check it often when the at a steady low speed. In the “HI” position, weather is bad. the wipers operate at a steady high speed. • Only fill the washer fluid reservoir To turn off the wipers, move the lever back 3/4 full during cold weather to allow to the “OFF” position. room for expansion if the temperature falls low enough to freeze the solution.
MARUTI 800 DOMESTIC 29 4-4 STEERING COLUMN CONTROLS 844-74E
HORN
844-04-009 Press the horn button of the steering wheel to sound the horn. The horn will sound with the ignition switch in any position. MARUTI 800DOMESTIC
4-5 30 844-74E INSTRUMENT PANEL
INSTRUMENT PANEL
Instrument Panel ...... 5-1 Instrument Cluster ...... 5-1 Warning and Indicator Lights ...... 5-2 Immobilizer System Light (if equipped)...... 5-2 Speedometer/Odometer...... 5-4 5 Fuel Gauge ...... 5-4 Temperature Gauge ...... 5-5 Ashtray (if equipped) ...... 5-5 Glove Box ...... 5-6 Head Light Leveling Switch (if equipped) ...... 5-6 Heating System (if equipped)...... 5-7 System Operating Instructions ...... 5-8 Air Conditioning System (if equipped) ...... 5-11 System Operating Instructions ...... 5-11
MARUTI 800 DOMESTIC 31 INSTRUMENT PANEL 844-74E
INSTRUMENT PANEL 1. Instrument cluster 2. Ignition switch 3. Lighting switch/Turn signal and dimmer switch 4. Windscreen wiper and washer switch 5. Hazard warning switch 6. Other switches (if equipped) 7. Heater control panel 8. Cigarette lighter (if equipped) 9. Ashtray (if equipped) 10. Bonnet release 11. Center ventilator 12. Side ventilator 13. Side defroster 14. Glove box 15. Fuse box
844-05-001 INSTRUMENT CLUSTER 1. Speedometer 2. Odometer
3. Fuel Gauge MARUTI 800DOMESTIC 4. Temperature gauge 5. Warning and indicator lights
844-05-002 5-1 32 844-74E INSTRUMENT PANEL
WARNING AND INDICATOR LIGHTS
2) Test the brakes by carefully starting and stopping at the side of the road. 3) If you determine that it is safe, drive carefully at low speed to the nearest dealer for repairs. or 4) Have the vehicle towed to the nearest dealer for repairs. w WARNING If any of the following conditions occur, you should immediately ask your MARUTI SUZUKI dealer to 844-05-003 inspect the brake system. 844-05-004 Brake fluid level warning light • If the brake fluid level warning light Oil Pressure Light This light operates when the fluid in the does not go out after the engine This light comes on when the ignition switch brake fluid reservoir falls below the specified has been started. is turned on, and goes out when the engine level. If the light comes on whilst you are • If the brake fluid level warning light is started. The light will come on and driving, it may mean that there is something does not come on when the ignition remain on if there is insufficient oil pressure. wrong with the vehicle’s braking system. If switch is turned to the “ON” If the light comes on when driving, pull off this happens, you should: position. the road as soon as you can and stop the • If the brake fluid level warning light engine. Check the oil level and add oil if 1) Pull off the road and stop carefully. comes on at any time during vehicle necessary. If there is enough oil, the operation. w WARNING lubrication system should be inspected by your MARUTI SUZUKI dealer before you Remember that stopping distance may NOTE: drive the vehicle again. be longer, you may have to push Because the disc brake system is self harder on the pedal, and the pedal adjusting, the fluid level will drop as the may go down farther than normal. brake pads become worn. Replenishing the brake fluid reservoir is considered normal periodic maintenance.
MARUTI 800 DOMESTIC 33 5-2 INSTRUMENT PANEL 844-74E
844-05-007 “Malfunction Indicator” Light Your vehicle has a computer-controlled emission control system. A “Malfunction Indicator” light is provided on the instrument panel to indicate when it is necessary to 844-05-005 844-05-006 have the emission control system serviced. The “Malfunction Indicator” light comes on CAUTION Charging Light This light comes on when the ignition switch when the ignition switch is turned to “ON” • If you operate the engine with this is turned on, and goes out when the engine and goes out when the engine is started. light on, severe engine damage can is started. The light will come on and If the “Malfunction Indicator” light comes on result. remain on if there is something wrong with when the engine is running, there is a • Do not rely on the Oil Pressure the battery charging system. If the light problem with the emission control system. Light to indicate the need to add oil. comes on when the engine is running, the Take the vehicle to your MARUTI SUZUKI Be sure to periodically check the charging system should be inspected dealer to have the problem corrected. engine oil level (see pages 9-7 and immediately by your MARUTI SUZUKI
9-8). dealer. CAUTION MARUTI 800DOMESTIC Continuing to drive the vehicle when CAUTION the “Malfunction Indicator” light is on Do not continue driving long with the can cause permanent damage to the charging light ON as this will drain the vehicle’s emission control system, and battery 'dead'. can affect fuel economy and driveability.
5-3 34 844-74E INSTRUMENT PANEL
Immobilizer System Light (if equipped) SPEEDOMETER/ODOMETER
844-05-008 844-05-009 When the ignition switch is turned to the Turn Signal Indicators “ON” position, this light comes on to let you When you turn on the left or right turn know the light is working. If this light blinks signals, the corresponding green arrow on with the ignition switch turned to “ON”, there the instrument panel will flash along with the may be something wrong with the immobi- respective turn signal lights. When you turn lizer system. Contact your MARUTI SUZUKI on the hazard warning switch, both arrows 844-05-011 dealer to have the system inspected. will flash along with all of the turn signal 1 Speedometer lights. 2 Odometer The speedometer indicates vehicle speed in km/h. The odometer records the total distance the vehicle has been driven. CAUTION Keep track of your odometer reading 844-05-010 and check the maintenance schedule Main Beam (High Beam) Indicator Light regularly for required services. This indicator comes on when headlight Increased wear or damage to certain main beams (high beams) are turned on. parts can result from failure to perform required services at the proper mileage intervals and your warranty rights may be affected.
MARUTI 800 DOMESTIC 35 5-4 INSTRUMENT PANEL 844-74E
FUEL GAUGE TEMPERATURE GAUGE ASHTRAY (if equipped)
844-05-012 844-05-013 844-05-014 This gauge gives an approximate indication When the ignition switch is on, this gauge Front of the amount of fuel in the fuel tank. “F” indicates the engine coolant temperature. To remove the front panel ashtray for stands for full and “E” stands for empty. Under normal driving conditions, the cleaning, push down on the metal plate, and indicator should stay within the normal, pull the ashtray completely out of its holder. NOTE: acceptable temperature range between “H” This vehicle has fuel gauge of new design. and “C”. If the indicator exceeds this range Even when the ignition switch is “OFF”, the and veers towards “H”, overheating is needle will not return to “E” position but will indicated. Follow the instructions for engine show the reading. overheating in the EMERGENCY
REMEDIES section. MARUTI 800DOMESTIC CAUTION Continuing to drive the vehicle when engine overheating is indicated, can result in severe engine damage.
5-5 36 844-74E INSTRUMENT PANEL
GLOVE BOX HEADLIGHT LEVELING SWITCH (if equipped)
844-05-015 844-05-016 844-05-017 Rear To open the glove box, pull the latch lever. Level the headlight beam according to the The rear ashtray is fitted on the left rear To close it, push the lid until it latches load condition of your vehicle by turning this door. securely. switch. The chart shows the appropriate To remove the rear ashtray, push down on switch position for different vehicle-load the tongue, and pull the ashtray out of its w WARNING conditions. holder. Never drive with the glove box lid w WARNING open. It could cause injury if an accident occurs. Make sure tobacco is fully extinguished before closing the ashtray. Never throw waste in the ashtray: it could create a fire hazard.
MARUTI 800 DOMESTIC 37 5-6 INSTRUMENT PANEL 844-74E
Vehicle load Switch Position Condition
Driver only 0
Driver + 1 passengers 0 (in front seat)
Driver + 3 passengers 1 No cargo
Driver + 3 passengers 2 Cargo added
Driver + full cargo 3
Dummy 4 MARUTI 800DOMESTIC
5-7 38 844-74E INSTRUMENT PANEL
HEATING SYSTEM (if equipped)
The heating system provides heating, demisting, and ventilation.
a. Windscreen defroster b. Side defroster c. Side outlet d. Center outlet e. Floor outlet
844-05-019
844-05-018
MARUTI 800 DOMESTIC 39 5-8 INSTRUMENT PANEL 844-74E
SYSTEM OPERATING INSTRUCTIONS
Description of Controls HEAT & DEFROST 6: Temp- Function selector 1: This selector is used erature-controlled air comes out to select one of the functions described of the floor outlets, the below: 844-05-024 windscreen defroster outlets, and the side defroster outlets. DEFROST & VENTILATION 2: Temperature-controlled air comes DEFROST 7 : Temperature- out of the center and side outlets controlled air comes out of the 844-05-020 of instrument panel, windshield windscreen defroster outlets and 844-05-025 defroster outlet and side defroster the side defroster outlets. outlets. Air Intake Lever 8: This lever is used to VENTILATION 3: Temperature- select between circulating outside air controlled air comes out of the (FRESH AIR) or recirculating inside air 844-05-026 center and side air outlets. (RECIRCULATED AIR). 844-05-021 Natural Ventilation BI-LEVEL 4 : Temperature- Temperature Control Dial 9: This dial is Move the function selector to controlled air comes out of the used to control the temperature of the air “VENTILATION”, the air intake lever to floor outlets and cooler air comes that comes out of the air outlets. “FRESH AIR”, The temperature control dial 844-05-022 out of the center and side outlets. to the desired temperature position, and the Fan switch 0: This switch is used to turn When the temperature control fan switch to “OFF”. Fresh air will flow on the fan and to select fan speed. There lever is in the fully “COOL” through the vehicle when it is moving. are four positions: OFF, LOW, MEDIUM and position or fully “HOT” position, HIGH. however, the air from the floor
outlets and the air from the center MARUTI 800DOMESTIC and side outlets will be the same temperature. HEAT 5: Temperature-controlled air comes out of the floor outlets.
844-05-023
5-9 40 844-74E INSTRUMENT PANEL
844-05-027 844-05-028 844-05-029 Forced Ventilation Normal Heating (Using outside air) Quick Heating (Using recirculated air) The lever settings are the same as for Move the function selector to “HEAT”, the The lever settings are the same as for natural ventilation except you move the fan air intake lever to “FRESH AIR”, the normal heating except you move the air switch to a position other than “OFF”. temperature control dial to the desired intake lever to “RECIRCULATED AIR”. If temperature position, and the fan switch to you use this heating method for an the desired fan speed position. Moving the extended period of time, the air in the fan switch to a higher fan speed position vehicle can become contaminated and the increases heating efficiency. windows can become misty. Therefore, use this method only for quick heating and change to the normal heating method as soon as possible.
MARUTI 800 DOMESTIC 41 5-10 INSTRUMENT PANEL 844-74E
844-05-030 844-05-031 844-05-032 Cool Face/Warm Feet Defrosting/Warm Feet Defrosting Move the function selector to “BI-LEVEL”, Move the function selector to “DEFROST & Move the function selector to “DEFROST”, the air intake lever to “FRESH AIR”, the HEAT”, the air intake lever to “FRESH AIR”, the air intake lever to “FRESH AIR”, the temperature control dial to the desired the temperature control dial to the desired temperature control dial to the desired temperature position, and the fan switch to temperature position, and the fan switch to temperature position, and the fan switch to the desired fan speed position. Unless the “HIGH”. When the windscreen has become “HIGH” Moving the temperature control dial temperature control dial is in the fully clear, move the fan switch to the desired to a higher temperature position increases “COOL” position or fully “HOT” position, the fan speed position. defrosting efficiency. When the windscreen air that comes out of the center and side has become clear, move the fan switch to
outlets will be cooler than the air that comes the desired fan speed position. MARUTI 800DOMESTIC out of the floor outlets.
5-11 42 844-74E INSTRUMENT PANEL
AIR CONDITIONING SYSTEM SYSTEM OPERATING INSTRUCTIONS (if equipped)
844-05-033 844-05-034 The air conditioning system can be used to During operation of the air conditioner, you Normal Cooling (using outside air) provide cooling and dehumidifying, as may notice slight changes in engine speed. push in the A/C button, move the function described below. To turn on the air These changes are normal, the system is selector to “VENTILATION”, the air intake conditioning system, push in the A/C button designed so that the compressor turns on lever to “FRESH AIR”, the temperature and move the fan switch to a position other or off to maintain the desired temperature. control dial to the “COOL” position, and the than “OFF”. An indicator light will come on Less operation of the compressor results in fan switch to the desired fan speed position. when the air conditioning system is on. To better fuel economy. Moving the fan switch to a higher fan speed turn off the air conditioning system, push position increases cooling efficiency. the A/C button again.
MARUTI 800 DOMESTIC 43 5-12 INSTRUMENT PANEL 844-74E
844-05-035 844-05-036 844-05-037 Quick Cooling (Using recirculated air) Dehumidifying NOTE: The lever settings are the same as for Push in the A/C button, move the function There are two types of air conditioning normal cooling except you move the air selector to the desired function position, the systems used in MA intake lever to “RECIRCULATED AIR”. If air intake lever to “FRESH AIR”, the One type uses refrigerant CFC-12, commonly RUTI you use this cooling method for a extended temperature control dial to the desired called R-12; the other typeSUZUKI uses the new period of time, the air in the vehicle can temperature position, and the fan switch to refrigerant HFC-134a, commonly vehicles.called R- become contaminated. Therefore, you the desired fan speed position. 134a. For each system, the correct should occasionally move the air intake NOTE: refrigerant must be used. To identify the lever to “FRESH AIR”. Because the air conditioner dehumidifies the system, a label that states "R134a" or NOTE: air, turning it on will help keep the windows "HFC134a" is stuck on the front side of the MARUTI 800DOMESTIC If your vehicle has been left in the sun with clear, even when blowing heated air using engine compartment. the windows closed, it will cool faster if you the DEMIST or HEATER & DEMIST CAUTION open the windows briefly while you operate functions. Using the wrong refrigerant may the air conditioner with the air intake lever damage the air conditioning system. at “FRESH AIR” and the fan at high speed. Use correct refrigerant only. Do not mix the two refrigerants.
5-13 44 844-74E OTHER CONTROLS AND EQUIPMENT
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 6 Assist Grips ...... 6-5 Bonnet...... 6-6 Tyre Changing Tools ...... 6-7 High Mount Stop Lamp (if equipped) ...... 6-7
MARUTI 800 DOMESTIC 45 OTHER CONTROLS AND EQUIPMENT 844-74E
PARKING BRAKE LEVER
w WARNING Always apply the parking brake fully before leaving your vehicle or it may move, causing injury or damage. When parking, make sure the gear shift lever is left in first gear or reverse. Remember, even though the transmission is in gear, you must always apply the parking brake fully.
844-06-001 844-06-002 844-06-003 The parking brake lever is located between w WARNING the seats. To apply the parking brake, hold the brake pedal down and pull the parking • Never drive your vehicle with the brake lever all the way up. To release the parking brake on: rear brake parking brake, hold the brake pedal down, effectiveness can be reduced from pull up slightly on the parking brake lever, over heating, brake life may be push the button on the end of the lever with shortened, or permanent brake your thumb, and lower the lever to its damage may result. original position. • If the parking brake does not hold
the vehicle securely or does not MARUTI 800DOMESTIC fully release, have your vehicle inspected immediately by an authorized MARUTI SUZUKI dealer.
6-1 46 844-74E OTHER CONTROLS AND EQUIPMENT
PEDALS GEAR LEVER
Brake Pedal 2 4 SPEED TRANSMISSION Your MARUTI SUZUKI vehicle is equipped with front disc brakes and rear drum brakes. Depressing the brake pedal applies both sets of brakes. You may hear occasional brake squeal when you apply the brakes. This is a normal condition caused by environmental factors such as cold, wet, snow, etc. w WARNING
844-06-003 If brake squeal is excessive and 844-06-004 occurs each time the brakes are Clutch Pedal 1 Your vehicle is equipped with either a 4- applied, you should have the brakes The clutch pedal is used to disengage the speed or 5-speed manual transmission.The checked by your MARUTI SUZUKI drive to the wheels when starting the gear change pattern for each transmission dealer. engine, stopping, or shifting the transmission is shown in the illustration. For details on lever. Depressing the pedal disengages the w WARNING how to use the transmission, refer to clutch. USING THE TRANSMISSION in the Do not “ride” the brakes by applying OPERATING YOUR VEHICLE section (See them continuously or resting your foot CAUTION page 7-3). on the pedal. This will result in Do not drive with your foot resting on overheating of the brakes which could the clutch pedal. It could result in cause unpredictable braking action, excessive clutch wear, clutch damage, longer stopping distances, or or unexpected loss of engine braking. permanent brake damage.
Accelerator Pedal 3 This pedal controls the speed of the engine. Depressing the accelerator pedal increases power output and speed. MARUTI 800 DOMESTIC 47 6-2 OTHER CONTROLS AND EQUIPMENT 844-74E
FUEL FILLER CAP
844-06-005 844-06-006 844-06-007 The fuel filler cap is located on the left rear w WARNING • To remove - turn the cap counterclock- side of the vehicle. To unlock the fuel filler wise. Turn the cap slowly to allow any lid, turn the key clockwise. To lock turn the Petrol is extremely flammable. Do not residual pressure to escape. key anticlockwise. smoke when refuelling, and make sure • To install - turn the cap clockwise. there are no open flames or sparks in w WARNING the area. CAUTION Remove the fuel filler cap slowly. The If you need to replace the fuel cap, fuel may be under pressure and may use only a cap specified for your spray out, causing injury. model. Using an improper fuel cap
can cause a serious malfunction of MARUTI 800DOMESTIC the fuel system. You can get the correct replacement cap from your MARUTI SUZUKI dealer.
6-3 48 844-74E OTHER CONTROLS AND EQUIPMENT
FOLDING REAR SEAT
w WARNING Luggage or other cargo should be stowed in the luggage compartment with the rear seat in an upright position, whenever possible. If you need to carry cargo in the passenger compartment with the rear seat back folded forward, be sure to secure the cargo or it may be thrown about, causing injury. Never pile cargo higher than the seatbacks.
844-06-008 844-06-009 The rear seat of your vehicle can be folded To lower the seatback, pull up the lock w WARNING forward to provide additional luggage space. knobs (1 and 2) simultaneously and fold When returning a rear seat to the forward the seatback. If your vehicle is normal position, make sure that equipped with split rear seats, the right and movement of the seatback is left seat backs can be individually folded unobstructed and the seatback is forward by pulling the corresponding knob. securely latched. To raise the seatback, lift it up and push back until it locks into place.
MARUTI 800 DOMESTIC 49 6-4 OTHER CONTROLS AND EQUIPMENT 844-74E
SUN VISOR INTERIOR LIGHT SWITCH ASSIST GRIPS
844-06-010 844-06-011 844-06-012 The sun visors can be pulled down to block This light switch has three positions which Assist grips are provided for passenger glare coming through the wind screen, or function as described below: convenience. they can be unhooked and turned to the 1 The light remains off even when the side to block glare coming through the side w WARNING door is opened. window. 2 The light comes on when the door is Do not hang items on the assist grips. They could obstruct the driver’s view, CAUTION opened. 3 The light comes on and stays on resulting in an accident, or could be When unhooking and hooking a sun regardless of whether the door is open thrown about in an accident or abrupt visor, be sure to handle it by the hard or closed. manoeuvre, causing injury. plastic parts or the sun visor can be MARUTI 800DOMESTIC damaged. NOTE: Only front doors are involved in lighting operation of interior light.
6-5 50 844-74E OTHER CONTROLS AND EQUIPMENT
BONNET
844-06-013 844-06-014 844-06-015 To open the bonnet: 2) Push the under-bonnet release lever 3) Continue to lift up the bonnet until it is upwards with your finger, as shown in high enough to support with the prop 1) Pull the bonnet release handle located the illustration. While pushing the lever, rod. on the outboard side of the driver’s side lift up the bonnet. of the instrument panel. This will w WARNING disengage the bonnet lock halfway. Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident.
MARUTI 800 DOMESTIC 51 6-6 OTHER CONTROLS AND EQUIPMENT 844-74E
TYRE CHANGING TOOLS HIGH MOUNT STOP LAMP (if equipped)
844-06-016 844-06-017 844-06-018 The jack, wheel wrench and jack handle are w WARNING High mount stop lamp is provided with your stowed in the luggage compartment behind vehicle and is fitted on back door. The stop the rear seat. The jack should be used only to lamp will glow as when the brake pedal will change wheels. It is important to read be depressed. To remove the jack, turn its shaft the jacking instructions in the To change the bulb of the stop lamp, counterclockwise and pull the jack out of the EMERGENCY SERVICE section of this remove the clips at both sides of the cover, storage bracket. To stow the jack, place it manual before attempting to use the by pressing the inner pin inside so that the in the storage bracket and turn the shaft jack. clip gets loose and remove the bulb on clockwise until the jack is securely held in turning it anticlock-wise. place. w WARNING The rating of bulb is 16W/12V. There are MARUTI 800DOMESTIC one bulb in high mount stop lamp. After using the jack, jack handle, and wheel wrench, be sure to stow them securely or they can cause injury if an accident occurs.
6-7 52 844-74E OPERATING YOUR VEHICLE
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 7 Trailer Towing ...... 7-6
MARUTI 800 DOMESTIC 53 OPERATING YOUR VEHICLE 844-74E
EXHAUST GAS WARNING DAILY INSPECTION CHECKLIST
w V WARNING
with the engine running, make sure the air intake lever is set to “FRESH AIR” and the fan is at high speed. • Avoid operating the vehicle with the
V hatchback open. If it is necessary to 844-07-002 operate the vehicle with hatchback Before driving: open, make sure all the windows are 1) Make sure that windows, mirrors, lights, closed, and the fan is at high speed and reflectors are clean and unobstructed. with the air intake lever set to 2) Check the tyres. “FRESH AIR”. 3) Look for fluid and oil leaks. 844-07-001 • To allow proper operation of your NOTE : w vehicle’s ventilation system, keep It is normal for water to drip from the air WARNING the air inlet grille in front of the conditioning system after use. Avoid breathing exhaust gases. windscreen clear of snow, leaves, or 4) Adjust the seat/head restraint Exhaust gases contain carbon other obstructions at all times. 5) Check the brake pedal and the parking monoxide, a potentially lethal gas that • Keep the exhaust tailpipe area clear brake lever. is colourless and odourless. Since of snow and other material to help 6) Adjust the mirrors. carbon monoxide is difficult to detect reduce the buildup of exhaust gases 7) Make sure that you and passengers by itself, be sure to take the following under the vehicle. This is have properly fastened your seat belts. precautions to help prevent carbon particularly important when parked 8) Make sure that all warning lights come monoxide from entering your vehicle. in blizzard conditions. on as the key is turned to the “ON” or MARUTI 800DOMESTIC • Do not leave the engine running in • Have the exhaust system inspected “START” position. garages or other confined areas. periodically for damage and leaks. 9) Check all gauges. • Do not park with the engine running Any damage or leaks should be 10)Make sure that the brake fluid level for a long period of time, even in an repaired immediately. warning light is off after restarting the open area. If it is necessary to sit engine.
for a short time in a parked vehicleV
7-1 54 844-74E OPERATING YOUR VEHICLE
STARTING THE ENGINE
Once a week, or each time you fill your fuel Before starting the engine: Starting a Cold/Warm Engine tank, perform the following under-bonnet 1) Make sure the parking brake is applied checks: fully. For Electronic fuel injection models 2) Shift into “N” (neutral) and depress the 1) Engine oil level. clutch pedal all the way to the floor. Hold • With your foot off the accelerator pedal, 2) Coolant level. it while starting the engine. crank the engine by turning the ignition 3) Brake fluid level. key to “START”. Release the key when 4) Windscreen washer fluid level. w WARNING the engine starts. 5) Battery solution level. • If the engine does not start after 15 6) Bonnet latch operation. Make sure that the parking brake is seconds of cranking, wait about 15 Pull the bonnet release handle inside the applied fully and the transmission is seconds, then press down the vehicle. Make sure that you can not in Neutral before attempting to start accelerator pedal to 1/3 of its travel and open the hood all the way without the engine. try cranking the engine again. Release releasing the secondary latch. Be sure the key and accelerator pedal when the to close the hood securely after checking CAUTION engine starts. for proper operation. See "All Latches, • Stop turning the starter immediately • If the engine still does not start, try Hinges & Locks" of "PERIODIC after the engine has started or the holding the accelerator pedal all the way MAINTENANCE SCHEDULE" in the starter system can be damaged. to the floor while cranking. This should "INSPECTION AND MAINTENANCE" • Do not crank the engine for more clear the engine if it is flooded. section for lubrication schedule. than 15 seconds at a time. If the w WARNING engine doesn’t start on the first try, wait about 15 seconds before trying Make sure the bonnet is fully closed again. and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident.
MARUTI 800 DOMESTIC 55 7-2 OPERATING YOUR VEHICLE 844-74E
USING THE TRANSMISSION
w WARNING • Reduce your speed and change down to a lower gear before going down a long or steep hill. A lower gear will allow the engine to provide braking. Avoid riding the brakes or they may overheat, resulting in brake failure. • When driving on slippery roads, be sure to slow down before changing down. Excessive and or sudden changes in engine speed may cause 844-07-003 844-07-004 loss of traction, which could cause Starting off Min speed Max. speed you to lose control. To start off, depress and maintain pressure • Make sure that the vehicle is upon the clutch pedal and change into 1st First - 30 km/h completely stationary before you gear. After releasing the parking brake, change into reverse. gradually release the clutch. When you hear Second 10 km/h 50 km/h a change in the engine’s sound (speed), Third 20 km/h 90 km/h gently apply pressure to the accelerator to CAUTION keep the engine sound (speed) constant Fourth 30 km/h Top Speed • To help avoid clutch damage, do not whilst continuing to gradually release the *Fifth 40 km/h Top Speed use the clutch pedal as a footrest
clutch. while driving or use the clutch to MARUTI 800DOMESTIC *Applicable for 5-speed transmission only keep the vehicle stationary on a hill. Gear changing Depress the clutch fully when All forward gears are synchronized, which changing gear. provides for quiet, easy changing. Always • When changing gears or starting off, depress the clutch pedal fully before do not race the engine. Racing the changing gears. To help gearshift, the engine can shorten engine life and following chart shows the recommended prevent smooth operation. speed range in each gear. 7-3 56 844-74E OPERATING YOUR VEHICLE
BRAKING RUNNING-IN
The distance needed to bring any vehicle w WARNING CAUTION to a halt increases with the speed of the vehicle. The braking distance needed, for If water gets into the brake drums, The future performance and reliability example, at 60 km/h will be approximately brake performance may become poor of the engine depends on the care 4 times greater than the braking distance and unpredictable. After driving and restraint exercised during its early needed at 20 km/h. Start to brake the through water or washing the life. It is especially important to vehicle when there is plenty of distance underside of the vehicle, test the observe the following precautions between your vehicle and the stopping brakes while driving at a slow speed during the initial 1000 km of vehicle point, and slow down gradually. to see if they have maintained their operation. normal effectiveness. If the brakes are • After starting, do not race the less effective than normal, dry them engine. Warm it up gradually. by repeatedly applying the brakes • Avoid prolonged vehicle operation at while driving slowly until the brakes a constant speed. Moving parts will have regained their normal bed in better if you vary your speed. effectiveness. • Do not exceed 100 km/h. • Start off from a stop slowly. Avoid full throttle starts. • If possible, avoid hard braking, especially during the first 320 km of driving. • Do not drive slowly with the transmission in a high gear. • Drive the vehicle at moderate engine speeds.
MARUTI 800 DOMESTIC 57 7-4 OPERATING YOUR VEHICLE 844-74E
CATALYTIC CONVERTER
CAUTION To minimize the possibility of catalyst or other vehicle damage: • Maintain the engine in the proper operating condition. • In the event of an engine malfunction, particularly one involving engine misfire or other apparent loss of performance, have the vehicle serviced promptly. • Do not turn off the engine or 844-07-005 interrupt the ignition when the 844-07-006 transmission is in gear and the The purpose of the catalytic converter w WARNING installed on your vehicle is to convert vehicle is in motion. exhaust pollutants to harmless water vapour, • Do not try to start the engine by Be careful where you park and drive; carbon dioxide, and nitrogen. Use of leaded pushing or towing the vehicle, or the catalytic converter and other fuel in vehicles equipped with catalytic coasting down a hill. exhaust components can get very hot. converters is prohibited, because lead • Do not idle the engine with any As with any vehicle, do not park or deactivates the pollutant-reducing spark plug wires disconnected or operate this vehicle in areas where components of the catalyst system. removed, such as during diagnostic combustible materials such as dry testing. grass or leaves can come in contact It is very important to keep the engine • Do not idle the vehicle for with a hot exhaust system. properly tuned. Engine misfiring, which can prolonged periods if idling seems MARUTI 800DOMESTIC result from an improperly tuned engine, may rough or there are other cause overheating of the catalyst. This may malfunctions. result in permanent heat damage to the • Do not allow the fuel tank to get catalyst and other vehicle components. near the empty level.
7-5 58 844-74E OPERATING YOUR VEHICLE
IMPROVING FUEL ECONOMY TRAILER TOWING
The following instructions will help you Keep the air cleaner clean: Your MARUTI SUZUKI was originally improve fuel economy. A dirty air cleaner will cause the carburation designed to carry people and a normal system to supply too much fuel to the amount of cargo, not to tow a trailer. Avoid excessive idling: engine for the amount of air being supplied. MARUTI SUZUKI does not recommend you If you are to wait for more than a minute The result is waste of fuel due to use your vehicle to tow a trailer. Towing a while you are parked, stop the engine and incomplete combustion. trailer can adversely affect handling, start it again later. When warming up a cold durability, and fuel economy. engine, allow the engine to idle until the Keep weight to a minimum: temperature gauge pointer comes up to the The heavier the load, the more fuel the “C” position. In this position, the engine is vehicle consumes. Take out any luggage or sufficiently warm for starting off. cargo when it is not necessary. Avoid “fast” starts: Keep tyre pressures correct: Fast starts away from lights or stop signs Under-inflation of the tyres can waste fuel will consume fuel unnecessarily and shorten due to increased running resistance of the engine life. Start off slowly. tyres. Keep your tyres inflated to the correct pressure shown on the label on the driver’s Avoid unnecessary stops: side door or door lock pillar. Avoid unnecessary deceleration and stopping. Try to maintain a slow, steady speed whenever possible. Slowing down and then accelerating again uses more fuel. Keep a steady cruising speed: Keep as constant a speed as road and traffic conditions will permit.
MARUTI 800 DOMESTIC 59 7-6 844-74E
MEMO
60 844-74E DRIVING TIPS AND SAFE DRIVING
DRIVING TIPS AND SAFE DRIVING
High Speed Driving ...... 8-1 Driving on Hills ...... 8-1 Driving on Slippery Roads ...... 8-1 Driving on Wet Roads ...... 8-2 Do’s and Don’ts for Safe Driving ...... 8-3
8
MARUTI 800 DOMESTIC 61 DRIVING TIPS AND SAFE DRIVING 844-74E
HIGH-SPEED DRIVING
When driving at a high-speed, pay attention normal power range. Change rapidly to to the following: prevent the car from losing momentum. • Stopping distance progressively • When driving down a hill, the engine increases with vehicle speed. Apply the should be used for braking by shifting to brakes far enough ahead of the stopping next lower gear. point to allow for the extra stopping w distance. WARNING • On rainy days, “Aquaplaning” can occur. Try not to hold the brake pedal down “Aquaplaning” is the loss of direct too long or too often while going contact between the road surface and down a steep or long hill. This could the vehicle’s tyres due to a water film cause the brakes to overheat, 844-08-001 forming between them. Steering or resulting in reduced braking efficiency. Failure to take this precaution could w braking the vehicle while “Aquaplaning” WARNING can be very difficult, and loss of control result in loss of vehicle control. • Wear Your Seat Belts at All Times. can occur. Keep speed down when the The driver and passengers should road surface is wet. CAUTION be properly restrained at all times, • At high speeds, the vehicle may be When descending a down hill, NEVER using the seatbelts provided. Refer affected by side winds. Therefore, reduce turn the ignition key to the “OFF” to the “SEATBELTS” section for speed and be prepared for unexpected position. Emission control system instructions on proper use of the buffeting, which can occur at the exits damage may result. seat belts. of tunnels, when passing by a cut of a • Never drive while under the hill, or when being overtaken by large DRIVING ON SLIPPERY ROADS MARUTI 800DOMESTIC influence of alcohol or other drugs. vehicles, etc. Under wet road conditions you should drive Alcohol and drugs can seriously DRIVING ON HILLS at a lower speed than on dry roads due to impair your ability to drive safely, • When climbing steep hills, the car may possible slippage of tyres during braking. greatly increasing the risk of injury begin to slow down and show a lack of When driving on icy, snowcovered, or to yourself and others. You should power. If this happens, you should muddy roads, reduce your speed and avoid also avoid driving when you are change to a lower gear so that the sudden acceleration, abrupt braking, or tired, sick, irritated, or under stress. engine will again be operating in its sharp steering movements. 8-1 62 844-74E DRIVING TIPS AND SAFE DRIVING
Snow Chains
If you must use snow chains to increase w WARNING w WARNING tyre traction, observe the following precautions: Do not allow anyone to stand near the • Make sure your tyres are in good vehicle when you are rocking it, and condition and always maintain the • Choose a safe place away from traffic do not spin the wheels faster than an specified tyre pressure. Refer to to install the chains. indicated 40 km/h on the speedometer. “TYRES” in the “INSPECTION AND • When installing the chains carefully Personal injury and/or vehicle damage MAINTENANCE” section for details. follow the manufacturer’s instructions. may result from spinning the wheels • Do not use tyres other than those • Install the chains on the front tyres. too fast. specified by MARUTI SUZUKI. never • With the chains on, drive only at slow use different sizes or types of tyres and moderate speeds. CAUTION on the front and rear wheels. For • If Your Vehicle Gets Stuck information regarding the specified Do not continue rocking the vehicle If your vehicle gets stuck in snow, mud, tyres, refer to the “SPECI- for more than a few minutes. or sand, follow the directions below: FICATIONS” section. Prolonged rocking can cause engine • Never use oversized tyres or special 1) Change back and forth between first overheating or transmission damage. shock absorbers and springs to gear and reverse. This will create a raise (jack up) your vehicle. This will DRIVING ON WET ROADS rocking motion which may give you change the handling characteristics. enough momentum to free the vehicle. CAUTION • After driving through water, test the Press gently on the accelerator to keep • When driving on wet roads, avoid brakes while driving at a slow speed wheel spin to a minimum. Remove your driving through large amount of to see if they have maintained their foot from the accelerator while changing standing water on the road. Large normal effectiveness. If the brakes gear. amount of water entering the engine are less effective than normal, dry Do not race the engine. Excessive wheel compartment may cause damage to them by repeatedly applying the spin will cause the tyres to dig deeper, the engine and or electrical brakes while driving slowly until the making it more difficult to free the components. brakes have regained their normal vehicle. • If stuck in deep water, do not start effectiveness. 2) If your vehicle remains stuck after a few till water level drops minutes of rocking, get another vehicle • Water is incompressible substance, to pull you out. water inside the engine is harmful to the engine. MARUTI 800 DOMESTIC 63 8-2 DRIVING TIPS AND SAFE DRIVING 844-74E
DO’S AND DON’TS FOR SAFE DRIVING Exercise care in handling your vehicle. Be conscious of not only your own safety but also the safety of others on the road, and thus enjoy the best and most comfortable driving experience. This section contains basic rules for safe driving. Read it carefully for good understanding of the content so that you can enjoy safe and pleasant driving in your Maruti vehicle.
844-08-002 844-08-003 Starting 2. Always follow other vehicles at a safe 1. Adjust the driver’s seat for the proper distance in order to prevent a rear-end driving posture. collision, should the vehicle ahead make a sudden stop. 2. Adjust the rear view mirror so as to 3. Turn ON the turn signal at least 30 obtain the best possible rear view. meters before making a turn or changing 3. Before moving off, look forward and back the lane so as not to be hit from behind. to confirm safety. 4. Before entering a corner, decelerate to a safe speed. Don’t apply brakes during 4. Don’t start quickly, for it is dangerous
cornering, or a cornering skid may occur. MARUTI 800DOMESTIC and wastes fuel. General driving 5. When overtaking other vehicles, watch 1. Be sure to stop before the stop light and out for the oncoming vehicle and stop sign. When moving into the carefully confirm the safety. intersection without any traffic lights or 6. Don’t attempt zigzag driving which will signs, drive slowly to confirm safety. hinder your control over the vehicle and cause an accident.
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844-08-005 844-08-006 especially dangerous when the tyres are 5. The higher the speed, the narrower the worn, for they allow a larger skid. driver’s visual range becomes. In such a state, it is difficult to anticipate any Use foot brake in three stages hazard and the driver feels much (1) Warn the vehicle behind you fatigued. (2) Gradually apply the brake. 6. Never do sharp handling during high (3) Bring the vehicle to a halt. speed driving. You will lose your control 3. When driving on a downhill, try not to over your vehicle. 844-08-004 apply the brake but use the engine 7. When overtaking or changing the lane Braking brake effectively. Overuse of the while driving at a high speed, keep an 1. Use the parking brake when parking footbrake may result in total brake ample vehicle-to-vehicle distance. your vehicle and shift the gear shift lever failure. Long distance driving into the first gear or reverse gear 4. Avoid reckless high speed driving and try 1. Be sure to perform safety checks before position for the sake of safety. to drive at a safe speed suitable for the starting a trip. 2. Don’t use handbraking unless road conditions while maintaining a 2. Take rest at certain intervals to prevent unavoidable. It causes the vehicle to skid constant speed. an accident which may occur when you and a rearend collision occur. It is are sleepy or tired.
MARUTI 800 DOMESTIC 65 8-4 DRIVING TIPS AND SAFE DRIVING 844-74E
MARGIN FOR SAFETY It is important to allow yourself a margin for safety during driving so that you can cope with erroneous or unexpected driving of other drivers. For that, observe the following. • Drive at a safe speed. • Maintain a sufficient distance between your vehicle and the vehicle ahead. • Don’t force yourself to overtake other vehicles. 844-08-007 844-08-008 • Don’t make quick start, hard steering or Night time driving sudden stops. 1. Drive more slowly at night than in the • Allow an ample time in the driving daytime, for the visual range is restricted schedule. at night. • Observe traffic rules and regulations. 2. Don’t overtake other vehicles at night. CONCLUSION Darkness bothers your sense of speed and hinders your judgement on the A perfect driver does not exist. The vehicle-to-vehicle distance. endeavour of every motorist should be to strive for perfection. Safety consciousness 3. Don’t use the high headlight beam
not only ensures your safety and the safety MARUTI 800DOMESTIC unless its use is inevitable. Its dazzle of other road users, it also helps reduce the may blitz the driver of the oncoming wear and tear on your vehicle, prolongs its vehicle, thus causing an accident. 844-08-009 life, gives more mileage and ensures a 4. Always keep the window glasses clean. comfortable driving experience. Don’t operate the windshield wiper when Follow the do’s and don’ts listed, and the windshield glass is dry or the wiper driving will never be the same again. blade and glass may get damaged.
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INSPECTION AND MAINTENANCE
Periodic Maintenance Schedule ...... 9-1 Drive Belt ...... 9-6 Engine Oil and Filter ...... 9-6 Gear 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 9 Fuses ...... 9-20 Bulb Replacement ...... 9-22 Wiper Blades ...... 9-25
MARUTI 800 DOMESTIC 67 INSPECTION AND MAINTENANCE 844-74E
PERIODIC MAINTENANCE SCHEDULE
w WARNING w WARNING The following table shows when regular maintenance on your vehicle is required.
You should take extreme care when •V Do not allow smoking, sparks, or This table shows in kilometres and months working on your vehicle to prevent flames around gasoline or the when inspections, adjustments, lubrication accidental injury. Here are a few battery. Flammable fumes are and other services should be performed. precautions that you should be present. especially careful to observe: w • Do not get under your vehicle if it WARNING • Do not leave the engine running in is supported only with the portable Maruti Suzuki recommends that garages or other confined areas. jack provided in your vehicle. maintenance on your Maruti Suzuki • When the engine is running, keep • Be careful not to cause accidental vehicle be performed by Maruti Suzuki hands, clothing, tools, and other short circuits between the positive Authorised Dealer/Service Station. objects away from the fan and water and negative battery terminals. pump belt. Even though the fan may • Keep used oil, coolant, and other not be moving, it can automatically CAUTION fluids away from children and pets. turn on without warning. Dispose of used fluids properly; Whenever it becomes necessary to • When it is necessary to do service never pour them on the ground, into replace parts on your vehicle, it is work with the engine running, make sewers, etc. recommended that you use MARUTI sure that the parking brake is GENUINE PARTS (MGP). applied fully and the transmission is in Neutral. • Do not touch ignition wires or other ignition system parts when starting the engine or when the engine is running, or you could receive an MARUTI 800DOMESTIC electric shock. • Be careful not to touch hot exhaust components such as the manifold, pipes, and mufflers. V
9-1 68 844-74E INSPECTION AND MAINTENANCE
A....Adjust. I....Inspect and correct or replace if necessary. T....Tighten to specified torque. C....Clean. R....Replace or change. O....Rotate L....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 – I Replace 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 – I 2. 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. MARUTI 800 DOMESTIC 69 9-2 INSPECTION AND MAINTENANCE 844-74E
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 FUEL 1. Air cleaner Paved-road Clean every 5,000 km. Replace every 40,000 km. Dusty condition Clean every 2,500 km or as required. Replace every 40,000 km. More frequent replacement if dust condition is severe. 2. Accelerator cable and Throttle shafts – I&L I&L I&L I&L I&L I&L I&L I&L I&L 3. Fuel tank cap, fuel lines & connections(leakage,damage) – I – – – I – – – I 4. Fuel filter (leakage) I I I I I R I I I R
CLUTCH AND TRANSMISSION 1. Clutch pedal (play) I I I I I I I I I I 2. Clutch slipping (dragging or excessive damage) I I I I I I I I I I 3. Manual Transmission/Transfer and Differential oil (level, leakage) I I I R I R I R I R DRIVE SHAFTS 1. Drive shafts boots (bent of boots damage) – I I I I I I I I I
BRAKE 1. Brake fluid (level, leakage) I I I R I R I R I R 2. Brake pedal (pedal-to-wall clearance) I I I I I I I I I I 3. Parking brake lever and cable (play, damage) I I I I I I I I I I 4. a. Brake discs and pads, (wear) – I I I I I I I I I b. Brake drums & shoes – – I I I I I I I I MARUTI 800DOMESTIC 5. Master cylinder and wheel cylinder or calliper (oil leakage, boot kit) I I I I I R I I I R 6. Brake hoses and pipes (leakage, damage) I I I I I I I I I I
9-3 70 844-74E INSPECTION AND MAINTENANCE
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 WHEEL 1. 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 SUSPENSION 1. 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 I 2. All rods and arms (loose, damage, wear) I I I I I I I I I I
ELECTRICAL 1. 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
MARUTI 800 DOMESTIC 71 9-4 INSPECTION AND MAINTENANCE 844-74E
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 ROAD TEST 1. Operation of Brakes, Gear shifting & speedometer I I I I I I I I I I 2. Body and Chassis noise I I I I I I I I I I
AIR CONDITIONER (if equipped) 1. Check belt tension I I I I I I I I I I 2. Check Receiver Drier bubbles. I I I I I I I I I I 3. Tighten compressor mounting bolts – T T T T T T T T T 4. Check all hose joints, tighten if necessary I I I I I I I I I I 5. Check functioning of Recirc flap I I I I I I I I I I 6. Clean condenser with low pressure water – C C C C C C C C C 7. Check belt for frayed edges, change if necessary – I I I I I I I I I 8. Check all mounting bolts – I I I I I I I I I
w WARNING ´ All maintenance should be carried out with the ignition switch in the “OFF” position and the car parked securely on the level ground unless otherwise specified. MARUTI 800DOMESTIC ´ If you are in any way unsure of your ability to undertake a task, then do not start it but contact your MARUTI SUZUKI dealer to perform the work for you.
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DRIVE BELT ENGINE OIL AND FILTER
844-09-001 844-09-002 844-09-003 w WARNING Water pump belt 6 - 7 mm Specified oil Be sure that the engine oil you use comes When the engine is running, keep Air conditioner belt 7 - 9 mm under the API classification of SF, SG or hands, hair, clothing, tools, etc. away SH. Select the appropriate oil viscosity from the fan and drive belt. Even The belt should also be examined to ensure according to the above chart. though the fan may not be moving, it that it is not damaged. If the belt needs to can automatically turn on without be replaced or adjusted, have it done by warning. your MARUTI SUZUKI dealer.
Make sure the drive belt tension is correct. If the belt is too loose, insufficient battery charging, engine overheating, or excessive belt wear can result. When you press the belt with your thumb midway between the pulleys, the belt deflection should be within the specification below.
MARUTI 800 DOMESTIC 73 9-6 INSPECTION AND MAINTENANCE 844-74E
844-09-004 844-09-005 844-09-006 Oil Level Check Refilling Tightening torque: It is important to keep the engine oil at the Remove the oil filler cap and pour oil slowly 5.0 kg-m (36.5 lb-ft) correct level for proper lubrication of your through the filler hole to bring the oil level w vehicle’s engine. Check the oil level with the to the upper limit on the dipstick. Be careful WARNING vehicle on a level surface. The oil level not to overfill. Too much oil is almost as The engine oil temperature may be indication may be inaccurate if the vehicle bad as too little oil. After refilling, start the high enough to burn your fingers is on a slope. The oil level should be engine and allow it to idle for about a when the drain plug is loosened. Wait checked either before starting the engine or minute. Stop the engine, wait for five until the drain plug is cool enough to at least five minutes after stopping the minutes and check the oil level again. touch with your bare hands. engine.
Changing Engine Oil and Filter MARUTI 800DOMESTIC Pull out the oil dipstick, wipe oil off with a Drain the engine oil while the engine is still clean cloth, insert the dipstick all the way warm. into the engine, then remove it again. The 1) Remove the oil filler cap. oil on the stick should be between the 2) Place a drain pan under the drain plug. upper and lower limits shown on the stick. 3) Using the correct spanner remove the If the oil level indication is near the lower drain plug and drain out the engine oil. limit, add enough oil to raise the level to the upper limit. 9-7 74 844-74E INSPECTION AND MAINTENANCE
w WARNING New and used oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used oil filters away from children and pets. Continuous contact with used engine oil has been found to cause (skin) cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used 844-09-007 844-09-008 oil, wear a long-sleeve shirt and Replace the oil filter Tightening torque: 1.4 kg-m (10.5 lb-ft) moistureproof gloves (such as 1) Using an oil filter wrench, turn the oil dishwashing gloves) when changing filter counterclockwise and remove it. CAUTION oil. If oil contacts your skin, wash 2) Using a clean rag, wipe off the mounting To tighten the oil filter properly, it is thoroughly with soap and water. surface on the engine where the new important to accurately identify the Launder any clothing or rags if wet filter will be seated. position at which the filter gasket with oil. 3) Smear a little engine oil around the first contacts the mounting surface. Recycle or properly dispose of used rubber gasket of the new oil filter. oil and filters. 5) Tighten the filter 3/4 turn from the point 4) Screw on the new filter by hand until the of contact with the mounting surface. [or filter gasket contacts the mounting to 1.4 kg-m (10.5 lb-ft)] using an oil filter 4) Reinstall the drain plug and gasket. surface. Tighten the plug to a torque of wrench. 5.0 kg-m (36.5 lb-ft). CAUTION To prevent oil leakage, make sure that the oil filter is tight, but do not overtighten it.
MARUTI 800 DOMESTIC 75 9-8 INSPECTION AND MAINTENANCE 844-74E
GEAR OIL
Refill with oil and check for leaks. 1) Pour oil through the filler hole and install the filler cap. For the approximate capacity of the oil, refer to the "CAPACITIES" item in the "SPECIFICATIONS" section. 2) Start the engine and look carefully for leaks at the oil filter and drain plug. Run the engine at various speeds for at least 5 minutes. 3) Stop the engine and wait a few minutes. Check the oil level again and add oil if necessary. Check for leaks again. 844-09-009 844-09-010 Specified Manual Transmission oil Gear oil level check CAUTION When adding gear oil, use the appropriate 4-speed transmission When replacing the oil filter, it is viscosity and grade as shown in the chart recommended that you use a genuine below. We highly recommend you use API w WARNING MARUTI replacement filter. GL-4 SAE 80W-90 gear oil. The cooling fan may suddenly start under a certain coolant temperature CAUTION Type of oil Gear oil, API GL-4 condition. When checking the oil level take care to keep hands, clothing, tie, Oil leaks from around the oil filter or scarf etc. away from the cooling fan. drain plug indicate incorrect MARUTI 800DOMESTIC installation or gasket damage. If you To check the gear oil level, use the find any leaks or are not sure that the following procedure: filter has been properly tightened, 1) Park the vehicle on a level surface with have the vehicle inspected by your the parking brake applied. MARUTI SUZUKI dealer. 2) Clean casing around oil level dipstick to remove risk of any loose dirt or debris entering the dipstick hole. Remove the dipstick. 9-9 76 844-74E INSPECTION AND MAINTENANCE
3) Bring face (A) of the oil level dipstick to 4) If the oil level is low, add gear oil face (B) of the transmission case and through the filler plug hole 1 until the check the oil level on the dipstick. If the oil level reaches the bottom of the filler oil level is between FULL level line 1 hole, then reinstall the plug. and LOW level line 2, the oil level is correct. If so reinstall the dipstick. w WARNING 4) If the oil level is low, add gear oil After driving the vehicle, the through the dipstick hole until the oil transmission oil temperature may be level reaches the full level, then reinstall high enough to burn you. Wait until the dipstick. the oil filler plug is cool enough to w WARNING touch with your bare hands before inspecting transmission oil. After driving the vehicle, the transm- 844-09-011 ission oil temperature may be high 5-speed transmission CAUTION enough to burn you. Wait until the oil Oil filler and level plug 1 dipstick is cool enough to touch with Tightening torque: 2.1 kg-m (15.5 lb-ft) When tightening the plug, apply your bare hands before inspecting sealing compound to the plug threads transmission oil. To check the gear oil level, use the to prevent oil leakage. following procedure: CAUTION 1) Park the vehicle on a level surface with Gear oil change the parking brake applied. Since special procedures, materials and • Be sure to add oil exactly to the 2) Clean casing around oil filler plug to tools are required, it is recommended that specified level. Overfilling will result remove risk of any loose dirt or debris you trust this job to your authorized in leakage. entering oil filler plug hole. Remove the MARUTI SUZUKI dealer. • After checking and adding oil, be oil filler plug 1. sure to tighten the dipstick securely. 3) Feel the inside of the hole with your finger. If the oil level comes up to the bottom of the plug hole, the oil level is correct. If so, reinstall the plug.
MARUTI 800 DOMESTIC 77 9-10 INSPECTION AND MAINTENANCE 844-74E
ENGINE COOLANT
Adding Coolant If the Coolant level is below the “LOW” mark, more coolant should be added. Remove the reservoir tank cap and add coolant until the reservoir tank level reaches the “FULL” mark. Never fill the reservoir tank above the “FULL” mark. CAUTION • When adding or replacing coolant, use a high quality ethylene glycol antifreeze and anticorrosion diluted 844-09-012 with distilled water. If the lowest 844-09-013 Coolant Level Check ambient temperature in your area is w WARNING Check the coolant level at the reservoir expected to be -150C (50F) or above, tank, not at the radiator. With the engine make the antifreeze concentration of It is dangerous to remove the radiator cool, the coolant level should be between the mixture you use at least 30% cap when the water temperature is the “FULL” and “LOW” marks. but no more than 50%. If -160C (30F) high, because scalding fluid and or below, make the concentration at steam may be blown out under least 50%. If the 50% concentration pressure. Wait until the coolant does not provide adequate temperature has lowered before protection agains freezing, follow removing the cap. the instructions on the antifreeze MARUTI 800DOMESTIC container to obtain the desired Coolant Replacement freezing point. Since special procedures, materials and tools are required, it is recommended that you trust this job to your authorized MARUTI SUZUKI dealer.
9-11 78 844-74E INSPECTION AND MAINTENANCE
WINDSCREEN WASHER FLUID AIR CLEANER
844-09-014 844-09-015 844-09-016 Check that there is washer fluid in the tank. If the air cleaner is clogged with dust, there Type-2 Take Refill it if necessary. Use a good quality will be greater intake resistance, resulting out the air cleaner case after opening bolt windscreen washer fluid, diluted with water in decreased power output and increased 1 Take out the air cleaner element after as necessary. fuel consumption. unhooking the clamps 2. as shown in the illustration. w WARNING Type-1 Do not use “antifreeze” solution in the Take out the air cleaner case after opening Blow off dust on air cleaner element by 2 3 windscreen washer reservoir. This can bolts and clamp . Take out the air compressed air. If the air cleaner element severely impair visibility when sprayed cleaner element after unhooking the clamps appears to be dirty, replace it with a new 1 on the windscreen, and can also as shown in the illustration. one. damage your vehicle’s paint. CAUTION Damage may result if the washer motor is operated whilst the fluid or fluid nozzles are frozen or with no fluid in the washer tank.
MARUTI 800 DOMESTIC 79 9-12 INSPECTION AND MAINTENANCE 844-74E
SPARK PLUGS
844-09-017 844-09-018 844-09-019 CAUTION You should inspect spark plugs periodically CAUTION for carbon deposits. When carbon
The air cleaner element should be accumulates on a spark plug, a strong V and 1.5 Kg-m (15 N-m, 10.5 lb-ft) for replaced every 40,000 km. More spark may not be produced. Remove F8D engine. Do not allow frequent replacement is necessary carbon deposits with a wire or pin and contaminants to enter the engine when you drive under dusty adjust the spark plug gap. through the spark plug holes when conditions. the plugs are removed. CAUTION • Never use spark plugs with the • When disconnecting the spark plug wrong thread size or length.
cables, pull on the boot, not on the MARUTI 800DOMESTIC cable itself. Pulling on the cable can CAUTION damage it. When replacing spark plugs, you • When installing the spark plugs, should use the brand and type screw them in with your fingers to specified for your vehicle. For the avoid stripping the threads. Tighten specified plugs, refer to the with a torque wrench to 2.5 kg-m “SPECIFICATIONS” section at the end (25 N-m, 18.5 lb-ft). for F8B engineV of this book. 9-13 80 844-74E INSPECTION AND MAINTENANCE
BRAKES
0.8 - 0.9 mm
844-09-020 844-09-022 844-09-023 Note : Brake Fluid If you experience some firing problem of Check the brake fluid level by looking at the spark plugs, such as, hard engine-starting. reservoir in the engine compartment. Check Misfire etc., the cause may be located not that the fluid level is between the “MAX” only on spark plugs but also on deteriorated and “MIN” lines. If the brake fluid level is ignition wiring (generally, used for more than near the “MIN” line, fill it up to the “MAX” 80,000 km or five years). If spark plugline with MARUTI GENUINE brake fluid. replacement does not solve the problem w WARNING have the ignition wiring and other ignition system inspected by your MARUTISUZUKI Failure to follow the guidelines below dealer. can result in personal injury or serious damage to the brake system. 844-09-021 • If the brake fluid in the reservoir drops below a certain level, the brake warning light on the
instrument panel will come on (theV
MARUTI 800 DOMESTIC 81 9-14 INSPECTION AND MAINTENANCE 844-74E
w WARNING NOTE: When measuring the distance between the engine must be running). Should the brake pedal and floor wall, be sure not to light come on, immediately ask your include any floor covering in the MARUTI SUZUKI dealer to inspect measurement. the brake system. • A rapid fluid loss indicates a leak in w WARNING the brake system which should be If you experience any of the following inspected by your MARUTI SUZUKI problems with your vehicle’s brake dealer immediately. system, have the vehicle inspected • Brake fluid can harm your eyes and immediately by your MARUTI SUZUKI damage painted surfaces. Use dealer. caution when refilling the reservoir. 844-09-024 • Poor braking performance w WARNING Brake Pedal • Uneven braking (Brakes not working Check if the brake pedal stops at the uniformly on all wheels.) • Do not use any fluid other than regular height without "spongy" feeling when • Excessive pedal travel MARUTI GENUINE brake fluid. Do not you depress it. If not, have the brake • Brake dragging use reclaimed fluid or fluid that has system inspected by your MARUTI SUZUKI • Excessive noise been stored in old or open dealer. If you doubt the brake pedal for the • Pedal pulsation (Pedal pulsates containers. It is essential that foreign regular height, check it as follows: when depressed.) particles and other liquids are kept out of the brake fluid reservoir. With the engine running, measure the distance between the brake pedal and floor
CAUTION wall when the pedal is depressed with MARUTI 800DOMESTIC approximately 30 kg (66 lbs) of force. The The brake fluid should be replaced minimum distance required is 85 mm (3.4 in). every two years or 20,000 km. Since your vehicle’s brake system is self- adjusting, there is no need for pedal NOTE: adjustment. If the pedal to floor wall distance With disc brakes, the fluid level can be as measured above is less than the minimum expected to gradually fall as the brake pads distance required, have your vehicle inspected wear. by your MARUTI SUZUKI dealer. 9-15 82 844-74E INSPECTION AND MAINTENANCE
STEERING CLUTCH PEDAL
844-09-025 844-09-026 844-09-027 Parking brake Check the play of the steering wheel by Measure the clutch pedal play by moving Check the parking brake for proper gently turning it from left to right and the clutch pedal with your hand and adjustment by counting the number of clicks measuring the distance that it moves before measuring the distance it moves until you made by the ratchet teeth as you slowly pull you feel slight resistance. The play should feel slight resistance. The play in the clutch up on the parking brake lever to the point be between 0 – 30 mm (0.0 – 1.2 in). pedal should be between 15 – 20 mm of full engagement. The parking brake lever (0.6 – 0.8 in). If the play is more or less Check that the steering wheel turns easily should stop between the 3rd and 6th ratchet than the above, or clutch dragging is felt and smoothly without rattling by turning it tooth and the rear wheels should be with the pedal fully depressed, have the all the way to the right and to the left while securely locked. If the parking brake is not clutch inspected by your MARUTI SUZUKI driving very slowly in an open area. If the properly adjusted or the brakes drag after dealer. amount of free play is outside the the lever has been fully released, have the specification or you find anything else to be parking brake inspected and/or adjusted by wrong, an inspection must be performed by your MARUTI SUZUKI dealer. your MARUTI SUZUKI dealer.
MARUTI 800 DOMESTIC 83 9-16 INSPECTION AND MAINTENANCE 844-74E
TYRES
w WARNING • Air pressures should be checked when the tyres are cold or you may get inaccurate readings. • Check the inflation pressure from time to time while inflating the tyre gradually, until the specified pressure is obtained. • Never underinflate or overinflate the tyres. Underinflation can cause unusual 844-09-028 handling characteristics or can 844-09-029 The front and rear tyre pressure cause the rim to slip on the tyre 2) Check that the depth of the tread groove specifications for your vehicle are listed on bead, resulting in an accident or is more than 1.6 mm (0.06 in). To help the Tyre Inflation Pressure Label and in the damage to the tyre or rim. you check this, the tyres have moulded- “SPECIFICATIONS” section at the end of Overinflation can cause the tyre to in tread wear indicators in the grooves. this book. Both the front and rear tyres burst, resulting in personal injury. When the indicators appear on the tread should have the specified tyre pressure. Overinflation can also cause surface, the remaining depth of the tread unusual handling characteristics is 1.6 mm (0.06 in) or less and the tyre Tyre Inspection which may result in an accident. should be replaced. Inspect your vehicle’s tyres periodically by performing the following checks: 3) Check for abnormal wear, cracks and damage. Any tyres with cracks or other MARUTI 800DOMESTIC 1) Measure the air pressure with a tyre damage should be replaced. If any tyres gauge. Adjust the pressure if necessary. show abnormal wear, have them inspected by your MARUTI SUZUKI dealer.
9-17 84 844-74E INSPECTION AND MAINTENANCE
w WARNING w WARNING Hitting curbs and running over rocks Replacing the wheels and tyres can damage tyres and affect wheel equipped on your vehicle with certain alignment. Be sure to have tyres and combinations of aftermarket wheels wheel alignment checked periodically and tyres can significantly change the by your MARUTI SUZUKI dealer. steering and handling characteristics of your vehicle. Therefore, use only 4) Check for loose wheel nuts. those wheel and tyre combinations 5) Check that there are no nails, stones, approved by MARUTI SUZUKI as or other objects sticking into the tyres. standard or optional equipment for your vehicle. w WARNING 844-09-030 Your MARUTI SUZUKI is equipped CAUTION Tyre Rotation with tyres which are all the same type Replacing the original tyres with tyres To avoid uneven wear of your tyres and to and size. This is important to ensure of a different size may result in false prolong their life, rotate the tyres as proper steering and handling of the speedometer or odometer readings. illustrated. Tyres should be rotated as vehicle. Never mix tyres of different recommended in the periodic maintenance size or type on the four wheels of schedule. After rotation, adjust front and rear your vehicle. The size and type of tyre pressures to the specification listed on tyres used should be only those your vehicle’s Tyre Inflation Pressure Label. approved by MARUTI SUZUKI as standard or optional equipment for Wheel Balancing your vehicle. If the vehicle vibrates abnormally on smooth road, have the wheels balanced at Maruti Suzuki authorized workshop. Wheel Alignment In case of abnormal tyre wear or pulling towards one side, have the wheel aligned at Maruti Suzuki authorized workshop.
MARUTI 800 DOMESTIC 85 9-18 INSPECTION AND MAINTENANCE 844-74E
844-09-031 844-09-032 844-09-033 Changing Wheels 5) Before installing the new wheel, clean 7) Lower the jack and fully tighten the nuts To change a wheel, use the following any mud or dirt off from the surface of [4.0 – 7.0 kg-m (28.9 – 50.5 lb-ft)] in a procedure: the wheel and hub with a clean cloth. crisscross fashion with a wrench as Clean the hub carefully; it may be hot shown in the illustration. 1) Remove the jack , tools and spare wheel from driving. from the vehicle w 6) Install the new wheel and replace the WARNING 2) Loosen, but do not remove the wheel wheel nuts with their cone shaped end Use MARUTI Genuine wheel nuts and nuts. facing the wheel. Tighten each nut tighten them to the specified torque 3) Jack up the vehicle (follow the jacking snugly by hand until the wheel is as soon as possible after changing instructions in the EMERGENCY securely seated on the hub. wheels. Incorrect wheel nuts or MARUTI 800DOMESTIC SERVICE section in this manual) improperly tightened wheel nuts may come loose or fall off, which can 4) Remove the wheel nuts and wheel. result in an accident. If you do not have a torque wrench, have the wheel nut torque checked by a MARUTI SUZUKI authorized dealer.
9-19 86 844-74E INSPECTION AND MAINTENANCE
BATTERY FUSES
w WARNING To avoid harm to yourself or damage to your vehicle or battery, follow the jump starting instructions in the EMERGENCY SERVICE section of this manual if it is necessary to jump start your vehicle.
The level of the battery solution must be kept between the “MAX” and the “MIN” level lines at all times. If the level is found to be 844-09-034 below the “MIN” level line, add distilled 844-09-035 water to the “MAX” level line. You should w WARNING This vehicle has two types of fuses, as periodically check the battery, battery described below : Batteries produce flammable hydrogen terminals, and battery hold-down bracket for gas. Keep flames and sparks away corrosion. Remove corrosion using a stiff Main Fuse (fusible link) - The main fuse from the battery or an explosion may brush and ammonia mixed with water, or takes current directly from the battery. occur. Never smoke when working in baking soda mixed with water. After Individual Fuses - These fuses are in the the vicinity of the battery . removing corrosion, rinse with clean water. fuse box and for individual electrical circuits. If your vehicle is not going to be driven for w Main Fuse (fusible link) WARNING a month or longer, disconnect the cable The main fuse is located on the positive When checking or servicing the from the negative terminal of the battery to terminal of battery in the engine battery, disconnect the negative cable. help prevent discharge. compartment. If the main fuse blows, no Be careful not to cause a short circuit electrical component will function. When by allowing metal objects to contact replacing the main fuse, use a MARUTI the battery posts and the vehicle at genuine replacement. the same time.
MARUTI 800 DOMESTIC 87 9-20 INSPECTION AND MAINTENANCE 844-74E
844-09-036 844-09-037 844-09-038 w WARNING To remove a fuse, hook the fuse with the NOTE: end hook on the fuse box cover, and pull Make sure that the fuse box always carries If the main fuse blows, be sure to out the fuse. two spare fuses. have your vehicle inspected by an authorized MARUTI SUZUKI dealer. w WARNING Always use a genuine MARUTI Always be sure to replace a blown replacement. Never use a substitute fuse with a fuse of the correct such as a wire even for a temporary amperage. Never use a substitute repair, or extensive electrical damage such as aluminum foil or wire to and a fire can result. replace a blown fuse. If you replace MARUTI 800DOMESTIC Fuse Box a fuse and the new one blows in a The fuse fox is located under the driver’s short period of time, you may have a side of the dashboard. Remove the fuse major electrical problem. Have your box cover by pushing in at both ends and vehicle inspected immediately by your pulling off the cover. To identify the MARUTI SUZUKI dealer. amperage and location, refer to the fuse list shown on the back of the fuse box cover. 9-21 88 844-74E INSPECTION AND MAINTENANCE
BULB REPLACEMENT
w WARNING • Light bulbs can be hot enough to burn your finger right after being turned off. This is true especially for halogen headlight bulbs. Replace the bulbs after they become cool enough. • The headlight bulbs are filled with pressurized halogen gas. They can burst and injure you if they are hit or dropped. Handle them carefully.
844-09-039 844-09-041 CAUTION Interior Light The oils from your skin may cause a Pull down on the rear part of lens to halogen bulb to overheat and burst remove. To install it, hook its front end in when the lights are on. Grasp a new and push it up. bulb with a clean cloth. The bulb can be removed by simply pulling it out. When replacing the bulb, make sure that the contact springs are holding the bulb CAUTION securely. Frequent replacement of a bulb indicates the need for an inspection of the electrical system. This should be carried out by your MARUTI SUZUKI 844-09-040 dealer.
MARUTI 800 DOMESTIC 89 9-22 INSPECTION AND MAINTENANCE 844-74E
844-09-042 844-09-043 844-09-044 Headlights Front Clearance/Turn Signal Light, Side To remove a round bulb from a bulb holder, Open the bonnet. Remove the socket and Turn Signal Light, rear Combination push in the bulb and turn it counter rubber cover. Then unhook the bulb holding Light, Registration Plate Light. clockwise. To install a new bulb, push it in spring and replace the bulb. To remove a bulb holder from a light and turn it clockwise. You can access the housing, turn the holder counterclockwise individual bulb holders as described below: NOTE: and pull it out. To install the holder, push Your vehicle is provided with two spare the holder in and turn it clockwise. headlight bulbs for replacement in Two types (small oval and round) of bulb emergency. are used for these lights. To remove and
install a small oval bulb, simply pull out or MARUTI 800DOMESTIC CAUTION push in the bulb. After bulb replacement, ensure rubber cover fitment by aligning 'TOP' marking with upperside of headlamp. If not properly fitted may lead to water entry in headlamp.
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844-09-045 844-09-046 844-09-048 Front clearance light Rear combination light (tail, stop, turn Open the bonnet and support it with the signal, etc.) prop rod. Undo the screws that secure the housing Front turn signal light and remove the housing. Undo the two screws and remove the lens. Side turn signal light Remove the lens by using a plain screw driver covered with a soft cloth.
844-09-047
MARUTI 800 DOMESTIC 91 9-24 INSPECTION AND MAINTENANCE 844-74E
WIPER BLADES
844-09-049 844-09-050 Registration plate light If the wiper blades become brittle or CAUTION Undo the two screws and remove the light damaged, or make streaks when wiping, housing. replace the wiper blades. The left and the right wiper arm assemblies are different from each CAUTION other. In case you have to remove the To avoid scratching or breaking the wiper arm assemblies for any reason, remember not to interchange the two window, do not let the wiper arm strike the windshield while replacing while fitting them back. Wrong fitment the wiper blade. may lead to windshield breakage. MARUTI 800DOMESTIC
9-25 92 844-74E EMERGENCY SERVICE
EMERGENCY SERVICE
Jacking Instructions ...... 10-1 Jump Starting Instructions ...... 10-2 Towing ...... 10-4 Emergency Remedies ...... 10-4 Warning triangle ...... 10-5
10
MARUTI 800 DOMESTIC 93 EMERGENCY SERVICE 844-74E
JACKING INSTRUCTIONS
844-10-001 844-10-002 1) Park the vehicle securely on hard level CAUTION w WARNING ground. 2) Choke the front and rear wheel Do not put the jack head on to the • Use the jack only to change wheels. diagonally opposite the wheel to be lateral rod (if equipped), or the lateral • Never jack up the vehicle on an changed. rod will be damaged. inclined surface. 3) Switch on the hazard warning flasher if • Never raise the vehicle with the jack your vehicle is in or near traffic. 6) Continue to raise the jack slowly and in a location other than the place 4) Slacken but do not remove wheel nuts smoothly until the tyre clears the ground. specified in the illustration near the on the wheel to be changed. Do not raise the vehicle more than wheel to be changed.
5) Position the jack vertically and raise the necessary. • Make sure that the jack is raised at MARUTI 800DOMESTIC jack by turning the jack handle clockwise least 2 inches (51 mm) before it until the jack head fits the front contacts the vehicle. Use of the jack suspension arm or the rear axle as when it is within 2 inches of being shown overleaf. fully collapsed may result in failure V of the jack.
10-1 94 844-74E EMERGENCY SERVICE
JUMP STARTING INSTRUCTIONS
w WARNING • Never attempt to jump start your vehicle if the battery appears to be frozen. Batteries in this condition may explode or rupture if jump starting is attempted. • When making jump lead connections, be certain that your hands and the jump leads remain clear from pulleys, belts, or fans. • Batteries produce flammable 844-10-003 844-10-004 hydrogen gas. Keep flames and sparks away from the battery or an w WARNING explosion may occur. Never smoke when working in the vicinity of the V • Never get under the vehicle when it battery. is supported by the jack. • If the booster battery you use for • Never run the engine when the jump starting is installed in another vehicle is supported by the jack and vehicle, make sure the two vehicles never allow passengers to remain in are not touching each other. the vehicle. • If your battery discharges repeatedly, for no apparent reason, have your vehicle inspected by an
authorized MARUTI SUZUKI dealer.V
MARUTI 800 DOMESTIC 95 10-2 EMERGENCY SERVICE 844-74E
w WARNING 3) Make jump lead connections as follows: a) Connect one end of the first jump •V To avoid harm to yourself or lead to the positive (+) terminal of the damage to your vehicle or battery, flat battery. follow the jump starting instructions b) Connect the other end to the positive below precisely and in order. If you (+) terminal of the booster battery. are in doubt, call for qualified road c) Connect one end of the second jump service. lead to the negative (-) terminal of the booster battery. CAUTION d) Make the final connection to an unpainted, heavy metal part of the • Vehicle equipped with electronic fuel engine of the vehicle with the flat injection system will not start by 844-10-005 battery. pushing or towing as the fuel pump When jump starting your vehicle, use the will not work in this condition. This following procedure: w WARNING starting method could also result in 1) Use only a 12 volt battery to jump start Never connect the jump lead directly permanent damage to the catalytic your vehicle. Position the good 12V to the negative (-) terminal of the converter. Use jump leads to start battery close to your vehicle so that the discharged battery, or an explosion a vehicle with a weak or flat battery. jump leads will reach both batteries. may occur. When using a battery installed on another vehicle, DO NOT LET THE 4) If the booster battery you are using is VEHICLES TOUCH. Apply the parking fitted to another vehicle, start the engine
brakes fully on both vehicles. MARUTI 800DOMESTIC of the vehicle with the booster battery. 2) Turn off all vehicle accessories, except Run the engine at moderate speed. those necessary for safety reasons (for 5) Start the engine of the vehicle with the example, headlights or hazard lights). flat battery. 6) Remove the jump leads in the exact reverse order in which you connected them.
10-3 96 844-74E EMERGENCY SERVICE
TOWING EMERGENCY REMEDIES
If you need to have your vehicle towed, If the Starter Does Not Operate: If the Engine Overheats contact a professional service. 1) Try turning the ignition switch to the The engine could overheat temporarily under “START” position with the headlights severe driving conditions. If the engine CAUTION turned on to determine the battery coolant temperature gauge indicates To help avoid damage to your vehicle condition. If the headlights go overheating during driving: excessively dim or go off, it usually during towing, proper equipment and 1) Turn off the air conditioner, if equipped. towing procedures must be used. means that either the battery is flat or the battery terminal contact is poor. 2) Take the vehicle to a safe place and Manual Transmission Recharge the battery or correct battery park. terminal contact as necessary. Whenever possible, your vehicle should be 3) Let the engine run at normal idle speed towed from the front with the front wheels 2) If the headlights remain bright, check the for a few minutes until the indicator is lifted. Before towing, make sure the steering fuses. If the reason for failure of the within the normal, acceptable is unlocked and the transmission is in starter is not obvious, there may be a temperature range between “H” and “C”. neutral. major electrical problem. Have the vehicle inspected by your authorized w WARNING MARUTI SUZUKI dealer. If you see or hear escaping steam, If the Engine is Flooded stop the vehicle in a safe place and If the engine is flooded with petrol, it may immediately turn off the engine to let be hard to start. If this happens, press the it cool. Do not open the bonnet when accelerator pedal all the way to the floor steam is present. When the steam can and hold it there while cranking the engine. no longer be seen or heard, open the (Do not operate the starter motor for more hood to see if the coolant is still than 15 seconds). Release the accelerator boiling. If it is, you must wait until it as soon as the engine has started. stops boiling before you proceed.
MARUTI 800 DOMESTIC 97 10-4 EMERGENCY SERVICE 844-74E
WARNING TRIANGLE
If the temperature indication does not come down to within the normal, acceptable range: 1) Turn off the engine and check that the water pump belt and pulleys are not damaged or slipping. If any abnormality is found, correct it. 2) Check the coolant level in the reservoir. 1 If it is found to be lower than the “LOW” line, look for leaks at the radiator, water pump, and radiator and heater hoses. If you locate any leaks that may have 844-10-006 844-10-007 caused the overheating, do not run the w WARNING In case of vehicle break-down or during engine until these problems have been emergency stopping, where, your vehicle corrected. It is dangerous to remove the radiator could become a potential traffic hazard, 3) If you do not find a leak, carefully add cap when the water temperature is keep the warning triangle, provided with coolant to the reservoir and then the high, because scalding fluid and your vehicle, on the road free from any radiator, if necessary. (Refer to “ENGINE steam may be blown out under obstacles behind your vehicle so as to warn COOLANT” in the “INSPECTION AND pressure. The cap should only be the approaching traffic, at an approximate MAINTENANCE” section.) taken off when the coolant distance of 50-100 m. The reflecting side temperature has lowered. of the triangle should face the on coming
traffic. Please activate the hazard warning MARUTI 800DOMESTIC w lamps before alighting the vehicle to keep WARNING the warning triangle. To help prevent personal injury, keep hands, tools and clothing away from the engine cooling fan and air- conditioner fan (if equipped). These electric fans can automatically turn on without warning. 10-5 98 844-74E EMERGENCY SERVICE
844-10-008 844-10-009 ● Remove the warning triangle carefully from the box as shown by arrow 1. ● Open both the reflector arms as shown by arrow and lock the arms with each other with the clip provided in the right arm. Open the botton stand in counter clock-wise direction as shown by arrow 3. Position the warning triangle behind the vehicle on a plain surface. ● Reverse the removal procedure for keeping inside the box.
MARUTI 800 DOMESTIC 99 10-6 844-74E
MEMO
100 844-74E BODY WORK CARE
BODY WORK CARE
Corrosion Prevention ...... 11-1 Vehicle Cleaning ...... 11-2
11
MARUTI 800 DOMESTIC 101 BODY WORK CARE 844-74E
CORROSION PREVENTION
It is important to take good care of your accelerated rate of corrosion to parts of Remove these types of deposits as quickly vehicle to protect it from corrosion. the vehicle which are not well ventilated as possible. If these deposits are difficult to Listed below are instructions for how to to permit quick drying. wash off, an additional cleaner may be maintain your vehicle to prevent corrosion. This information illustrates the necessity of required. Be sure that any cleaner you use Please read and follow these instructions keeping your vehicle (particularly the is not harmful to painted surfaces and is carefully. underbody) as clean and dry as possible. specifically intended for your purposes. It is equally important to repair any damage Follow the manufacturer’s directions when Important Information About Corrosion to the paint or protective coatings as soon using these special cleaners. Common causes of corrosion as possible. Repair finish damage 1) Accumulation of road salt, dirt, moisture, Carefully examine your vehicle for damage or chemicals in hard to reach areas of How to Help Prevent Corrosion the vehicle underbody or frame. Wash your vehicle frequently to the painted surfaces. Should you find any chips or scratches in the paint, touch them 2) Chipping, scratches and any damage to The best way to preserve the finish on your up immediately to prevent corrosion from treated or painted metal surfaces vehicle and to help avoid corrosion is to resulting from minor accidents or keep it clean with frequent washing. starting. If the chips or scratches have gone through to the bare metal, have a qualified abrasion by stones and gravel. Wash your vehicle regularly during the body shop make the repair. Environmental conditions which winter and immediately after the winter. accelerate corrosion Keep your vehicle, particularly the Keep Passenger and luggage compar- 1) Road salt, dust control chemicals, sea underside, as clean and dry as possible. tments clean. air or industrial pollution will all If you frequently drive on salted roads, your Moisture, dirt or mud can accumulate under accelerate the corrosion of metal. vehicle should be washed at least once a the floor mats and may cause corrosion. 2) High humidity will increase the rate of month during the winter. If you live near the Occasionally, check under these mats to corrosion particularly when the ocean, your vehicle should be washed at ensure that this area is clean and dry. More MARUTI 800DOMESTIC temperature range is just above the least once a month throughout the year. frequent checks are necessary if the vehicle freezing point. For washing instructions, refer to the is used off road or in wet weather. 3) Moisture in certain areas of a vehicle for “VEHICLE CLEANING” section. Certain cargos such as chemicals, fertilizers, an extended period of time may promote Remove foreign material deposits cleaners, salts, etc., are extremely corrosive corrosion even though other body Foreign material such as salts, chemicals, by nature. These products should be sections may be completely dry. road oil or tar, tree sap, bird droppings and transported in sealed containers. If a spill 4) High temperatures will cause an industrial fall-out may damage the finish of or leak does occur, clean and dry the area your vehicle if it is left on painted surfaces. immediately. 11-1 102 844-74E BODY WORK CARE
VEHICLE CLEANING
Store your vehicle in a dry, well- w WARNING cleaner for tougher stains. If you use a ventilated area. fabric cleaner, carefully follow the Do not park your vehicle in a damp, poorly When cleaning the interior or exterior manufacturer’s instructions and precautions. ventilated area. If you often wash your of the vehicle, NEVER USE flammable Seat Belts vehicle in the garage or if you frequently solvents such as lacquer thinners, Clean seat belts with a mild soap and drive it in when wet, your garage may be petrol, benzene or cleaning materials water. Do not use bleach or dye on the damp. The high humidity in the garage may such as bleach or strong household belts. They may weaken the fabric in the cause or accelerate corrosion. A wet vehicle detergents. The materials could cause belts. may corrode even in a heated garage if the personal injury or damage to the ventilation is poor. vehicle. Vinyl floor mats w Ordinary dirt can be removed from vinyl with WARNING Cleaning the Interior water or mild soap. Use a brush to help Do not apply additional undercoating Vinyl upholstery loosen dirt. After the dirt is loosened, rinse or rust preventive coating on or Prepare a solution of soap or mild detergent the mat thoroughly with water and dry it in around exhaust system components mixed with warm water. Apply the solution the shade. such as the exhaust pipes, etc. A fire to the vinyl with a sponge or soft cloth and Carpets could be started if the undercoating let it soak for a few minutes to loosen dirt. Remove dirt and soil as much as possible substance becomes overheated. Rub the surface with a clean, damp cloth with a vacuum cleaner. Using a mild soap to remove dirt and the soap solution. If solution, rub stained areas with a clean Cover your vehicle some dirt still remains on the surface, damp cloth. To remove soap, rub the areas If you cannot regularly park your vehicle in repeat this procedure. again with a cloth dampened with water. a garage, we recommend you use a vehicle Repeat this until the stain is removed, or cover. Years of exposure to midday sun can Fabric upholstery Remove loose dirt with a vacuum cleaner. use a commercial carpet cleaner for tougher cause the colours in paint, plastic parts, and stains. If you use a carpet cleaner, carefully fabrics to fade. Covering your vehicle with Using a mild soap solution, rub stained areas with a clean damp cloth. To remove follow the manufacturer’s instructions and a high-quality, “breathable” vehicle cover can precautions. help protect the finish from the harmful UV soap, rub the areas again with a cloth rays in sunlight, and can reduce the amount dampened with water. Repeat this until the of dust and air pollution reaching the stain is removed, or use a commercial fabric surface.
MARUTI 800 DOMESTIC 103 11-2 BODY WORK CARE 844-74E
Cleaning the Exterior When washing the vehicle, follow the 4) Once the dirt has been completely instructions below: removed, rinse off the detergent with CAUTION 1) Flush the underside of body and wheel running water. It is important that your vehicle be housings with pressurized water to 5) After rinsing, wipe off the vehicle body kept clean and free from dirt. Failure remove mud and debris. Use plenty of with a wet chamois or cloth and allow to keep your vehicle clean may result water. it to dry in the shade. in fading of the paint or corrosion to 6) Check carefully for damage to painted various parts of the vehicle body. CAUTION surfaces. If there is any damage, “Touchup” the damage following the When washing the vehicle, avoid procedure below: Washing directing steam or hot water of more than 800C (1760F) on plastic parts. a) Clean all damaged spots and allow w WARNING them to dry. • Never attempt to wash and wax your 2) Remove dirt and mud from the body b) Stir the paint and “touchup” the vehicle with the engine running. exterior with running water. You may use damaged spots lightly using a small • When cleaning the underside of the a soft sponge or brush. Do not use hard brush. body and fender, where there may materials which can scratch the paint. c) Allow the paint to dry completely. be sharp-edged parts, you should 3) Wash the entire exterior with a mild Waxing wear gloves and a longsleeved shirt detergent or car wash soap using a After washing the vehicle, waxing and to protect your hands and arms sponge or soft cloth. The sponge or polishing are recommended to further from being cut. cloth should be frequently soaked in the protect and beautify the paint. • After washing your vehicle, carefully soap solution. • Only use waxes and polishes of good test the brakes before driving to quality. make sure they have maintained CAUTION • When using waxes and polishes, MARUTI 800DOMESTIC their normal effectiveness. When using a commercial car wash observe the precautions specified by the product, observe the cautions manufacturers. specified by the manufacturer. Never use strong household detergents or soaps.
11-3 104 844-74E GENERAL INFORMATION
GENERAL INFORMATION
Vehicle Identification ...... 12-1
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MARUTI 800 DOMESTIC 105 GENERAL INFORMATION 844-74E
VEHICLE IDENTIFICATION
844-12-001 844-12-002 Chassis Serial Number Engine Serial Number The chassis and/or engine serial numbers The engine serial number is stamped on the are used to register the vehicle. They are cylinder block as shown in the illustration also used to assist your dealer when and also on the identification plate. ordering or referring to special service information. Whenever you have occasion to consult your MARUTI SUZUKI dealer, remember to identify your vehicle with this number. Should you find the number difficult
to read, you will also find it on the MARUTI 800DOMESTIC identification plate.
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FOR LPG KIT FITTED VEHICLE (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 ...... 13-7 Petrol 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
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MARUTI 800 DOMESTIC 107 LIQUID PETROLEUM GAS (LPG) 844-74E
LOCATION OF LPG SYSTEM AND MAJOR COMPONENTS
SIDE VIEW MARUTI 800DOMESTIC 1. LPG Switch 7. Pressure Regulator 13 LPG Ventilation Hose 2. LPG Controller 8. High Pressure pipe joint 14. LPG Ventilation Duct 3. LPG Filter cum Solenoid Valve 9. Filler Valve 15. High Pressure Pipe 4. Stepper Motor 10. Multivalve 16. Wiring Harness 5. Low Pressure Hose 11. Gas Tight Housing 17. LPG Filling Pipe 6. Coolant Hose 12. LPG Tank
13-1 108 844-74E LIQUID PETROLEUM GAS (LPG)
INTRODUCTION TO LPG SAFETY PRECAUTIONS (Do's)
LPG is a clean, high octane and eco-friendly CAUTION • Please check the position of the selector fuel. It is basically a mixture of Butane and switch before starting the vehicle. Propane and is obtained from Natural Gas In case of any symptom of leakage (or • Always maintain some amount of petrol Fractionation and Crude Oil Refining. LPG releasing noise) of LPG, do not panic. in petrol tank. is a gas at atmospheric pressure, but can • Stop the vehicle and switch off the • Always start the vehicle in Auto or petrol be liquified when moderate pressure is engine, roll down the windows and mode. applied or when the temperature is open all the doors. • If engine does not start in Forced LPG sufficiently reduced. LPG produces less • Ensure to close Manual shut off mode, start in Petrol mode and get the harmful exhaust gases as compared to valve on the Multivalve. vehicle inspected by Maruti Suzuki petrol and diesel. • The closure of manual shut off authorized workshop. knob on the multivalve will ensure • Ensure that the Gas Tank Cover (plastic) that the vehicle does not start in is always in closed position and not LPG mode even by accident. damaged. Replace the same as soon as • Contact your Maruti Suzuki damage is noticed. authorized work shop for further • Ensure that conduit pipes are always in assistance. good condition and secured firmly. • You can drive the vehicle normally Replace in case damage is noticed. in petrol mode till the leakage is • Always repair your vehicle at Maruti repaired. Suzuki authorized workshop only. • Get the auto LPG cylinder checked for CAUTION every 5 years at Maruti Suzuki authorized workshop. DO NOT USE DOMESTIC LPG IN YOUR • If any minor work, body repair or welding VEHICLE is to be carried out, ensure to close Manual shut off valve on the multivalve. Then remove the Auto LPG cylinder from the vehicle.
MARUTI 800 DOMESTIC 109 13-2 LIQUID PETROLEUM GAS (LPG) 844-74E
SAFETY PRECAUTIONS (Dont's)
• It is recommended to run the vehicle on • Do not use Domestic LPG in your Note : Always maintain some amount of Petrol for 5-10 Kilometers after every vehicle. petrol in petrol tank 300-500 Kilometers run in LPG mode to • Never install any other gas cylinder in keep the fuel system in good condition. place of LPG. • In case of any symptom of LPG leakage: • Never install CNG or any other gas 1. Stop the vehicle and switch off the cylinder in place of LPG. Engine. • Never adjust setting of the LPG System. 2. Ensure to close Manual Shut-Off • The Auto LPG cylinder should never be valve which is located on the repaired under any circumstances, multivalve assembly on the LPG incase of any problem, consult with cylinder. Maruti Suzuki authorized workshop. 3. Do not run the vehicle in LPG • Never carry inflammable material near mode. Auto LPG cylinder. 4. Call the nearest Maruti Suzuki • Never handle LPG system components. authorized workshop for assistance. In case of replacement of any Note: It is recommended to carry two component, always contact Maruti Suzuki numbers of government certified dry powder authorized workshop. fire extinguisher (1 Kg. each) in your • Avoid frequent change over from LPG mode to petrol mode and petrol mode vehicle. to LPG mode to avoid engine missing and back fire. • Do not try to fill more then 19 Ltrs of LPG. MARUTI 800DOMESTIC
13-3 110 844-74E LIQUID PETROLEUM GAS (LPG)
VEHICLE STARTING MODES MANUAL SHUT OFF VALVE LPG LEVEL INDICATOR
1 Orange LED - Petrol 2 LPG Changeover switch 3 Green LED - LPG 4 Level Indicators
Selector switch is installed on the Manual shut off valve (A) is located on LED for indicating LPG quantity in the dashboard, on the right hand side of the Multivalve, mounted on the Auto LPG cylinder is installed on the dashboard, on steering wheel. One can choose the type cylinder. The valve should always be in the right-hand side of steering wheel. Auto of mode by gentle push on the switch (2). open position to allow the flow of LPG to LPG cylinder also houses a level indicator This switch has three modes i.e. Auto, engine. In the close position, LPG supply on the Multivalve. All four green LED (4) will Petrol and Forced LPG. Each mode is to the engine is stopped. The shut off valve glow when the tank is filled to 80% of the indicated by LED (light) on the switch. must be closed in case of any repair in the maximum capacity. With reducing level of In Ignition switch “ON” condition, before cylinder or any symptoms of LPG leakage. LPG in the tank, number of LED (lights) cranking the engine, if : TURN CLOCKWISE - CLOSE glowing will reduce. RED LED (5) glows, when LPG in the tank GREEN light (3) blinking & ORANGE TURN ANTICLOCKWISE - OPEN light (1) glowing - indicates Auto mode is in reserve condition. LPG refilling should be done in this condition, immediatly. Do not ORANGE light (1) glowing - indicates run the vehicle till the fuel tank is completly PETROL mode empty. GREEN light (3) Glowing - indicates Note : Numbers of LEDs (Green) glowing Forced LPG mode is only indicative display of residual LPG.
MARUTI 800 DOMESTIC 111 13-4 LIQUID PETROLEUM GAS (LPG) 844-74E
STARTING MODES OF THE VEHICLE
Auto Mode Petrol Mode
Auto Mode : Vehicle when started in auto Note : It is recommended to start the Petrol Mode : Vehicle can be started in mode will get started in Petrol with GREEN vehicle in Auto mode/Petrol mode. Petrol mode with ignition switch ON and light (3) blinking & ORANGE light (1) glows selecting Petrol Mode by gently pressing the Note: In auto mode engine will start with until coolant temperature and engine RPM mode selector switch (2) till ORANGE LED petrol. Engine will switch to LPG reaches certain predefined value and then (1) glows. At this stage vehicle will start and automatically the system will automatically shift to LPG In warmed up condition,o changeover from run on petrol only. reaches around when 40C. coolant temperature mode (during deceleration). At this stage the petrol to LPG will happen after around 5 When the vehicle is running in LPG mode, GREEN LED (3) will start glowing seconds of starting the engine. it can be shifted to petrol mode by pressing continuously, which indicate that the vehicle the mode switch (2). At this stage ORANGE is running in LPG. LED (1) will start glowing and the vehicle MARUTI 800DOMESTIC will start running in petrol mode. At this stage no green LED will glow. Note : If the vehicle is switched OFF in Petrol mode, then next time it will start in Petrol mode only.
13-5 112 844-74E LIQUID PETROLEUM GAS (LPG)
SPARE WHEEL LOCATION SPARE WHEEL REMOVAL PROCEDURE Forced LPG Mode
Forced LPG Mode : In case of emergency, Spare wheel is mounted on the LPG tank To remove the spare wheel, unscrew spare vehicle can be started in Forced LPG mode and secured tightly with the help of spare wheel screw in anti-clockwise direction using with ignition switch ON and pressing the wheel screw. wheel wrench as show in the figure. mode selector switch (2) for more then 8 Reverse the above procedure for fitting the seconds till the GREEN LED (3) & (4) glows spare wheel. continuously. At this stage the LED's (4) will continuously glow, indicating the quantity of Note : During fitment of spare wheel, LPG in the cylinder. position of the air filler nozzle should be facing upward and towards rear seat. CAUTION It is not recommended to start the vehicle in Forced LPG mode unless there is no petrol in the vehicle
Note: In forced LPG mode, vehicle will not switch to Auto/Petrol mode. In case you want to changeover, switch OFF and start vehicle in required mode. MARUTI 800 DOMESTIC 113 13-6 LIQUID PETROLEUM GAS (LPG) 844-74E
LPG FILLING PETROL TANK CAPACITY PERIODIC MAINTENANCE SCHEDULE
Note : The interval should be judged by odometer reading. Over and above the PETROL TANK regular maintenance schedule described in LID the main owner's manual (supplied with the vehicle) following has to be checked only by Maruti Suzuki authorized workshop. Check Auto LPG cylinder every five years at Maruti Suzuki authorized workshop. For periodic maintenance refer next page.
LPG filler Valve (1) is installed on left hand Your vehicle is fitted with petrol tank of 28 side of your vehicle. LPG Filling will stop litres capacity. automatically once cylinder is filled upto Note : The tank should always have 80% of the capacity. The cylinder fitted in sufficient quantity of petrol. your vehicle is of 24 liters water capacity. When filling an empty cylinder, it is advised to fill maximum 19 liters of LPG in the tank of your vehicle. Incase, filling is being done after removal and/or fitment of Auto LPG
cylinder, have the joints checked for LPG MARUTI 800DOMESTIC leakage by applying soap solution on all the joints. CAUTION Do not fill more than 19 liters of LPG in tank.
13-7 114 844-74E LIQUID PETROLEUM GAS (LPG)
PERIODIC MAINTENANCE SCHEDULE FOR LPG KIT PARTS
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 IIIIIIII LPG Filter with ‘O’ rings C C R R R RRRRRRR Gas Solenoid Valve Plunger - - C C C C I C C C C C Coolant Hoses (Leakage,Damage) I I I I IIIIIIII 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, TT TTTTTTTTTT Solenoid Valve. Idle RPM, Idle CO/HC, Idle screw setting II IIIIIIIIII in Gas mode Ignition Wiring (Damage, Deterioration) I - I I IIIIIIII Spark plugs (Clean & Adjust the Gap) I - I R I R I R I R I R Tappet Clearance - I I I IIIIIIII
T...... Tighten to specified torque. I...... Inspect and correct or replace if necessary. C...... Clean R...... Replace
MARUTI 800 DOMESTIC 115 13-8 LIQUID PETROLEUM GAS (LPG) 844-74E
MAINTENANCE (FUSE) LPG KIT IDENTIFICATION
The LPG system is protected against short w WARNING LPG kit Identification plate (1) is located circuit / overload using fuse (5A) fitted in above the LPG Filler valve. the fuse box under the driver's side of the Always be sure to replace a blown dashboard as shown in the figure. The fuse with the fuse of correct changing of fuse should be only done at amperage. Never use a substitute Maruti Suzuki Authorized Workshop.5 such as aluminium foil or wire to Ampere Fuse: When this fuse blows off, replace a blown fuse. If you replace following symptoms may be observed. a fuse and the new fuse blows in a • All LED's on the switch will go off. short period of time, have your vehicle
• If vehicle is running in LPG mode and inspected immediately by your Maruti MARUTI 800DOMESTIC the fuse blows off, the system may Suzuki authorized workshop. shutdown at lower RPM and/ or may shift to Petrol mode at higher RPM. • In this case vehicle can be started again in petrol mode only.
13-9 116 844-74E LIQUID PETROLEUM GAS (LPG)
SCRAPPING OF LPG TANKS AFTER EXPIRY DATE After emptying and purging of the tank it should be rendered unsuitable for further LPG service by : 1 Mechanical crushing 2 Piercing holes 3 Cutting the body into two or more pieces 4 For mechanical crushing & piercing only pneumatic or hydraulic power should be used but not electrical tools 5 Once scrapped the parts may be recycled through the recycling/waste disposal system.
Note : Expiry date is mentioned on the LPG Tank of your vehicle.
MARUTI 800 DOMESTIC 117 13-10 844-74E
MEMO
118 844-74E SPECIFICATIONS
SPECIFICATIONS
NOTE: Specifications are subject to change without notice.
DIMENSIONS UNIT:mm
Overall length 3335 Overall width 1440 Overall height 1405 Wheelbase 2175 Tread front 1215 rear 1200 Ground clearance 170
MASS (WEIGHT) UNIT:Kg Petrol LPG
Kerb mass (weight) WITH A/C WITHOUT A/C WITH A/C WITHOUT A/C 665 650 700 683 Gross vehicle mass (weight) rating 1000 1000 1000 1000 Seating Capacity 4 Person 4 Person 4 Person 4 Person
ENGINE Type F8B - Four-stroke cycle, 6 Valve, water cooled (SOHC) or F8D - Four-stroke cycle, 12 Valve, water cooled (SOHC) Number of cylinders 3 Bore 68.5 mm Stroke 72.0 mm Piston displacement 796 cm3 Compression ratio 8.8 ± 0.2:1 14
MARUTI 800 DOMESTIC 119 SPECIFICATIONS 844-74E
ELECTRICAL Standard spark plug F8B CHAMPOIN - RN10YC, MICO - WR8DC F8D ...... NGK -- DCPR7E Battery 38B20R (28AH/5HR) Fuses See “INSPECTION AND MAINTENANCE” section Headlight 12V 60/55W Turn signal light 12V 21W Side turn signal light 12V 5W Clearance light 12V 5W Tail/brake light 12V 5/21W Registration plate light 12V 5W Reversing light 12V 21W WHEEL AND SUSPENSION Tyre size, front and rear 145/70R12 Tyre pressures front/rear 1.9 kg/cm2 Suspension type front strut rear Leaf spring or Coil spring
STEERING Toe-in 1±2 mm
CAPACITIES PETROL LPG MARUTI 800DOMESTIC Coolant 3.6 L 3.6 L (Including reservoir tank) Fuel tank 28 L 19 L (80% of cylinder capacity) Engine oil 2.7 L (Replacement with Oil Filter) 2.7 L (Replacement with Oil Filter) Transmission oil 2.0 L (4-speed transmission) 2.0 L (4-speed transmission) 2.1 L (5-speed transmission) 2.1 L (5-speed transmission)
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