2005 SUZUKI MARUTI transmission

Downloaded from www.Manualslib.com manuals search engine 8783KVEHICLE LOADING AND TOWING
VEHICLE LOADING AND TOWING
Vehicle LoadingYour vehicle was designed for specific weight
capacities. The weight capacities of your
vehicle are indicated by the Gross Vehicle
Weight Rating (GVWR) and the Gross Axle
Weight Rating (GAWR, front and rear). The
GVWR and GAWR (front and rear) are listed
in the “SPECIFICATIONS” section.
GVWR – Maximum permissible overall weight
of the fully loaded vehicle (including all the
occupants, accessories and cargo plus the
trailer nose weight if towing a trailer).
GAWR – (Front and Rear) Maximum per-
missible weight on an individual axle.
Actual weight of the loaded vehicle and actual
loads at the front and rear axles can only be
determined by weighing the vehicle. Compare
these weights to the GVWR and GAWR (front
and rear). If the gross vehicle weight or the
load on either axle exceeds these ratings, you
must remove enough weight to bring the load
down to the rated capacity.
w ww w
w WARNING
Always distribute cargo evenly. To
avoid personal injury or damage to your
vehicle, always secure cargo to prevent
it from shifting if the vehicle moves
suddenly. Place heavier objects on the
floor and as far forward in the cargo
area as possible. Never pile cargo
higher than the top of the seat backs.
w ww w
w WARNING
Never overload your vehicle. The gross
vehicle weight (sum of the weights of
the vehicle, all the occupants,
accessories, cargo plus trailer nose
V VV V
V
w ww w
w WARNING
V VV V
Vweight if towing a trailer) must never
exceed the Gross Vehicle Weight
Rating (GVWR). In addition, never
distribute a load so that the weight on
either the front or rear axle exceeds
the Gross Axle Weight Rating (GAWR).Trailer TowingYour MARUTI SUZUKI was originally
designed to carry people and a normal
amount of cargo, not to tow a trailer. MARUTI
SUZUKI does not recommend you use your
vehicle to tow a trailer if there is not any local
regulation about towing capacity permitted (for
example, registered or statutory towing
capacity). Towing a trailer can adversely affect
handling, durability, and fuel economy.When you tow your vehicle, follow the
instructions below to avoid accidents
and damage to your vehicle. In addition,
be sure to observe government and
local requirements regarding vehicle
lighting and trailer hitches or tow bars.
w ww w
w WARNING
Towing Your VehicleYour vehicle may be towed behind another
Vehicle (such as a motorhome), provided
you use the proper towing method specified
for your vehicle. The towing method you
must use depends on the specifications of
your vehicle: whether it is a manual
transmission vehicle or an automatic
transmission vehicle.
Use the towing instruction table to select the
proper towing method for your vehicle, and
carefully follow the corresponding
instructions. Be sure to use proper towing
equipment designed for recreational towing
and make sure that towing speed does not
exceed 90 km/h.
w ww w
w WARNING
A safety chain should always be used
when you tow your vehicle.
8-1

Downloaded from www.Manualslib.com manuals search engine 9083K
You should take extreme care when
working on your vehicle to prevent
accidental injury. Here are a few pre-
cautions that you should be especially
careful to observe:
To prevent damage or unintended
activation of the air bag system be
sure the battery is disconnected and
the ignition switch has been in the
“LOCK” position for at least 90
seconds before performing any
electrical service work on your
vehicle. Do not touch air bag sys-
tem components and wires. The
wires are wrapped with yellow tape
or yellow tubing, and the couplers
are yellow for easy identification.
w ww w
w WARNING
83K-07-001
w ww w
w WARNING
w ww w
w WARNING
INSPECTION AND MAINTENANCE
9-1
V VV V
V
Do not leave the engine running in
garages or other confined areas.
When the engine is running, keep
hands, clothing, tools, and other
objects away from the fan and drive
belt. Even though the fan may not
be moving, it can automatically turn
on without warning.
When it is necessary to do service
work with the engine running, make
sure that the parking brake is
applied fully and the transmission is
in Neutral.
Do not touch ignition wires or other
ignition system parts when starting
the engine or when the engine is
running, or you could receive an
electric shock.
Be careful not to touch a hot
engine, exhaust manifold and pipes,
muffler, radiator and water hoses.
Do not allow smoking, sparks, or
flames around petrol or the battery.
Flammable fumes are present.
Do not get under your vehicle if it
is supported only with the portable
jack provided in your vehicle.V VV V
V
V VV V
V
Be careful not to cause accidental
short circuits between the positive
and negative battery terminals.
Keep used oil, coolant, and other
fluids away from children and pets.
Dispose of used fluids properly;
never pour them on the ground, into
sewers, etc.V VV V
V
83K-07-002
Maintenance ScheduleThe following table shows the times when
you should perform regular maintenance on
your vehicle. This table shows in kilometers
and months when you should perform
inspections, adjustments, lubrication and
other services.EXAMPLE

Downloaded from www.Manualslib.com manuals search engine 9383K
FREE INSPECTION PERIODIC MAINTENANCE AT COST
Interval: This interval should be judged by odometer km (x1000) 1 5 10 20 30 40 50 60 70 80
reading or months, whichever comes first.months 1 6 12 24 36 48 60 72 84 96
CLUTCH AND TRANSMISSION
4-1. Clutch Pedal (Play) PetrolIIIIIIIIII
4-2.Clutch Fluid (Level, Leakage) Diesel I I I R I R I R I R
4-3. Clutch Slipping (Dragging or Excess Damage)IIIIIIIIII
4-4.
Manual Transmission/Transfer or Differential Oil (Level, Leakage)
I I IRIRIRIR
4.5. Automatic transmission Fluid (Level, Leakage) Replace at 1,65,000 KM or 11 years whichever comes first
4.6. Hose, Automatic transmission fluidIIIIIIIIII
DRIVE SHAFT
5-1. Drive shaft boot (boot damage) -IIIIIIIII
BRAKE
6-1. Brake Fluid (Level, Leakage) I I I R I R I R I R
6-2.Brake Pedal (pedal - wall clearance)IIIIIIIIII
6-3.Parking brake lever and cable (Play, damage)IIIIIIIIII
6-4.Brake disc and pad (Wear) -IIIIIIIII
6-5.Brake drum and shoes (Wear) - -IIIIIIII
6-6. Master cylinder/wheel cylinder/caliper (Oil leakage, boot cut)
IIIIIRIIIR
(replace piston and boot kits)
6-7.Brake hoses and pipes (Leakage, damage)IIIIIIIIII
WHEEL
7-1.Tyres (air pressure, abnormal wear, crack and rotation) I I&O I&O I&O I&O I&O I&O I&O I&O I&O
7-2. Wheels (Damage)IIIIIIIIII
7-3.Front/Rear wheel bearing (Loose, damage)IIIIIIIIII
FRONT / REAR SUSPENSION
8-1.Suspension strut (Oil leakage, damage)IIIIIIIIII
8-2. Suspension arms / Knuckle support (Loose, damage) -IIIIIIIII
8-3.Rear spring (Damage)IIIIIIIIII
8-4.Shock absorbers (Oil leakage, damage)IIIIIIIIII
8-5.All bolts and nuts (Loose) -TTTTTTTTT
8-6. Suspension arms and torsion rods -IIIIIIIII
INSPECTION AND MAINTENANCE
9-4

Downloaded from www.Manualslib.com manuals search engine 10283K
INSPECTION AND MAINTENANCE
9-13
CAUTION
fied for your vehicle. For the specified
spark plugs, refer to the “SPECIFI-
CATIONS” section at the end of this
book. It is recommended to trust this
job on your MARUTI SUZUKI dealer.
83K-07-026
NOTE:
If your engine is equipped with the high-
tension cord type ignition wiring and you
experience some firing problem of spark
plugs, such as, hard engine-starting, misfire
etc., the cause may be located not only on
spark plugs but also on deteriorated ignition
wirings (generally, used for more than 80000
km or five years). If spark plug replacement
does not solve the problem, have theEXAMPLEV VV V
V
ignition wiring and other ignition system
inspected by your MARUTI SUZUKI dealer.Gear OilTransmission OilWhen adding gear oil, use gear oil with the
appropriate viscosity and grade.
We highly recommend you use:
API GL-4 SAE 75W-90.
83K-07-027
Gear Oil Level Check
(1) Oil filler and level plug
(for petrol engine model)
(2) Oil filler and level plug
(for diesel engine model)
To check the gear oil level, use the follow-
ing procedure:
1) Park the vehicle on a level surface withthe parking brake applied. Then, stop the
engine.
2) Remove the oil filler plug.
3) Feel the inside of the hole with your fin-
ger. If the oil level comes up to the bot-
tom of the plug hole, the oil level is
correct. If so, reinstall the plug.
4) If the oil level is low, add gear oil
through the oil filler plug hole (1) until
the oil level reaches the bottom of the
filler hole, then reinstall the plug.
Tightening torque (1):
21 Nm (2.1 kg-m, 15.5 lb-ft)
w ww w
w WARNING
After driving the vehicle, the trans-
mission oil temperature may be high
enough to burn your skin. Wait until
the oil filler plug is cool enough to
touch with your bare hands before
inspecting transmission oil.
CAUTION
When tightening the plug, apply the
following sealing compound or
equivalent to the plug threads to pre-
vent oil leakage.
Manual transmission sealant:
SUZUKI Bond No. “1217G”

Downloaded from www.Manualslib.com manuals search engine 12583K
EMERGENCY SERVICE
10-4
83K-08-010
VEHICLES TOUCH. Apply the parking
brakes fully on both vehicles.
2) Turn off all vehicle accessories, except
those necessary for safety reasons (for
example, headlights or hazard lights).
3) Make jump lead connections as follows:
1. Connect one end of the first jump
lead to the positive (+) terminal of
the flat battery (1).
2. Connect the other end to the positive
(+) terminal of the booster battery (2).
3. Connect one end of the second jump
lead to the negative (–) terminal of
the booster battery (3).
4. Make the final connection to an
unpainted, heavy metal part (i.e.
engine mounting stud/nut (4)) of the
engine of the vehicle with the flat
battery (1).4) If the booster battery you are using is
fitted to another vehicle, start the engine
of the vehicle with the booster battery.
Run the engine at moderate speed.
5) Start the engine of the vehicle with the
flat battery.
6) Remove the jump leads in the exact
reverse order in which you connected them.
TowingIf you need to have your vehicle towed,
contact a Maruti Suzuki authorised dealer
/ service stations.
w ww w
w WARNING
Never connect the jump lead directly
to the negative (–) terminal of the dis-
charged battery, or an explosion may
occur.
CAUTION
To help avoid damage to your vehicle
during towing, proper equipment and
towing procedures must be used.
CAUTION
The steering colum is not strong
enough to withstand shocks trans-
mitted from the front wheels during
towing always unlock the steering
wheel before towing.
Your vehicle may be towed using either of
the following methods.
1) From the front, with the front wheels
lifted and the rear wheels on the ground.
Before towing, make sure that the
parking brake is released.
2) From the rear, with the rear wheels lifted
and the front wheels on the ground,provided the steering and drivetrain are
in operational condition. Before towing,
make sure that transmission is in neutral,
the steering wheel is unlocked (the
ignition key should be in the “ACC”
position), and the steering wheel is
secured with a clamping device designed
for towing service.If the Starter Does Not
Operate1) Try turning the ignition switch to the
“START” position with the headlights turned
on to determine the battery condition. If the
headlights go excessively dim or go off, it
usually means that either the battery is flat
or the battery terminal contact is poor.
Recharge the battery or correct battery
terminal contact as necessary.
2) If the headlights remain bright, check the
fuses. If the reason for failure of the
starter is not obvious, there may be a
major electrical problem. Have the vehi-
cle inspected by your MARUTI SUZUKI
authorized dealer.
EXAMPLE

Downloaded from www.Manualslib.com manuals search engine 13383KSPECIFICATIONSNOTE:ITEM: Dimensions UNIT: mmPetrol Diesel
A/T M/T M/T only
Overall length3775 3775 3775
Overall width1680/1687 1680/1687 1680/1687
Overall height1620 1620 1620
Wheelbase2360 2360 2360
Track front165 tyre1470 1470 1470
185 tyre -1460 1460
rear 165 tyre1480 1480 1480
185 tyre -1470 1470
Ground clearanpce 170 170 170ITEM: Mass (weight) UNIT: kgPetrol Diesel
AT MT M/T only
Curb mass (weight)1035 990~1030 1075~1125
Gross vehicle mass (weight) rating1430 143001520
Gross axle mass (weight) rating front 800 800 835
rear 800 800 800
SPECIFICATIONS
13-1
M/T: Manual TransmissionA/T: Automatic Transmission
Specifications are subject to change without notice.

Downloaded from www.Manualslib.com manuals search engine 13683K
ITEM: Capacities (approx.)
CoolantPetrol M/T4.27 L
(including reservoir tank)A/T 4.9 L
Diesel M/T 5.9 L
Fuel tank 43 L
Engine oil Petrol/Diesel3.1 L (with filter)
Transmission oil M/T Petrol 2.2 L
Diesel 2.6 L
A/T 2.7 L (5.6 L when overhauling)SPECIFICATIONS
13-4ITEM: Wheel and Suspension
Tire Size 165/80R14 85S / 85T 185/70R14 88S
Rim Size14X5J 14X5.5J
Front Rear Front Rear
Tire Pressure (kg/cm2) Petrol MT 2.0 2.0
AT2.3 2.3
——
Diesel MT 2.5 2.3 2.2 2.0