SUZUKI MARUTI 800 ALTO MB308 Workshop Service Manual

IMPORTANT WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the words WARNING, CAUTION and NOTE have special mean- ings. Pay special attention to the messages high- lighted by these signal words. WARNING: Indicates a potential hazard that could result in death or injury. CAUTION: Indicates a potential hazard that could result in vehicle damage. NOTE: Indicates special information to make mainte- nance easier or instructions clearer. WARNING: This service manual is intended for autho- rized Maruti dealers and qualified service mechanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly per- form the services described in this manual. Improper repair may result in injury to the mechanic and may render the vehicle un- safe for the driver and passengers.

FOREWORD This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul). Applicable model: MB308 The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on next page. And on the first page of each individual section is an index of that section. This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use MARUTI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description. All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice. Related Manual Manual Name Manual No. MB308 WIRING DIAGRAM MANUAL 99512M84400-74E SERVICE DEPARTMENT

6 6A 6B 6C 6E1 6F 6G 6H 6K 7A 7A1 7C 8A 9 10 0A 1A 1B 3 3A 3B 3C 3D 3E 3E1 3F 4 5 0B 6A1 8 NOTE: The screen toned Section 8A WIRING DIAGRAM is not contained in this manual. The Section 8A is contained in WIRING DIAGRAM MANUAL mentioned in FOREWORD of this manual. GENERAL INFORMATION General Information Maintenance and Lubrication HEATING AND AIR CONDI- TIONING Heater and Ventilation Air Conditioning (If Equipped) STEERING, SUSPENSION, WHEELS AND TIRES Steering, Suspension, Wheels and Tires Front End Alignment Manual Rack and Pinion Steering Wheel and Column Front Suspension Rear Suspension (Leaf Spring Type) Rear Suspension (Coil Spring Type) Wheels and Tires DRIVE SHAFT AND PROPEL- LER SHAFT Front Drive Shaft BRAKE SYSTEM Brakes 1A 0B SECTION 0A 1B 3A 3 3B 3C 3D 3E 3E1 3F 4 5 TABLE OF CONTENTS ENGINE Engine Diagnosis Engine Mechanical (F8B Engine) Engine Mechanical (F8D Engine) Engine Cooling Engine Fuel Engine and Emission Control System Ignition System Cranking System Charging System Exhaust System TRANSMISSION, CLUTCH AND DIFFERENTIAL Manual Transmission (4-speed) Manual Transmission (5-speed) Clutch ELECTRICAL SYSTEM Electrical System Wiring Diagram BODY SERVICE RESTRAINT SYSTEM Restraint System SECTION 8B 6A 6A1 6B 6C 6E1 6F 6G 6H 6K 7A 7A1 7C 8 8A 9 10 6

0A GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION CONTENTS HOW TO USE THIS MANUAL 0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS 0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions 0A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Catalytic Converter 0A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions for Electrical Circuit Service 0A- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Circuit Inspection Procedure 0A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent and Poor Connection 0A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precaution for Installing Mobile Communication Equipment 0A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDENTIFICATION INFORMATION 0A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number 0A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Identification Number 0A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Identification Number 0A-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE LIFTING POINTS 0A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS MAY BE USED IN THIS MANUAL 0A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METRIC INFORMATION 0A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric Fasteners 0A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fasteners Strength Identification 0A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Tightening Torque 0A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO USE THIS MANUAL 1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL on the third page of this manual, whereby you can easily find the section that offers the information you need. Also, there is a CONTENTS on the first page of EACH SECTION, where the main items in that section are listed. 2) Each section of this manual has its own pagination. It is indi- cated at the top of each page along with the Section name. 3) The SPECIAL TOOL usage and TORQUE SPECIFICATION are given as shown in figure below. 6) Install oil pump. Refer to “Oil pump”. 7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle). Using special tool, lock flywheel or drive plate, and tighten flywheel or drive plate bolts to specified torque. Special Tool (A): 09924-17810 Tightening Torque (c): 78 N . m (7.8 kg-m, 56.0 lb-ft) 1. Flywheel bolts or drive plate bolts for A/T vehicle 4) A number of abbreviations are used in the text. For their full explanations, refer to “ABBREVIATIONS MAY BE USED IN THIS MANUAL” of this section. 5) The SI, metric and foot-pound systems are used as units in this manual. 6) DIAGNOSIS are included in each section as necessary. 7) At the end of each section, there are descriptions of SPECIAL TOOLS, REQUIRED SERVICE MATERIALS and TIGHT- ENING TORQUE SPECIFICATIONS that should be used for the servicing work described in that section. 0A-2 GENGERAL INFORMATION

PRECAUTIONS GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS” on SECTION 0A. D When it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto- matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running. D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. D Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system. When working with toxic or flammable materials (such as gasoline and refriger- ant), make sure that the area you work in is well-ventilated. D To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tailpipe, muffler, etc. D New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani- mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters. D 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. CAUTION: D Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g, buttons) may cause damage to the vehicle’s finish. D When performing service to electrical parts that does not require use of battery power, disconnect the negative cable of the battery. GENERAL INFORMATION 0A-3

D When removing the battery, be sure to disconnect the nega- tive cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be re- installed in the proper order and position. D Whenever you use oil seals, gaskets, packing, O-rings, locking washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, be- fore installing new gaskets, packing, etc., be sure to remove any residual material from the mating surfaces. D Make sure that all parts used in reassembly are perfectly clean. D When use of a certain type of lubricant, bond or sealant is specified, be sure to use the specified type. “A”: Sealant 99000-31150 D Be sure to use special tools when instructed. Special Tool (A): 09917-98221 (B): 09916-58210 0A-4 GENGERAL INFORMATION

D When disconnecting vacuum hoses, attach a tag describ- ing the correct installation positions so that the hoses can be reinstalled correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure, or fuel can be sprayed out under pressure. PRECAUTIONS FOR CATALYTIC CONVERT- ER For vehicles equipped with a catalytic converter, use only un- leaded gasoline and be careful not to let a large amount of un- burned gasoline enter the converter or it can be damaged. – Conduct a spark jump test only when necessary, make it as short as possible, and do not open the throttle. – Conduct engine compression checks within the shortest possible time. – Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is nearly empty.) GENERAL INFORMATION 0A-5

PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE D When disconnecting and connecting coupler, make sure to turn ignition switch OFF, or electronic parts may get dam- aged. D Be careful not to touch the electrical terminals of parts which use microcomputers (e.g. electronic control unit like as ECM, PCM, P/S controller, etc.). The static electricity from your body can damage these parts. D Never connect any tester (voltmeter, ohmmeter, or whatev- er) to electronic control unit when its coupler is discon- nected. Attempt to do it may cause damage to it. D Never connect an ohmmeter to electronic control unit with its coupler connected to it. Attempt to do it may cause dam- age to electronic control unit and sensors. D Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained or personal injury may result. If not specified, use a voltmeter with high- impedance (MW/V minimum) or a digital type voltmeter. D When taking measurements at electrical connectors using a tester probe (2), be sure to insert the probe from the wire harness side (backside) of the connector (1). D When connecting meter probe (2) from terminal side of cou- pler (1) because it can’t be connected from harness side, use extra care not to bend male terminal of coupler of force its female terminal open for connection. In case of such coupler as shown connect probe as shown to avoid opening female terminal. Never connect probe where (3) male terminal is supposed to fit. 0A-6 GENGERAL INFORMATION

D When checking connection of terminals, check its male half for bend and female half for excessive opening and both for locking (looseness), corrosion, dust, etc. D Before measuring voltage to check for electrical system, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis. ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various electrical circuit inspection methods, de- scribed here is a general method to check its open and short circuit by using an ohmmeter and a voltmeter. OPEN CIRCUIT CHECK Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully. D Loose connection of connector D Poor contact of terminal (due to dirt, corrosion or rust on it, poor contact tension, entry of foreign object etc.) D Wire harness being open When checking system circuits including an electronic control unit such as ECM, TCM, ABS control module, etc., it is important to per- form careful check, starting with items which are easier to check. 1) Disconnect negative cable from battery. 2) Check each connector at both ends of the circuit being checked for loose connection. Also check lock condition of connector if equipped with connector lock. 1. Check for loose connection Sensor ECM GENERAL INFORMATION 0A-7