Get Maintenance and Lubrication Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

MAINTENANCE AND LUBRICATION0B-1

SECTION 0B

MAINTENANCE AND LUBRICATION

CONTENTS

PERIODIC MAINTENANCE SCHEDULE 0B-2 . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SERVICE 0B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine 0B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System 0B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 0B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emission Control System 0B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake 0B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis and Body 0B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Inspection 0B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RECOMMENDED FLUIDS AND LUBRICANTS 0B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interval:

This interval should be judged by

odometer reading or months, which-

ever comes first.

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.

Km (x 1,000) 1 5 10 20 30 40 50 60 70 80

Months 1 6 12 24 36 48 60 72 84 96

0B-2 INSPECTION AND MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

ENGINE

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

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)

IIIIIIIIII

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 RIR IR IR

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) IIIIIRIIIR

CLUTCH AND TRANSMISSION

1. Clutch pedal (play) IIIIIIIIII

2. Clutch slipping (dragging or excessive damage) IIIIIIIIII

3. Manual Transmission/Transfer and Differential oil

(level, leakage)

IIIRIRIRIR

Notes:

"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.

Interval:

This interval should be judged by

odometer reading or months, which-

ever comes first.

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.

Km (x 1,000) 1 5 10 20 30 40 50 60 70 80

Months 1 6 12 24 36 48 60 72 84 96

INSPECTION AND MAINTENANCE 0B-3

DRIVE SHAFTS

1. Drive shaft boots (Bent of boot damage) IIIIRIIRII

BRAKE

1. Brake fluid (level, leakage) I I I R I R I R I R

2. Brake pedal (pedal-to-wall clearance) IIIIIIIIII

3. Parking brake lever and cable (play, damage) IIIIIIIIII

4. Brake discs & pads (wear) — I I I I I I I I I

5. Brake drums & shoes — — I I I I I I I I

6. Master cylinder and wheel cylinder

(oil leakage, boot kit)

IIIIIRIIIR

7. Brake hoses and pipes (leakage, damage) IIIIIIIIII

WHEEL

1. Tyres (air pressure, abnormal wear, crack, ROTATION) Rotate and inspect every 5,000 km

2. Wheels (damage) IIIIIIIIII

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) IIIIIIIIII

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

Notes:

"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.

Interval:

This interval should be judged by

odometer reading or months, which-

ever comes first.

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.

Km (x 1,000) 1 5 10 20 30 40 50 60 70 80

Months 1 6 12 24 36 48 60 72 84 96

0B-4 INSPECTION AND MAINTENANCE

STEERING

1. Steering wheel (play, loose) I I I III II II

2. Power Steering fluid (level, leakage)/Connections IIIIIIIIII

3. All rods and arms (loose, damage, wear) IIIIIIIIII

ELECTRICAL

1. Battery electrolyte (level, leakage) IIIIIIIIII

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

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

4. Horn (operation) IIIIIIIIII

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

ROAD TEST

1. Operation of Brakes, Gear shifting & speedometer IIIIIIIIII

2. Body and Chassis noise IIIIIIIIII

AIR CONDITIONER (if equipped)

1. Check belt tension I I I III II II

2. Check receiver drier bubbles I I I III II II

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 III II II

5. Check functioning of Recir flap I I I III II II

6. Clean condenser with low pressure water I 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

Notes:

"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.

MAINTENANCE SERVICE

ENGINE

Drive Belt Inspection and Replacement

Water pump/generator belt inspection

1)Disconnect negative cable from battery.

2)Inspect belt for cracks, cuts, deformation, wear and cleanliness.

Replace if any defect exists.

3)Check pump belt for tension and adjust if it is out of specifica-

tion.

Water pump/generator belt tension “a”:

6 – 7 mm (0.24 – 0.27 in.) deflection under 100N, 10 kg or 22

lb pressure

NOTE:

When replacing belt with a new one, adjust belt tension to

5 – 6 mm (0.20 – 0.23 in.).

4)Connect negative cable to battery.

Water pump belt replacement

Replace belt with new one referring to “Water Pump Belt Removal

and Installation” in Section 6B.

WARNING:

Disconnect negative cable at battery before checking

and replacing belt tension.

A/C compressor drive belt inspection (If equipped)

1)Disconnect negative cable from battery.

2)Inspect belt for cracks, cuts, wear and deterioration.

Replace if any defect exists.

3)Check belt for tension.

A/C compressor drive belt tension “b”:

7 – 9 mm (0.28 – 0.35 in.) deflection under 100N, 10 kg or 22

lb pressure

3)If belt tension is out of above specification, adjust it.

4)Connect negative cable to battery.

A/C compressor drive belt replacement

1)Disconnect negative cable from battery.

2)Remove water pump/generator belt.

3)Loosen belt tension and replace belt with new one.

4)Adjust belt tension to specification.

5)Install water pump/generator belt.

6)Connect negative cable to battery.

MAINTENANCE AND LUBRICATION0B-5

Engine Oil and Filter Change

Use engine oil of SE, SF, SG, SH or SJ grade.

Select the appropriate oil viscosity according to the left chart.

WARNING:

New and used engine oil can be hazardous.

Be sure to read “WARNING” in General Precaution in Section

0A and observe what in written there.

Proper Engine Oil Viscosity Chart

Before draining engine oil, check engine for oil leakage. If any evi-

dence of leakage is found, make sure to correct defective part be-

fore proceeding to the following work.

1)Drain engine oil by removing drain plug (1).

2)After draining oil, wipe drain plug clean. Reinstall drain plug,

and tighten it securely as specified below.

Tightening Torque

(a): 50 N·m (5.0 kg-m, 36.0 lb-ft)

1, (a)

3)Loosen oil filter (1) by using oil filter wrench (Special tool).

Special Tool

(A): 09915-47310

4)Apply engine oil to new oil filter “O” ring.

5)Screw new filter on oil filter stand by hand until filter “O” ring con-

tacts mounting surface.

CAUTION:

To tighten oil filter properly, it is important to accurate-

ly identify the position at which filter “O” ring first con-

tacts mounting surface.

6)Tighten filter 3/4 turn from the point of contact with mounting sur-

face using an oil filter wrench.

Special Tool

(A): 09915-47310

Tightening Torque (Reference)

(a): 14 N·m (1.4 kg-m, 10.5 lb-ft)

MAINTENANCE AND LUBRICATION0B-7

7)Replenish oil until oil level is brought to FULL level mark on dip-

stick (oil pan and oil filter capacity). Filler inlet is at the top of cyl-

inder head cover.

8)Start engine and run it for three minutes. Stop it and wait another

5 minutes before checking oil level. Add oil, as necessary, to

bring oil level to FULL level mark on dipstick.

1.Low level mark (hole)

2.Full level mark (hole)

NOTE:

Engine oil capacity is specified as left table.

However, note that amount of oil required when actually

changing oil may somewhat differ from data in left table de-

pending on various conditions (temperature, viscosity,

etc.).

9)Check oil filter and drain plug for oil leakage.

Engine oil capacity

Engine Coolant Change

Refer to Section 6B of this manual for coolant capacity.

WARNING:

To help avoid danger of being burned, do not remove ra-

diator cap while engine and radiator are still hot. Scald-

ing fluid and steam can be blown out under pressure if

cap is taken off too soon.

CAUTION:

When changing engine coolant, use mixture of 50% wa-

ter and 50% ethylene-glycol base coolant (Anti-Freeze/

Anti-corrosion coolant) for the market where ambient

temperature falls lower than –16 C (3 F) in winter and mix-

ture of 70% water and 30% ethylene-glycol base coolant

for the market where ambient temperature doesn’t fall

lower than –16 C (3 F).

Even in a market where no freezing temperature is antici-

pated, mixture of 70% water and 30% ethylene-glycol

base coolant should be used for the purpose of corro-

sion protection and lubrication.

0B-8MAINTENANCE AND LUBRICATION

Oil pan capacity

about 2.5 liters

(5.3/4.4 US/lmp pt.)

Oil filter capacity

about 0.2 liter

(0.4/0.3 US/lmp pt.)

Others

about 0.3 liter

(0.6/0.5 US/lmp pt.)

Total

about 3.0 liters

(6.3/5.3 US/lmp pt.)

1) Remove radiator cap when engine is cool.

2) Loosen radiator drain plug (1) to drain coolant if radiator is

equipped with drain plug. If radiator is not equipped with drain

plug, disconnect outlet hose from radiator to drain coolant.

3) Remove reservoir and drain.

4) Tighten drain plug securely or connect outlet hose to radiator.

Also install reservoir.

5) Slowly pour specified amount of coolant to the base of radiator

filler neck, and run engine, with radiator cap removed, until ra-

diator upper hose is hot. This drives out any air which may still

be trapped within cooling system. Add coolant as necessary un-

til coolant level reaches filler throat of radiator. Reinstall radiator

cap.

6) Add coolant to reservoir so that its level aligns with FULL level

line.

MAINTENANCE AND LUBRICATION 0B-9

Exhaust System Inspection

WARNING:

To avoid danger of being burned, do not touch exhaust

system when it is still hot.

Any service on exhaust system should be performed

when it is cool.

When carrying out periodic maintenance or vehicle is raised for

other service, check exhaust system as follows:

D Check rubber mountings for damage and deterioration.

D Check exhaust system for leakage, loose connections, dents

and damages.

If bolts or nuts are loose, tighten them to specification.

Refer to Section 6K for torque specification of bolts and nuts.

D Check nearby body areas for damaged, missing or misposi-

tioned parts, open seams, holes, loose connections or other de-

fects which could permit exhaust fumes to seep into vehicle.

D Make sure that exhaust system components have enough clear-

ance from underbody to avoid overheating and possible dam-

age to floor carpet.

D Any defects should be fixed at once.

IGNITION SYSTEM

Spark Plugs Replacement

Replace spark plugs with new ones referring to Section 6F.

Distributor Cap and Rotor Inspection

D Check distributor cap and rubber caps for cracks.

D Clean dusty and stained parts using a dry, soft cloth.

D Check center electrode and terminals for wear.

D Check rotor for cracks and its electrode for wear.

Repair or replace any component which is found to be in malcondi-

tion.

0B-10MAINTENANCE AND LUBRICATION

FUEL SYSTEM

Air Cleaner Filter Inspection

1)Remove air cleaner case bracket bolts and unclamp case

clamps.

2)Take cleaner filter out of air cleaner case.

3)Visually check that air cleaner filter is not excessively dirty, dam-

aged or oily.

4)Clean filter with compressed air from air outlet side of filter.

5)Install air cleaner filter into case.

6)Clamp case securely and install case to bracket.

Air Cleaner Filter Replacement

Replace air cleaner filter with new one according to procedure de-

scribed in Section 6A or 6A1.

Fuel Lines Inspection

Check fuel lines for loose connection, deterioration or damage

which could cause leakage. Make sure all clamps are secure.

Replace any damaged or deteriorated parts.

There should be no sign of fuel leakage or moisture at any fuel con-

nection.

Fuel Filter Replacement

Fuel filter (1) is installed in front of fuel tank (2) inside the left side of

vehicle body.

Replace fuel filter with new one, referring to Section 6C for removal

and installation.

WARNING:

This work must be performed in a well ventilated area and

away from any open flames (such as gas hot water heaters).

MAINTENANCE AND LUBRICATION0B-11

Fuel Tank Inspection

Check fuel tank for damage, cracks, fuel leakage, corrosion and

tank bolts looseness.

If a problem is found, repair or replace.

Fuel Tank Cap Inspection

Check fuel filler cap (1) for malfunction and damage, gasket (2) for

even filler neck imprint, deterioration and damage. Replace if

faulty.

EMISSION CONTROL SYSTEM

PCV (Positive Crankcase Ventilation) Valve Inspec-

tion

Check crankcase ventilation hoses and PCV hoses for leaks,

cracks or clog, and PCV valve (1) for stick or clog. Refer to Section

6E1 for PCV valve checking procedure.

Fuel Evaporative Emission Control System (if

equipped)

Check EVAP (Evaporative Emission) canister for damage, clog

and operation referring to Section 6E1.

0B-12MAINTENANCE AND LUBRICATION

BRAKE

Brake Discs, Pads, Drums and Shoes Inspection

Brake discs and pads

1)Remove wheel and caliper but don’t disconnect brake hose

from caliper.

2)Check front disc brake pads and discs for excessive wear, dam-

age and deflection. Replace parts as necessary. For the details,

refer to Section 5.

3)Install caliper and wheel.

Brake drums and shoes

1)Remove wheel and brake drum.

2)Check rear brake drums and brake linings for excessive wear

and damage.

At the same time, check wheel cylinders for leakage.

Replace as necessary.

For the details, refer to Section 5.

3)Install brake drum and wheel.

Brake Hoses and Pipes Inspection

Perform this inspection where there is enough light and use a mir-

ror as necessary.

D Check brake hoses and pipes for proper hook-up, leaks, cracks,

chafing, wear, corrosion, bends, twists and other damage.

Replace any of these parts as necessary.

D Check all clamps for tightness and connections for leakage.

D Check that hoses and pipes are clear of sharp edges, moving

parts.

CAUTION:

After replacing any brake pipe or hose, be sure to carry

out air purge operation.

MAINTENANCE AND LUBRICATION0B-13

Brake Fluid Change

Change brake fluid as follows.

Drain existing fluid from brake system completely, fill system with

specified fluid and carry out air purge operation.

For air purging procedure, refer to Section 5.

CAUTION:

Since brake system of this vehicle is factory-filled with

brake fluid indicated on reservoir tank cap, do not use or

mix different type of fluid when refilling; otherwise seri-

ous damage will occur.

Do not use old or used brake fluid, or any fluid from a un-

sealed container.

Brake Lever and Cable Inspection

Parking brake lever

D Check tooth tip of each notch for damage or wear. If any damage

or wear is found, replace parking lever.

D Check parking brake lever for proper operation and stroke, and

adjust it if necessary.

For checking and adjusting procedures, refer to Section 5.

“a”:Parking brake lever stroke:

3 – 6 notches (With 20 kg or

44 lbs of pull pressure)

Parking brake cable

Inspect brake cable for damage and smooth movement.

Replace cable if it is in deteriorated condition.

CHASSIS AND BODY

Clutch Pedal Free Travel Inspection

Check clutch pedal (1) for height and free travel “a” referring to Sec-

tion 7C.

Adjust or correct if necessary.

0B-14MAINTENANCE AND LUBRICATION

Tire and Wheel Disc Inspection

[Tire inspection]

1)Check tire for uneven or excessive wear, or damage. If defec-

tive, replace.

1.Wear indicator

2)Check inflating pressure of each tire and adjust pressure to

specification as necessary.

NOTE:

D Tire inflation pressure should be checked when tires are

cool.

D Specified tire inflation pressure should be found on tire

placard or in owner’s manual which came with vehicle.

[Wheel disc inspection]

Inspect each wheel disc for dents, distortion and cracks. A disc in

badly damaged condition must be replaced.

[Tire rotation]

Rotate tires referring to Section 3F.

Wheel Bearing Inspection

1)Check front wheel bearing for wear, damage, abnormal noise

or rattles. For details, refer to Section 3D.

2)Check rear wheel bearing for wear, damage abnormal noise or

rattle. For details, refer to Section 3E.

Drive Shaft (Axle) Boot Inspection

Check drive shaft boots (wheel side and differential side) for leak-

age, detachment, tear or any other damage.

Replace boot as necessary.

MAINTENANCE AND LUBRICATION0B-15

Suspension System Inspection

D Inspect front strut and rear shock absorber for evidence of oil

leakage, dents or any other damage on sleeves; and inspect an-

chor ends for deterioration.

Replace defective parts, if any.

D Check front and rear suspension systems for damaged, loose

or missing parts; also for parts showing signs of wear or lack of

lubrication.

Repair or replace defective parts, if any.

D Check front suspension arm ball joint stud dust seals (boots) for

leakage, detachment, tear or any other damage.

Replace defective boot, if any.

Steering System Inspection

1)Check steering wheel for play and rattle, holding vehicle straight

on ground.

Steering wheel play “a”: 0 – 30 mm (0 – 1.1 in.)

2)Check bolts and nuts for tightness and retighten them as neces-

sary. Repair or replace defective parts, if any.

“a”

3)Check steering linkage for looseness and damage. Repair or

replace defective parts, if any.

4)Check boots (1) and (2) of steering linkage and steering gear

case for damage (leaks, detachment, tear, etc.). If damage is

found, replace it with new one.

5)Check universal joints (3) of steering shaft for rattle and dam-

age. If rattle or damage is found, replace it with a new one.

6)Check that steering wheel can be turned fully to the right and

left. Repair or replace defective parts, if any.

7)If equipped with power steering system, check also, in addition

to above check items, that steering wheel can be turned fully to

the right and left more lightly when engine is running at idle

speed than when it is stopped. Repair, if found faulty.

8)Check wheel alignment. For the details of wheel alignment, re-

fer to Section 3A.

0B-16MAINTENANCE AND LUBRICATION

Manual Transmission Oil Inspection and Change

Oil Inspection for 5-speed M/T

1)Inspect transmission case for evidence of oil leakage.

Repair leaky point if any.

2)Make sure that vehicle is placed level for oil level check.

3)Remove oil filler/level plug (1) of transmission.

4)Check oil level.

Oil level can be checked roughly by means of filler/level plug

hole. That is, if oil flows out of level plug hole or if oil level is found

up to hole when level plug is removed, oil is properly filled.

If oil is found insufficient, pour specified oil up to level hole.

For specified oil, refer to description of oil change under On-Ve-

hicle Service in Section 7A1.

5)Apply sealant to filler/level plug and tighten it to specified torque.

Oil change for 5-speed M/T

1)Place vehicle level and drain oil by removing drain plug (2).

2)Apply sealant to drain plug after cleaning it and tighten drain

plug to specified torque.

3)Pour specified oil up to level hole.

4)Tighten filler plug to specified torque.

For recommended oil, its amount and tightening torque data, re-

fer to On-Vehicle Service of Section 7A1.

5-Speed M/T

Oil inspection for 4-speed M/T

1)Inspect transmission case for evidence of oil leakage. Repair

leaky point if any.

2)Make sure that vehicle is placed level for oil level check.

3)Take out oil level gauge from transmission case and wipe off oil.

4)Bring face (1) of the oil level gauge to contact face (2) of the

transmission case (3) and check oil level indicated by the oil on

the gauge.

Oil level must be somewhere between FULL level line (4) and LOW

level line (5) on the gauge.

4-Speed M/T

MAINTENANCE AND LUBRICATION0B-17

Oil change for 4-speed M/T

1)Place vehicle level and drain by removing two drain plugs (1).

2)Apply sealant to drain plug after cleaning it and tighten drain

plug to specified torque.

3)Pour specified oil up to specified level.

For specified oil, its amount and tightening torque, refer to On-

Vehicle Service of Section 7A.

4)Install oil level gauge securely.

All Latches, Hinges and Locks Inspection

Doors

Check that each door of front, rear and back doors opens and

closes smoothly and locks securely when closed.

If any malfunction is found, lubricate hinge and latch or repair door

lock system.

Engine hood

Check that secondary latch operates properly (check that second-

ary latch keeps hood from opening all the way even when pulling

hood release handle inside vehicle.) Also check that hood opens

and closes smoothly and properly and hood locks securely when

closed.

If any malfunction is found, lubricate hinge and latch, or repair hood

lock system.

0B-18MAINTENANCE AND LUBRICATION

MAINTENANCE AND LUBRICATION 0B-19

FINAL INSPECTION

Seats

Check that seat slides smoothly and locks securely at

any position. Also check that reclining mechanism of

front seat back allows it to be locked at any angle.

Seat Belt

Inspect belt system including webbing, buckles, latch

plates, retractors and anchors for damage or wear.

Check that seat belt is securely locked.

Battery Electrolyte Level Check

Check that the electrolyte level of all battery cells is

between the upper and lower level lines on the case.

If battery is equipped with built-in indicator, check bat-

tery condition by the indicator.

Accelerator Pedal Operation

Check that pedal operates smoothly without getting

caught or interfered by and other part.

Engine Start

Check engine start for readiness.

On manual transmission vehicles, place the shift lever

in “Neutral,” depress clutch pedal fully and try to start.

Exhaust System Check

Check for leakage, cracks or loose supports.

Clutch (For Manual transmission)

Check for the following.

D Clutch is completely released when depressing

clutch pedal,

D No slipping clutch occurs when releasing pedal and

accelerating,

D Clutch itself is free from any abnormal condition.

Gearshift or Select Lever (Transmission)

Check gear shift or select lever for smooth shifting to

all positions and for good performance of transmis-

sion in any position.

Brake

[Foot brake]

Check the following;

D that brake pedal has proper travel,

D that brake works properly,

D that it is free from noise,

D that vehicle does not pull to one side when brake is

applied,

D and that brake do not drag.

[Parking brake]

Check that parking brake lever has proper travel.

Check to ensure that parking brake is fully effective

when the vehicle is stopped on the safe slope and

brake lever is pulled all the way.

WARNING:

When carrying out road tests, select a safe

place where no man or no running vehicle is

seen so as to prevent any accident.

WARNING:

Before performing the following check, be

sure to have enough room around the ve-

hicle. Then, firmly apply both the parking

brake and the regular brakes. Do not use the

accelerator pedal. If the engine starts, be

ready to turn off the ignition promptly. Take

these precautions because the vehicle could

move without warning and possibly cause

personal injury or property damage.

WARNING:

With vehicle parked on a fairly steep slope,

make sure nothing is in the way downhill to

avoid any personal injury or property dam-

age. Be prepared to apply regular brake

quickly even if vehicle should start to move.

0B-20 MAINTENANCE AND LUBRICATION

Steering

D Check to ensure that steering wheel is free from in-

stability, or abnormally heavy feeling.

D Check that the vehicle does not wander or pull to

one side.

Engine

D Check that engine responds readily at all speeds.

D Check that engine is free from abnormal noise and

abnormal vibration.

Body, Wheels and Power Transmitting

System

Check that body, wheels and power transmitting sys-

tem are free from abnormal noise and abnormal vibra-

tion or any other abnormal condition.

Meters and Gauge

Check that speedometer, odometer, fuel meter, tem-

perature gauge, etc. are operating accurately.

Lights

Check that all lights operate properly.

Windshield Defroster

Periodically check that air comes out from defroster

outlet when operating heater or air conditioning.

Set fan switch lever to “HI” position for this check.

RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil

SE, SF, SG, SH or SJ (Refer to engine oil viscosity chart in item 1-4.)

Engine coolant

(Ethylene glycol base coolant)

“Antifreeze/Anticorrosion coolant”

Brake fluid DOT3 or SAE J1703

Manual transmission oil API GL-4, SAE75W-90 (Refer to Section 7A or 7A1 for detail)

Door hinges

Engine oil or water resistance chassis grease

Hood latch assembly

Engine

oil

water

resistance

chassis

grease

Key lock cylinder Spray lubricant

Maintenance and Lubrication for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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