Get Inspection and Maintenance Guide for Suzuki Alto 4 Door Sixth Generation (2004-2008)

76G-74E

INSPECTION AND MAINTENANCE

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

Alto ............................................................................................................. 9-2

Alto K-10 .................................................................................................... 9-6

Drive Belt ............................................................................................................ 9-10

Engine Oil and Filter .......................................................................................... 9-11

Gear Oil ............................................................................................................... 9-14

Engine Coolant ................................................................................................... 9-15

Windscreen Washer Fluid ................................................................................. 9-18

Air Cleaner .......................................................................................................... 9-18

Spark Plugs ........................................................................................................ 9-19

Fuel Filter Replacement .................................................................................... 9-21

Brakes .................................................................................................................9-21

Parking Brake ..................................................................................................... 9-23

Steering ............................................................................................................... 9-23

Clutch Pedal ....................................................................................................... 9-24

Tyres .................................................................................................................. 9-24

Tubeless Tyre (if equipped) .............................................................................. 9-27

Battery ................................................................................................................. 9-28

Fuses .................................................................................................................. 9-29

Bulb Replacement .............................................................................................. 9-32

Wiper Blades ...................................................................................................... 9-35

76G-74E

You should take extreme care when

working on your vehicle to prevent

accidental injury. Here are a few

precautions that you should be

especially careful to observe:

• Do not leave the engine running in

garages or other confined areas.

• When the engine is running, keep

hands, clothing, tools, and other

objects away from the fan and water

pump 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 gasoline 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.

• 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.

INSPECTION AND MAINTENANCE

9-1

w WARNING

PERIODIC MAINTENANCE SCHEDULE

The following table shows when regular

maintenance on your vehicle is required.

This table shows in kilometres and months

when inspections, adjustments, lubrication

and other services should be performed.

MARUTI SUZUKI recommends that

maintenance on your MARUTI SUZUKI

vehicle be performed by MARUTI

SUZUKI Authorised Dealer/Service

Station.

Whenever it becomes necessary to

replace parts on your vehicle, it is

recommended that you use MARUTI

GENUINE PARTS (MGP).

w WARNING

CAUTION

76G-09-001

76G-74E

INSPECTION AND MAINTENANCE

9-2

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

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

3. Distributor cap and rotor (wear and deterioration)* – – – I – I – I – I

*For LX only

ALTO

76G-74E

INSPECTION AND MAINTENANCE

9-3

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

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

76G-74E

INSPECTION AND MAINTENANCE

9-4

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

76G-74E

INSPECTION AND MAINTENANCE

9-5

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. Tighten compressor mounting bolts – T T T T T T T T T

3. Check all hose joints, tighten if necessary I I I I I I I I I I

4. Check functioning of Recirc flap I I I I I I I I I I

5. Clean condenser with low pressure water – C C C C C C C C C

6. Check belt for frayed edges, change if necessary – I I I I I I I I I

7. Check all mounting bolts – I I I I I I I I I

76G-74E

INSPECTION AND MAINTENANCE

9-7

76G-74E

INSPECTION AND MAINTENANCE

9-8

76G-74E

w WARNING

The rear shock absorbers are filled with

high pressure gas. Never attempt to

disassemble it or throw it into a fire.

Avoid storing it near a heater or heating

device. When scrapping the absorber,

the gas must be released from the

absorber safely. Ask your dealer for

assistance.

• 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.

• 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.

w WARNING

INSPECTION AND MAINTENANCE

9-9

76G-74E

INSPECTION AND MAINTENANCE

9-10

DRIVE BELT

When the engine is running, keep

hands, hair, clothing, tools, etc. away

from the fan and drive belt. Even

though the fan may not be moving, it

can automatically turn on without

warning.

Water pump belt (A) 8 - 9 mm

Air conditioner belt (B) 8 - 9 mm

w WARNING

76G-09-002

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.

The belt should also be examined to ensure

that it is not damaged. If the belt needs to

be replaced or adjusted, have it done by

your MARUTI SUZUKI dealer.

DEF: 4.0 – 4.5 mm

(0.16 – 0.18 in.)

DEF: 7 – 8 mm

(0.28 – 0.31 in.)

: 100 N (10 kg, 22 lbs) press

GE: Generator

DEF: Deflection

AC: Air conditioner compressor

ALTO K10

ALTO

76G-74E

INSPECTION AND MAINTENANCE

9-11

ENGINE OIL AND FILTER

Specified oil

Be sure that the engine oil you use comes

under the API classification of SF, SG or

SH. The recommended engine oil is SF

20W40 (1). Select the appropriate oil

viscosity according to the above chart.

Oil Level Check

It is important to keep the engine oil at the

correct level for proper lubrication of your

vehicle’s engine. Check the oil level with the

vehicle on a level surface. The oil level

indication may be inaccurate if the vehicle

is on a slope. The oil level should be

checked either before starting the engine or

at least 5 minutes after stopping the engine.

Pull out the oil dipstick, wipe oil off with a

clean cloth, insert the dipstick all the way

into the engine, then remove it again. The

oil on the stick should be between the

upper and lower limits shown on the stick.

If the oil level indication is near the lower

limit, add enough oil to raise the level to

the upper limit.

76G-09-003 76G-09-004

(1) Preferred

Be sure that the engine oil you use comes

under the quality classification of SG+, SL

& SJ. Select the appropriate oil viscosity

according to the above chart.

SAE 5W30 (1) is the best choice for good

fuel economy, and good starting in cold

weather.

Failure to check the oil level regularly

could lead to serious engine trouble

due to insufficient oil.

ALTO K10

ALTO

EXAMPLE

CAUTION

76G-74E

INSPECTION AND MAINTENANCE

9-12

Refilling

Remove the oil filler cap and pour oil slowly

through the filler hole to bring the oil level

to the upper limit on the dipstick. Be careful

not to overfill. Too much oil is almost as

bad as too little oil. After refilling, start the

engine and allow it to idle for about a

minute. Stop the engine, wait for five

minutes and check the oil level again.

Changing Engine Oil and Filter

Drain the engine oil while the engine is still

warm.

1) Remove the oil filler cap.

2) Place a drain pan under the drain plug.

3) Using the correct spanner remove the

drain plug and drain out the engine oil.

The engine oil temperature may be high

enough to burn your fingers when the

drain plug is loosened. Wait until the

drain plug is cool enough to touch with

your bare hands.

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 may cause (skin) cancer.

Brief contact with used oil may irritate

skin.

To minimize your exposure to used

oil, wear a long-sleeve shirt and

moistureproof gloves (such as

dishwashing gloves) when changing

oil. If 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.

4. Reinstall the drain plug and new gasket.

Tighten the plug with a wrench to the

specified torque.

w WARNING

76G-09-005 76G-09-006

Tightening torque for drain plug (1):

35 Nm (3.5 kg-m, 25.5 lb-ft)

ALTO

ALTO K10

Tightening Torque :

49± 5 N.m

76G-74E

INSPECTION AND MAINTENANCE

9-13

Replace the oil filter

1) Using an oil filter wrench, turn the oil

filter counterclockwise and remove it.

2) Using a clean rag, wipe off the mounting

surface on the engine where the new

filter will be seated.

3) Smear a little engine oil around the

rubber gasket of the new oil filter.

4) Screw on the new filter by hand until the

filter gasket contacts the mounting

surface.

To tighten the oil filter properly, it is

important to accurately identify the

position at which the filter gasket

first contacts the mounting surface.

5. Tighten the filter specified turn from the

point of contact with the mounting sur-

face (or to the specified torque) using an

oil filter wrench.

Tightening torque for oil filter

1 turn or

14 Nm (1.4 kg-m, 10.5 lb-ft)

CAUTION

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 for 5 minutes.

Check the oil level again and add oil if

necessary. Check for leaks again.

When replacing the oil filter, it is

recommended that you use a genuine

MARUTI replacement filter.

Oil leaks from around the oil filter or

drain plug indicate incorrect installa-

tion or gasket damage. If you find any

leaks or are not sure that the filter

has been properly tightened, have the

vehicle inspected by your MARUTI

SUZUKI dealer.

CAUTION

76G-09-007 76G-09-008

To prevent oil leakage, make sure

that the oil filter is tight, but do not

overtighten it.

(1) Oil filter

(2) 1 Turn

76G-74E

INSPECTION AND MAINTENANCE

9-14

GEAR OIL

Oil filler and level plug 1

Tightening torque: 21 Nm (2.1 kg-m, 15.5

lb-ft)

Specified Manual Transmission oil

When adding gear oil, use the appropriate

viscosity and grade as shown in the chart

below. We highly recommend you use API

GL-4 SAE 75W-90 (1) gear oil.

Type of oil Gear oil, API GL-4

Gear oil level check

To check the gear oil level, use the

following procedure:

1) Park the vehicle on a level surface with

the parking brake applied. Then, stop the

engine.

2) Clean casing around oil filler plug to

remove risk of any loose dirt or debris

entering oil filler plug hole. Remove the

oil filler plug 1.

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.

4) If the oil level is low, add gear oil

through the filler plug hole 1 until the

oil level reaches the bottom of the filler

hole, then reinstall the plug.

After driving the vehicle, the

transmission oil temperature may be

high enough to burn you. Wait until

the oil filler plug is cool enough to

touch with your bare hands before

inspecting transmission oil.

When tightening the plug, apply

sealing compound to the plug threads

to prevent oil leakage.

Gear oil change

Since special procedures, materials and

tools are required, it is recommended that

you trust this job to your authorized

MARUTI SUZUKI dealer.

w WARNING

CAUTION

76G-09-009 76G-09-010

76G-74E

INSPECTION AND MAINTENANCE

9-15

ENGINE COOLANT

76G-09-011

ALTO

76G-09-012

EXAMPLE

ALTO K10

EXAMPLE

ALTO

ALTO K10

Selection of Coolant

To maintain optimum performance and

durability of your engine, use MARUTI

Genuine Coolant or equivalent.

This type of coolant is best for your cooling

system as it:

• Helps maintain proper engine temperature.

• Gives proper protection against freezing

and boiling.

• Gives proper protection against corrosion

and rust.

Failure to use the proper coolant can dam-

age your cooling system. Your MARUTI

SUZUKI authorized dealer can help you

select the proper coolant.

76G-74E

INSPECTION AND MAINTENANCE

9-16

CAUTION

To avoid damaging your cooling sys-

tem:

• Always use a high quality ethylene

glycol base non-silicate type cool-

ant diluted with distilled water at

the correct mixture concentration.

• Make sure that the proper mix is 30/

70 coolant to distilled water.

Concentrations greater than 70/30

coolant to distilled water will cause

over heating conditions.

• Do not use straight coolant nor

plain water.

• Do not add extra inhibitors or addi-

tives. They may not be compatible

with your cooling system.

• Do not mix different types of base

coolants. Doing so may result in

accelerated seal wear and/or the

possibility of severe overheating

and extensive engine damage.

Coolant Level Check

Check the coolant level at the reservoir

tank, not at the radiator. With the engine

cool, the coolant level should be between

the “FULL” and “LOW” marks.

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

• The mixture you use should con-

tain 50% concentration of anti-

freeze.

• If the lowest ambient temperature

in your area is expected to be –

35°C (–31°F) or below, use higher

concentrations up to 60% following

the instructions on the antifreeze

container.

• When putting the cap on the reser-

voir tank, line up the arrow on the

cap and the arrow on the tank. Fail-

ure to follow this can result in cool-

ant leakage.

100

76G-74E

Coolant Replacement

Trust this job to your Maruti Suzuki

Authorised Workshop.

76G-09-013

w WARNING

76G-09-014

It is dangerous to remove the radia-

tor cap when the water temperature

is high, because scalding fluid and

steam may be blown out under pres-

sure. Wait until the coolant tempera-

ture has lowered before removing the

cap.

w WARNING

Engine coolant is harmful or fatal if

swallowed or inhaled. Do not drink

antifreeze or coolant solution. If swal-

lowed, do not induce vomiting. Imme-

diately contact a poison control center

or a physician. Avoid inhaling mist or

hot vapors. If inhaled, expose yourself

to fresh air. If coolant gets in eyes,

flush eyes with water and seek medi-

cal attention. Wash thoroughly after

handling. Solution can be poisonous to

animals. Keep out of the reach of

children and animals.

9-17

INSPECTION AND MAINTENANCE

101

76G-74E

WINDSCREEN WASHER FLUID

Check that there is washer fluid in the tank.

Refill it if necessary. Use a good quality

windscreen washer fluid, diluted with water

as necessary.

Do not use “antifreeze” solution in the

windscreen washer reservoir. This can

severely impair visibility when sprayed

on the windscreen, and can also

damage your vehicle’s paint.

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.

w WARNING

CAUTION

76G-09-016

AIR CLEANER

If the air cleaner is clogged with dust, there

will be greater intake resistance, resulting

in decreased power output and increased

fuel consumption.

Take out the air cleaner element after

unhooking the clamps shown in the

illustration. Blow off dust on air cleaner

element by compressed air. If the air

cleaner element appears to be dirty, replace

it with a new one.

76G-09-017

ALTO K10

INSPECTION AND MAINTENANCE

9-18

EXAMPLE

ALTO

EXAMPLE

102

76G-74E

The air cleaner element should be

replaced every 40,000 km. More

frequent replacement is necessary

when you drive under dusty

conditions.

CAUTION

SPARK PLUGS

You should inspect spark plugs periodically

for carbon deposits. When carbon

accumulates on a spark plug, a strong

spark may not be produced. Remove

carbon deposits with a wire or pin and

adjust the spark plug gap.

76G-09-018

76G-09-019

ALTO K10

INSPECTION AND MAINTENANCE

9-19

ALTO

103

76G-74E

76G-09-020

ALTO K10

EXAMPLE

To access the spark plugs,

For Alto

1. Disconnect the coupler while pushing the

release lever,

2. Remove the bolts, and

3. Pull the spark plug boots.

For Alto K10

1. Unclamp and remove the air cleaner case.

2. If necessary, disconnect the coupler (1)

while pushing the release lever.

3. Remove the ignitor bolts.

4. Pull the spark plug boots out.

CAUTION

76G-09-021

Spark Plug gap "a"

Alto - 0.85 ± 0.5 mm

Alto K10 - 1.0 ± 0.05 mm

INSPECTION AND MAINTENANCE

9-20

ALTO

EXAMPLE

• When disconnecting the spark plug

cables, pull on the boot, not on the

cable itself. Pulling on the cable can

damage it.

• When installing the spark plugs,

screw them in with your fingers to

avoid stripping the threads. Tighten

with a torque wrench to :

Alto - 13.0–22.0 N-m (1.3–2.2 kg-m,

9.4–15.9 lb-ft)

Alto K10 - 25 N-m (2.5 kg-m, 18.0

lb-ft).

Do not allow contaminants to enter

the engine through the spark plug

holes when the plugs are removed.

• Never use spark plugs with the

wrong thread size or length.

CAUTION

When replacing spark plugs, you

should use the brand and type

specified for your vehicle. For the

specified plugs, refer to the

“SPECIFICATIONS” section at the end

of this book.

NOTE:

When installation, make sure the wires,

couplers, sealing rubber of top cover and

washers, are correctly returned in place.

104

76G-74E

INSPECTION AND MAINTENANCE

9-21

NOTE:

If 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 wiring (generally, used for more than

80,000 km or five years). If spark plug

replacement does not solve the problem,

have the ignition wiring and other ignition

system inspected by your MARUTI SUZUKI

dealer.

76G-09-022

BRAKES

Brake Fluid

Check the brake fluid level by looking at the

reservoir in the engine compartment. Check

that the fluid level is between the “MAX”

and “MIN” lines. If the brake fluid level is

near the “MIN” line, fill it up to the “MAX”

line with MARUTI GENUINE brake fluid.

Failure to follow the guidelines below

can result in personal injury or

serious damage to the brake system.

• If the brake fluid in the reservoir

drops below a certain level, the

brake warning light on the

instrument panel will come on (the

w WARNING

76G-09-023

EXAMPLE

FUEL FILTER REPLACEMEMT

Trust this replacement job to your MARUTI

SUZUKI authorised workshop.

105

76G-74E

parking brake must be fully

disengaged with ignition switch in

"ON" position). Should the light

come on, immediately ask your

MARUTI SUZUKI dealer to inspect

the brake system.

• A rapid fluid loss indicates a leak in

the brake system which should be

inspected by your MARUTI SUZUKI

dealer immediately.

• Brake fluid can harm your eyes and

damage painted surfaces. Use

caution when refilling the reservoir.

w WARNING

76G-09-024

INSPECTION AND MAINTENANCE

9-22

• Do not use any fluid other than

MARUTI GENUINE brake fluid. Do

not use reclaimed fluid or fluid that

has been stored in old or open

containers. It is essential that

foreign particles and other liquids

are kept out of the brake fluid

reservoir.

The brake fluid should be replaced

every two years or 20,000 km.

NOTE:

With disc brakes, the fluid level can be

expected to gradually fall as the brake pads

wear.

w WARNING

CAUTION

76G-09-025

Brake Pedal

Check if the brake pedal stops at the

regular height without "spongy" feeling when

you depress it. If not, have the brake

system inspected by your MARUTI SUZUKI

dealer. If you doubt the brake pedal for the

regular height, check it as follows:

With the engine running, measure the

distance between the brake pedal and floor

silencer mat when the pedal is depressed

with approximately 30 kg (66 lbs) of force.

The minimum distance required is 110 mm

(4.3 in). Since your vehicle’s brake system

is self-adjusting, there is no need for pedal

adjustment. If the pedal to floor wall distance

as measured above is less than the minimum

distance required, have your vehicle inspected

by your MARUTI SUZUKI dealer.

76G-09-026

106

76G-74E

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9-23

NOTE:

When measuring the distance between the

brake pedal and floor wall, be sure not to

include any floor covering other than

silencer mat in the measurement.

If you experience any of the following

problems with your vehicle’s brake

system, have the vehicle inspected

immediately by your MARUTI SUZUKI

dealer.

• Poor braking performance

• Uneven braking (Brakes not working

uniformly on all wheels.)

• Excessive pedal travel

• Brake dragging

• Excessive noise

• Pedal pulsation (Pedal pulsates

when depressed.)

w WARNING

Ratchet tooth specification "b"

4th- 9th

Lever pull force (1)

200 N (20kg. 44 lbs)

Check the parking brake for proper

adjustment by counting the number of clicks

made by the ratchet teeth as you slowly pull

up on the parking brake lever to the point

of full engagement. The parking brake lever

should stop between the specified ratchet

teeth and the rear wheels should be

securely locked. If the parking brake is not

properly adjusted or the brakes drag after

the lever has been fully released, have the

parking brake inspected and/or adjusted by

your MARUTI SUZUKI dealer.

76G-09-027

STEERING

Check the play of the steering wheel by

gently turning it from left to right and

measuring the distance that it moves before

you feel slight resistance. The play should

be between 0 – 30 mm (0.0 – 1.2 in).

Check that the steering wheel turns easily

and smoothly without rattling by turning it

all the way to the right and to the left while

driving very slowly in an open area. If the

amount of free play is outside the

specification or you find anything else to be

wrong, an inspection must be performed by

your MARUTI SUZUKI dealer.

76G-09-028

EXAMPLE

PARKING BRAKE

107

76G-74E

9-24

INSPECTION AND MAINTENANCE

CLUTCH PEDAL

Measure the clutch pedal play by moving

the clutch pedal with your hand and

measuring the distance it moves until you

feel slight resistance. The play in the clutch

pedal should be between 15 – 20 mm (0.6

– 0.8 in) If the play is more or less than

the above, or clutch dragging is felt with the

pedal fully depressed, have the clutch

inspected by your MARUTI SUZUKI dealer.

76G-09-029

TYRES

The front and rear tyre pressure

specifications for your vehicle are listed on

the Tyre Inflation Pressure Label and in the

“SPECIFICATIONS” section at the end of

this book. Both the front and rear tyres

should have the specified tyre pressure.

Tyre Inspection

Inspect your vehicle’s tyres periodically by

performing the following checks:

1) Measure the air pressure with a tyre

gauge. Adjust the pressure if necessary.

Remember to check the spare tyre too.

76G-09-030

• 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

handling characteristics or can

cause the rim to slip on the tyre

bead, resulting in an accident or

damage to the tyre or rim.

Overinflation can cause the tyre to

burst, resulting in personal injury.

Overinflation can also cause

unusual handling characteristics

which may result in an accident.

w WARNING

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INSPECTION AND MAINTENANCE

9-25

2) Check that the depth of the tread groove

is more than 1.6 mm (0.06 in). To help

you check this, the tyres have moulded-

in tread wear indicators in the grooves.

When the indicators appear on the tread

surface, the remaining depth of the tread

is 1.6 mm (0.06 in) or less and the tyre

should be replaced.

3) Check for abnormal wear, cracks and

damage. Any tyres with cracks or other

damage should be replaced. If any tyres

show abnormal wear, have them

inspected by your MARUTI SUZUKI

dealer.

76G-09-031

Hitting curbs and running over rocks

can damage tyres and affect wheel

alignment. Be sure to have tyres and

wheel alignment checked periodically

by your MARUTI SUZUKI dealer.

4) Check for loose wheel nuts.

5) Check that there are no nails, stones,

or other objects sticking into the tyres.

Your MARUTI SUZUKI is equipped

with tyres which are all the same type

and size. This is important to ensure

proper steering and handling of the

vehicle. Never mix tyres of different

size or type on the four wheels of

your vehicle. The size and type of

tyres used should be only those

approved by MARUTI SUZUKI as

standard or optional equipment for

your vehicle.

w WARNING

Replacing the wheels and tyres

equipped on your vehicle with certain

combinations of aftermarket wheels

and tyres can significantly change the

steering and handling characteristics

of your vehicle. Therefore, use only

those wheel and tyre combinations

approved by MARUTI SUZUKI as

standard or optional equipment for

your vehicle.

Replacing the original tyres with tyres

of a different size may result in false

speedometer or odometer readings.

w WARNING

CAUTION

109

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INSPECTION AND MAINTENANCE

9-26

Tyre Rotation

To avoid uneven wear of your tyres and to

prolong their life, rotate the tyres as

illustrated. Tyres should be rotated as

recommended in the periodic maintenance

schedule. After rotation, adjust front and rear

tyre pressures to the specification listed on

your vehicle’s Tyre Inflation Pressure Label.

Wheel Balancing

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.

76G-09-032

Changing Wheels

To change a wheel, use the following

procedure:

1) Remove the jack , tools and spare wheel

from the vehicle

NOTE:

If it is hard to loosen the bolt that secures

the spare tyre, use the jack crank as

illustrated.

2) Loosen, but do not remove the wheel

nuts.

3) Jack up the vehicle (follow the jacking

instructions in the EMERGENCY

SERVICE section in this manual)

76G-09-033

4) Remove the wheel nuts and wheel.

5) Before installing the new wheel, clean

any mud or dirt off from the surface of

the wheel and hub with a clean cloth.

Clean the hub carefully; it may be hot

from driving.

6) Install the new wheel and replace the

wheel nuts with their cone shaped end

facing the wheel. Tighten each nut

snugly by hand until the wheel is

securely seated on the hub.

7) Lower the jack and fully tighten the nuts

[to 8.5 kg-m (61.5 lb-ft)] in a crisscross

fashion with a wrench as shown in the

illustration.

76G-09-034

110

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INSPECTION AND MAINTENANCE

9-27

76G-09-035

76G-09-036

Use MARUTI Genuine wheel nuts and

tighten them to the specified torque

as soon as possible after changing

wheels. Incorrect wheel nuts or

improperly tightened wheel nuts may

come loose or fall off, which can

result in an accident. If you do not

have a torque wrench, have the wheel

nut torque checked by a MARUTI

SUZUKI authorized dealer.

w WARNING

Tubeless Tyres (If equipped)

The vehicle is equipped with Tubeless

Tyres. In tubeless tyre, a thin layer of butyl

rubber is used for lining the inside of the

tubeless tyre. This layer is to prevent air

loss and fulfilling the purpose of tube. The

air pressure is maintained by the sealing

between tyre bead and wheel rim. Tubeless

tyres are having advantage of slow air loss

and preventing sudden deflation while

driving.

Care and maintenance tips for tubeless

tyres

1. Always maintain recommended inflation

pressure. Driving continously at low

inflation pressure can lead to tyre dam-

age.

2. In case any leakage is found, check for

any nail penetration/valve core damage

or rim bent. Damaged wheel must not

be used.

3. In case tyre has run at low pressue, it

must be inspected for any defect.

4. Whenver new tyre is fitted, replace the

valve.

5. If continous high speed driving is

required, increase tyres pressure by 5

psi over recommended inflation pressure.

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INSPECTION AND MAINTENANCE

9-28

6. Never run the tyre beyond TWI (Tread

wear indicator). The tyre is recommen-

ded to be replaced when the remaining

tread has worn to this point. The indica-

tors are spaced across the tread around

the tyre marked by a triagular symbol

(TWI).

7. Always prefer tubeless tyre mounting

machine. In case of manual mounting-

tyre/wheel rim damage may occur.

8. In case of any problem, please get in

touch with MARUTI SUZUKI authorised

dealer.

76G-09-037

76G-09-038

Batteries produce flammable hydrogen

gas. Keep flames and sparks away

from the battery or an explosion may

occur. Never smoke when working in

the vicinity of the battery.

When checking or servicing the

battery, disconnect the negative cable.

Be careful not to cause a short circuit

by allowing metal objects to contact

the battery posts and the vehicle at

the same time.

w WARNING

EXAMPLE-1

EXAMPLE-2

BATTERY

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INSPECTION AND MAINTENANCE

9-29

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

below the “MIN” level line, add distilled

water to the “MAX” level line. You should

periodically check the battery, battery

terminals, and battery hold-down bracket for

corrosion. Remove corrosion using a stiff

brush and ammonia mixed with water, or

baking soda mixed with water. After

removing corrosion, rinse with clean water.

If your vehicle is not going to be driven for

a month or longer, disconnect the cable from

the negative terminal of the battery to help

prevent discharge.

w WARNING

FUSES

1. Main fuse

2. Primary fuse (IG)

3. Primary fuse (Not under ignition switch)

4. Empty

5. Empty

6. Headlight (R)

7. Headlight (L)

8. Empty

9. Radiator fan motor fuse

0. Fuel injection system fuse

c. Air conditioner (If equipped)

76G-09-039

1. Main fuse

2. Primary fuse (IG)

3. Primary fuse (Not under ignition switch)

4. Empty

5. Empty

6. Headlight (R)

7. Headlight (L)

8. Blower

9. Radiator fan motor fuse

0. Fuel injection system fuse

c. Air conditioner (If equipped)

76G-09-039

ALTO

ALTO K10

113

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INSPECTION AND MAINTENANCE

9-30

This vehicle has three types of fuses, as

described below :

Main Fuse - The main fuse takes current

directly from the battery.

Primary Fuses - These fuses are between

the main fuse and individual fuses, and are

for electrical load groups.

Individual Fuses - These fuses are in the

fuse box and for individual electrical circuits.

76G-09-040

EXAMPLE

1. HEATER 10A

2. WIPER/WASHER 15A

3. BLANK

4. STOP 10A

5. TAIL 10A

6. RADIO/DOME 15A

7. HORN HAZARD 15A

8. BLOWER 25A

9. IG 15A

0. TURN/BACK 10A

c. STEERING 30A

d. CIGAR 15A

e. STARTER FUSE 30A

f. FUSE PULLER

Main Fuse and Primary Fuses

The main fuse and primary fuses are

located in the engine compartment. If the

main fuse blows, no electrical component

will function. If a primary fuse blows, no

electrical component in the corresponding

load group will function. When replacing the

main fuse or a primary fuse, use a MARUTI

genuine replacement.

If the main fuse or a primary fuse

blows, be sure to have your vehicle

inspected by an authorized MARUTI

SUZUKI dealer. Always use a MARUTI

genuine replacement. Never use a

substitute such as a wire even for a

temporary repair, or extensive

electrical damage and a fire can result.

w WARNING

MAIN FUSE / PRIMARY FUSES

80A All Electric Load

60A

CIGAR, TURN/BACK, I.G./METER,

(IG)

HEATER, REAR DEFG, WIPER/

WASHER, POWER WINDOW

60A

DOOR LOCK, TAIL, STOP, RADIO/

DOME, HORN/HAZARD

76G-09-041

ALTO

114

76G-74E

9-31

INSPECTION AND MAINTENANCE

1. HEATER 10A

2. WIPER/WASHER 15A

3. DOOR LOCK 20A

4. STOP 10A

5. TAIL 10A

6. RADIO/DOME 15A

7. HORN HAZARD 15A

8. POWER STEERING 30A

9. IG 15A

0. TURN/BACK 10A

c. METER 10A

d. ACC 15A

e. CIGAR 15A

f. STARTER FUSE 30A

g. FUSE PULLER

h. POWER WINDOW 30A

76G-09-041A

ALTO K10

Fuse Box

The fuse boxes are located in the engine

compartment and under the driver’s side of

the dashboard.

To remove the fuse box cover under the

dashboard pull off the cover.

NOTE:

Alto

To remove the fuse from the fuse box use

the fuse puller given in the fuse box (under

dashboard) as shown in the illustration.

76G-09-042

ALTO

Fuse Box (under dashboard)

76G-09-042A

ALTO K10

Fuse Box (under dashboard)

NOTE:

Alto K10

Replace the fuse as described on the fuse

box cover. Use the fuse puller given in the

fuse box and keeping cover rib (1) in

downward direction as shown.

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INSPECTION AND MAINTENANCE

9-32

Always be sure to replace a blown

fuse with a fuse of the correct

amperage. Never use a substitute

such as aluminium foil or wire to

replace a blown fuse. If you replace

a fuse and the new one blows in a

short period of time, you may have a

major electrical problem. Have your

vehicle inspected immediately by your

MARUTI SUZUKI dealer.

NOTE:

Make sure that the fuse box always carries

spare fuses.

w WARNING

76G-09-043

BULB REPLACEMENT

• 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.

The oils from your skin may cause a

halogen bulb to overheat and burst

when the lights are on. Grasp a new

bulb with a clean cloth.

Frequent replacement of a bulb

indicates the need for an inspection of

the electrical system. This should be

carried out by your MARUTI SUZUKI

dealer.

CAUTION

w WARNING

76G-09-044

76G-09-045

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INSPECTION AND MAINTENANCE

9-33

Front Interior Light

Press the front part of the lens toward you

and pull down the lens. To install it, simply

push it back in.

The bulb can be removed by simply pulling

it out. When replacing the bulb, make sure

that the contact springs are holding the bulb

securely.

76G-09-046

Front Clearance/Turn Signal Light, Side

Turn Signal Light, rear Combination

Light, Registration Plate Light.

To remove a bulb holder from a light

housing, turn the holder counterclockwise

and pull it out. To install the holder, push

the holder in and turn it clockwise.

Two types (small oval and round) of bulb

are used for these lights. To remove and

install a small oval bulb, simply pull out or

push in the bulb.

76G-09-048

Headlights

Open the bonnet. Disconnect the coupler.

Remove the sealing rubber.

Push the retaining spring forward and

unhook it. Then remove the bulb. Install a

new bulb in the reverse order of removal.

Note:

Your vehicle is provided with two spare

he a d l i g h t b ul b s f o r r e pl a ce m e n t i n

emegency.

76G-09-047

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INSPECTION AND MAINTENANCE

9-34

To remove a round bulb from a bulb holder,

push in the bulb and turn it

counterclockwise. To install a new bulb,

push it in and turn it clockwise. You can

access the individual bulb holders as

described below:

76G-09-049

Side turn signal light

Remove the lens by using a plain screw

driver covered with a soft cloth.

76G-09-051

Front clearance light / Turn Light

Trust this replacement job to your MARUTI

SUZUKI authorised workshop.

76G-09-050

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INSPECTION AND MAINTENANCE

9-35

Rear combination light (tail, stop, turn

signal, etc.)

Undo the screws that secure the housing

and remove the housing by sliding in the

direction of the white arrow in the

illustration.

76G-09-052

WIPER BLADES

If the wiper blades become brittle or

damaged, or make streaks when wiping,

replace the wiper blades.

To install new wiper blades, follow the

procedure below.

To avoid scratching or breaking the

window, do not let the wiper arm

strike the windshield while replacing

the wiper blade.

CAUTION

76G-09-054

Registration plate light

Turn the lens counterclockwise and pull it

off

76G-09-053

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9-36

w WARNING

NOTE:

Some wiper blades may be different from the

ones described here depending on vehicle

specifications. If so consult your MARUTI

SUZUKI dealer for proper replacement method.

The left and the right wiper arm

assemblies are different from each

other. In case you have to remove the

wiper arm assemblies for any reason,

remember not to interchange the two

while fitting them back. Wrong fitment

may lead to windshield breakage.

2. Squeeze lock lever (A) towards wiper

arms (B) and remove the wiper frame

from the arm as shown.

76G-09-056

For windshield wipers:

1. Hold the wiper arm away from the

window.

76G-09-055

Inspection and Maintenance for Your Suzuki Alto 4 Door Sixth Generation (2004-2008)

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