MARUTI SUZUKI ZEN-AX Owner'S Manual Download Page 100

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100

72F-74E

Front turn signal light

TYPE-1
Undo the two screws and remove the lens.

TYPE-2 (Zen-Classic)
Trust this job to your authorized MARUTI
dealer.

Side turn signal light
Remove the lens by using a plain screw
driver covered with a soft cloth.

Rear combination light (tail, stop, turn
signal, etc.)
Undo the two screws that secure the
housing and remove the housing by sliding
in the direction of the white arrow in the
illustration.

The wiring grommet may come off during
bulb replacement. Ensure that the grommet
is in place before refitting the housing.

INSPECTION AND MAINTENANCE

9-29

70F-07-053

70F-07-054

72F-09-009E

Summary of Contents for ZEN-AX

Page 1: ...CONTENTS MAINTENANCE SERVICE RECORD WARRANTY POLICY BEFORE DRIVING STEERING COLUMN CONTROLS INSTRUMENT PANEL OTHER CONTROLS AND EQUIPMENT OPERATING YOUR VEHICLE DRIVING TIPS AND SAFE DRIVING INSPECTION AND MAINTENANCE EMERGENCY SERVICE BODY WORK CARE GENERAL INFORMATION SPECIFICATIONS SERVICE NETWORK ...

Page 2: ...2 8 PAGES MARUTI 800 ESTEEM ZEN CARBURETTOR 843 63B 72F D ...

Page 3: ...The next owner will need this information also You are invited to avail the three free inspection services as described in this manual Three free inspection coupons are attached to this manual Please show this manual to your dealer when you take your vehicle for any Service To prolong the life of your vehicle and reduce maintenance costs the periodic maintenance must be carried out according to th...

Page 4: ...tted without explicit approval by MARUTI UDYOG LIMITED INFORMATION ON EMISSION w w w w w CAUTION Maruti recommends that maintenance on your vehicle be performed by Maruti Authorised Dealer Service Station If you take your vehicle for Service or Pollution check up at workshop other than Maruti Authorised Dealer Service Station please make sure that the Second air hose connecting second air valve an...

Page 5: ..._______________________________________________________________________TEL NO ________________ ADDRESS STAMP OF SELLING DEALER SELLING DEALER CODE SHOWROOM IMPORTANT INFORMATION TO CUSTOMER WORKSHOP Dear Customer For any assistance with regard to our product please contact General Manager Works Manager at any of our Dealer or Authorised Service Station For additional enquiry you may contact our Re...

Page 6: ...00 ESTEEM ZEN CARBURETTOR MAINTENANCE SERVICE RECORD DATE OF KIND OF MILEAGE DESCRIPTION OF JOB NAME OF SERVICING JOB CARD MECHANIC S SERVICE SERVICE km DEALER MASS NO SIGNATURE F free Service P Paid Service W Warranty A Accident 1 2 ...

Page 7: ...Maruti Owner s Manual j any vehicle which has been assembled disassembled adjusted or repaired by other than an Maruti authorised dealer service station Maruti Udyog Limited hereinafter called Maruti warrants that each new Maruti vehicle distributed in India by Maruti and sold by an authorised Maruti dealer will be free under normal use and service from any defects in material and workmanship at t...

Page 8: ... of each owner to a make certain that the warranty registration PDI card was completed at the time of delivery of the vehicle b have performed at his own expenses by an Maruti authorised dealer service station all the service inspections specified in the Maruti Owner s Manual and Service Booklet and maintain adequate proof that such service inspections have been performed c make certain that the M...

Page 9: ...9 72F 74E 3 BEFORE DRIVING BEFORE DRIVING Fuel Recommendation 3 1 Keys 3 2 Door Locks 3 3 Windows 3 5 Mirrors 3 7 Front Seat Adjustment 3 8 Adjustable Head Restraints if equipped 3 9 Seat Belts 3 9 ...

Page 10: ...t the responsibility of MARUTI and may not be covered under Warranty Fuels containing 5 or less methanol may be suitable for use in your vehicle if they contain cosolvents and corrosion inhibitors NOTE If you are not satisfied with the driveability or fuel economy of your vehicle when you are using a petrol alcohol blend you should switch back to unleaded petrol containing no alcohol Be careful no...

Page 11: ...ate key place your order with a MARUTI dealer only Note Keep the spare key very carefully When it is lost consult your dealer by quoting key number The fuel tank has an air space to allow for fuel expansion in hot weather If you continue to add fuel after the filler nozzle has automatically shut off or an initial blowback occurs the air chamber will become full Exposure to heat when fully fuelled ...

Page 12: ...ver Pull out the lock lever to unlock the door Always lock all doors when driving Locking the door prevents occupants from being thrown from the vehicle in the event of an accident It also helps prevent unintentional opening of the doors w w w w w WARNING 3 3 Child Proof Locks if equipped As illustrated a child proof lock is provided for both rear doors When the lock lever is down position 1 the c...

Page 13: ... from entering the car Completely closing the hatchback lid also helps prevent occupants from being thrown from the vehicle in the event of an accident w w w w w WARNING Central door locking system if equipped You can lock and unlock all the side doors simultaneously by using the key in the driver s door lock You can also lock or unlock all the side doors by moving the driver s door lock lever rea...

Page 14: ...perated when the ignition switch is in the ON position TYPE 1 To close a window push the top part of the switch and to open the window push the rear part of the switch The driver s window has an auto down and auto up feature for added convenience at toll booths or drive through restaurants for example This means you can open or close the window without holding the window switch in the Down or Up p...

Page 15: ...g it again You should always push in the lock button when there are children in the vehicle Children can be seriously injured if they get part of their body caught by the window during operation w w w w w WARNING w w w w w WARNING w w w w w CAUTION TYPE 2 To open a window push the top part of the switch and to close the window lift up the top part of the switch The driver s window has an auto down...

Page 16: ...adjust the mirror with the selector set to the day position Only use the night position if it is necessary to reduce glare from the headlights of vehicles behind you Be aware that in this position you may not be able to see some objects that could be seen in the day position w w w w w WARNING MIRRORS Day Night Rearview Mirror if equipped To adjust the interior rearview mirror set the selector tab ...

Page 17: ...er for each front seat is located under the front of the seat on the inboard side To adjust the seat position pull up on the adjustment lever and slide the seat forward or rearward After adjustment try to move the seat forward and rearward to ensure that it is securely latched To avoid excessive seat belt slack which reduces the effectiveness of the seat belts as a safety device make sure that the...

Page 18: ...aints removed Do not attempt to adjust the head restraint while driving Head restraints are designed to help reduce the risk of neck injuries in the case of an accident Adjust the head restraint to the position which places the top of the head restraint closest to the top or your ears There are two height positions for the head restraints To raise the head restraint pull upward on the restraint un...

Page 19: ...only during a sudden stop or impact No modifications or additions of any sort should be made to the seat belt or its operating mechanism w w w w w WARNING 3 10 70F 01 024E To reduce the risk of sliding under the belt during a collision position the lap portion of the belt across your lap as low on your hips as possible and adjust the belt to a snug fit using the proper method described below Make ...

Page 20: ... small children can be purchased locally and should be used Make sure that the system you purchase meets applicable safety standards Read and follow all the directions provided by the manufacturer Avoid contamination of seat belt webbing by polishes oils chemicals and particularly battery acid Cleaning may safely be carried out using mild soap and water For children if the shoulder belt irritates ...

Page 21: ...ERING COLUMN CONTROLS STEERING COLUMN CONTROLS Ignition Switch 4 1 Lighting Turn Signal Control Lever 4 2 Hazard Warning Switch 4 4 Windscreen Wiper and Washer Lever 4 4 Horn 4 5 Electric Power Steering if equipped 4 5 ...

Page 22: ... ignition and prevents normal use of the steering wheel after the key is removed To release the steering lock fully insert the key and turn it clockwise to one of the other positions If you have trouble turning the key to unlock the steering try turning the steering wheel slightly to the right or left while turning the key To avoid possible injury do not operate controls by reaching through the st...

Page 23: ...ever remove the ignition key while the vehicle is moving The steering wheel will lock and you will not be able to steer the vehicle Do not leave children alone in a parked vehicle Unattended children could cause accidental movement of the vehicle which could result in severe personal injury Always remove the key when parked to prevent unintentional operation of the vehicle and to improve security ...

Page 24: ...ion move the lever up or down to activate the left or right turn signals Normal Turn Signal Move the lever clockwise until it clicks to signal a right turn or anticlockwise to signal a left turn When the turn is completed the signal will cancel and the lever will return to its normal position Lane Change Signal Some times such as when changing lanes the steering wheel is not turned far enough to c...

Page 25: ...r turn signal lights and both turn signal indicators will flash simultaneously To turn off the lights push the switch again Use the hazard warning lights to warn other traffic during emergency parking or when your vehicle could otherwise become a traffic hazard Windscreen Washer To spray windscreen washer fluid pull the lever toward you The windscreen wipers will automatically turn on at low speed...

Page 26: ... operating the wipers Clear ice or packed snow from the wiper blades before using the wipers Check the washer fluid level regularly Check it often when the weather is bad Only fill the washer fluid reservoir 3 4 full during cold weather to allow room for expansion if the temperature falls low enough to freeze the solution Press the center piece of the steering wheel to sound the horn The horn will...

Page 27: ... Gauge 5 6 Choke Knob 5 7 Rear Window Wiper Washer Switch if equipped 5 7 Rear Window Defroster Switch if equipped 5 8 Ashtray 5 8 Glove Box 5 8 Cigarette Lighter if equipped 5 9 Fog light switch if equipped 5 9 Heating System if equipped 5 10 System Operating Instructions 5 11 Air Conditioning System if equipped 5 14 System Operating Instructions 5 14 ...

Page 28: ... switch 4 Windscreen wiper and washer switch 5 Hazard warning switch 6 Rear window wiper washer switch if equipped 7 Heater control panel 8 Cigarette lighter if equipped 9 Ashtray 10 Bonnet release 11 Center ventilator 12 Side ventilator 13 Side defroster 14 Glove box 15 Fuse box 16 Choke knob 5 1 72F 05 015 ...

Page 29: ... 72F 74E INSTRUMENT PANEL 1 Speedometer 2 Odometer 3 Trip meter if equipped 4 Trip meter reset knob 5 Fuel gauge 6 Temperature gauge 7 Warning and indicator lights 5 2 72F 05 016 72F 05 017 TYPE 1 TYPE 2 ...

Page 30: ...dealer to inspect the brake system If the brake fluid level warning light does not go out after the engine has been started and the parking brake has been fully released If the brake fluid level warning light does not come on when the ignition switch is turned to the START position If the brake fluid level warning light comes on at any time during vehicle operation NOTE Because the disc brake syst...

Page 31: ... along with the respective turn signal lights When you turn on the hazard warning switch both arrows will flash along with all of the turn signal lights Charging Light This light comes on when the ignition switch is turned on and goes out when the engine is started The light will come on and remain on if there is something wrong with the battery charging system If the light comes on when the engin...

Page 32: ...cords the total distance the vehicle has been driven The tripmeter can be used to measure the distance travelled on short trips or between fuel stops You can reset the tripmeter to zero by pushing the reset knob Keep track of your odometer reading and check the maintenance schedule regularly for required services Increased wear or damage to certain parts can result from failure to perform required...

Page 33: ...F 05 020E TEMPERATURE GAUGE When the ignition switch is on this gauge indicates the engine coolant temperature Under normal driving conditions the indicator should stay within the normal acceptable temperature range between H and C If the indicator approaches H and maintains that reading overheating is indicated Follow the instructions for engine overheating in the EMERGENCY REMEDIES section Conti...

Page 34: ...OW WIPER WASHER SWITCH if equipped With the ignition switch in the ON position push the wiper switch to turn on the rear wiper To turn the wiper off push the switch again To spray window washer fluid hold in the washer switch Washer fluid will stop spraying when you release the switch 70F 03 017 70F 03 020E 72F 05 023E ...

Page 35: ...s securely Never drive with the glove box lid open It could cause injury if an accident occurs w w w w w WARNING w w w w w WARNING 5 8 REAR WINDOW DEFROSTER SWITCH if equipped When the rear window is misted push this switch to clear the window An indicator light will be lit when the defroster is on The defroster will only work when the ignition switch is in the ON position To turn off the defroste...

Page 36: ...h it all tha way into the receptacle and release it It will automatically heat up and will pop out to its normal position when it is ready for use FOG LIGHT SWITCH if equipped 70F 03 023E The fog light comes on when the fog light switch is pushed in with the head light switch turned to the second position ...

Page 37: ...TRUMENT PANEL HEATING SYSTEM if equipped The heating system provides heating demisting and ventilation a Windscreen defroster b Side defroster c Side outlet d Center outlet e Floor outlet 5 10 72F 05 004 70F 03 028E ...

Page 38: ...indscreen defroster outlets and the side defroster outlets DEFROST 6 Temperature controlled air comes out of the windscreen defroster outlets and the side defroster outlets Air Intake Lever 7 This lever is used to select between circulating outside air FRESH AIR or recirculating inside air RECIRCULATED AIR Temperature Control Lever 8 This lever is used to control the temperature of the air that co...

Page 39: ... to the desired fan speed position Moving the fan switch to a higher fan speed position increases heating efficiency Quick Heating Using recirculated air The lever settings are the same as for normal heating except you move the air intake lever to RECIRCULATED AIR If you use this heating method for an extended period of time the air in the vehicle can become contaminated and the windows can become...

Page 40: ...r intake lever to FRESH AIR the temperature control lever to the desired temperature position and the fan switch to HIGH When the windscreen has become clear move the fan switch to the desired fan speed position Cool Face Warm Feet Move the function selector to BI LEVEL the air intake lever to FRESH AIR the temperature control lever to the desired temperature position and the fan switch to the des...

Page 41: ...button again During operation of the air conditioner you may notice slight changes in engine speed These changes are normal the system is designed so that the compressor turns on or off to maintain the desired temperature Less operation of the compressor results in better fuel economy Normal Cooling using outside air push in the A C button move the function selector to VENTILATION the air intake l...

Page 42: ...dows closed it will cool faster if you open the windows briefly while you operate the air conditioner with the air intake lever at FRESH AIR and the fan at high speed Dehumidifying Push in the A C button move the function selector to the desired function position the air intake lever to FRESH AIR the temperature control lever to the desired temperature position and the fan switch to the desired fa...

Page 43: ...CONTROLS AND EQUIPMENT Parking Brake Lever 6 1 Pedals 6 2 Gear Lever 6 3 Fuel Filler Cap 6 3 Folding Rear Seats 6 5 Sun Visor 6 6 Interior Light Switch 6 6 Assist Grips 6 7 Bonnet 6 7 Tyre Changing Tools 6 8 Luggage Compartment Cover if equipped 6 9 ...

Page 44: ... apply the parking brake fully The parking brake lever is located between the seats To apply the parking brake hold the brake pedal down and pull the parking brake lever all the way up To release the parking brake hold the brake pedal down pull up slightly on the parking brake lever push the button on the end of the lever with your thumb and lower the lever to its original position For automatic t...

Page 45: ...he transmission lever Depressing the pedal disengages the clutch Do not drive with your foot resting on the clutch pedal It could result in excessive clutch wear clutch damage or unexpected loss of engine braking Brake Pedal 2 2 2 2 2 Your MARUTI vehicle is equipped with front disc brakes and rear drum brakes Depressing the brake pedal applies both sets of brakes You may hear occasional brake sque...

Page 46: ...e page 7 4 The fuel filler cap is located on the left rear side of the vehicle The fuel filler lid can be unlocked by pulling up the opener lever located on the outboard side of the driver s seat and locked by simply closing the lid Remove the fuel filler cap slowly The fuel may be under pressure and may spray out causing injury w w w w w WARNING OTHER CONTROLS AND EQUIPMENT 70F 04 005E 72F 06 001...

Page 47: ...p slowly to allow any residual pressure to escape To install turn the cap clockwise If you need to replace the fuel cap use only a cap specified for your model Using an improper fuel cap can cause a serious malfunction of the fuel system You can get the correct replacement cap from your MARUTI dealer w w w w w WARNING w w w w w CAUTION OTHER CONTROLS AND EQUIPMENT 72F 06 002 72F 06 003E ...

Page 48: ...If you need to carry cargo in the passenger compartment with the rear seat back folded forward be sure to secure the cargo or it may be thrown about causing injury Never pile cargo higher than the seatbacks When returning a rear seat to the normal position make sure that movement of the seatback is unobstructed and the seatback is securely latched The rear seat of your vehicle can be folded forwar...

Page 49: ... it by the hard plastic parts or the sun visor can be damaged This light switch has three positions which function as described below 1 The light comes on and stays on regardless of whether the door is open or closed 2 The light comes on when the door is opened 3 The light remains off even when the door is opened NOTE Only front doors are involved in lighting operation of interior light w w w w w ...

Page 50: ...upt manoeuvre causing injury BONNET To open the bonnet 1 Pull the bonnet release handle located on the outboard side of the driver s side of the instrument panel This will disengage the bonnet lock halfway 2 Push the under bonnet release lever sideways with your finger as shown in the illustration While pushing the lever lift up the bonnet w w w w w WARNING 6 7 OTHER CONTROLS AND EQUIPMENT 70F 04 ...

Page 51: ...s shaft counterclockwise and pull the jack out of the storage bracket To stow the jack place it in the storage bracket and turn the shaft clockwise until the jack is securely held in place The jack should be used only to change wheels It is important to read the jacking instructions in the EMERGENCY SERVICE section of this manual before attempting to use the jack After using the jack jack handle a...

Page 52: ...partment are hidden from view by a luggage compartment cover Do not carry items on top of the luggage compartment cover even if they are small and light Objects on top of the cover could be thrown about in an accident causing injury or could obstruct the driver s rear view OTHER CONTROLS AND EQUIPMENT 6 9 70F 04 023 ...

Page 53: ...OPERATING YOUR VEHICLE Exhaust Gas Warning 7 1 Daily Inspection Checklist 7 1 Starting the Engine 7 2 Using the Transmission 7 2 Braking 7 5 Running in 7 6 Catalytic Converter if equipped 7 6 Improving Fuel Economy 7 7 Trailer Towing 7 7 ...

Page 54: ... w w WARNING Before driving 1 Make sure that windows mirrors lights and reflectors are clean and unobstructed 2 Check the tyres 3 Look for fluid leaks 4 Adjust the seat 5 Check the brake pedal 6 Adjust the mirrors 7 Make sure that you and passengers have properly fastened your seat belts 8 Make sure that all warning lights come on as the key is turned to the ON or START position 9 Check all gauges...

Page 55: ...nob fully if the atmospheric temperature is below 250 C NOTE Press the accelerator pedal 3 4 times before pulling choke knob if the atmospheric temperature is below 100 C Release your foot from the pedal Turn the ignition switch to the START position to start the engine Adjust the choke knob position so that the engine runs at a moderately fast idle speed Continue choke control until the engine ca...

Page 56: ...pedal The higher the vehicle speed is the more you will need to press the accelerator pedal to get a downshift This will give you increased acceleration for overtaking 2 Low 2 Use this position to provide extra power when climbing hills or to provide engine braking when going down hills Do not change into Low 2 at speeds greater than 97 km h L Low 1 Use this position to provide maximum power when ...

Page 57: ...120 km h Fifth 40 km h Top Speed Reduce your speed and change down to a lower gear before going down a long or steep hill A lower gear will allow the engine to provide braking Avoid riding the brakes or they may overheat resulting in brake failure When driving on slippery roads be sure to slow down before changing down Excessive and or sudden changes in engine speed may cause loss of traction whic...

Page 58: ...can easily loose traction such as gravel etc the stopping distance required for your vehicle may be greater than for a comparable vehicle with a conventional brake system Allow for extra stopping distance when driving on loose surfaces The distance needed to bring any vehicle to a halt increases with the speed of the vehicle The braking distance needed for example at 60 km h will be approximately ...

Page 59: ...ed because lead deactivates the pollutant reducing components of the catalyst system It is very important to keep the engine properly tuned Engine misfiring which can result from an improperly tuned engine may cause overheating of the catalyst This may result in permanent heat damage to the catalyst and other vehicle components To minimize the possibility of catalyst or other vehicle damage Mainta...

Page 60: ... maintain a slow steady speed whenever possible Slowing down and then accelerating again uses more fuel Keep a steady cruising speed Keep as constant a speed as road and traffic conditions will permit Keep the air cleaner clean A dirty air cleaner will cause the carburation system to supply too much fuel to the engine for the amount of air being supplied The result is waste of fuel due to incomple...

Page 61: ...61 72F 74E DRIVING TIPS AND SAFE DRIVING 8 DRIVING TIPS AND SAFE DRIVING High Speed Driving 8 1 Driving on Hills 8 1 Driving on Slippery Roads 8 2 Do s and Don ts for Safe Driving 8 3 ...

Page 62: ...rol can occur Keep speed down when the road surface is wet At high speeds the vehicle may be affected by side winds Therefore reduce speed and be prepared for unexpected buffeting which can occur at the exits of tunnels when passing by a cut of a hill or when being overtaken by large vehicles etc When climbing steep hills the car may begin to slow down and show a lack of power If this happens you ...

Page 63: ... the handling characteristics After driving through water test the brakes while driving at a slow speed to see if they have maintained their normal effectiveness If the brakes are less effective than normal dry them by repeatedly applying the brakes while driving slowly until the brakes have regained their normal effectiveness Under wet road conditions you should drive at a lower speed than on dry...

Page 64: ...ction contains basic rules for safe driving Read it carefully for good understanding of the content so that you can enjoy safe and pleasant driving in your Maruti vehicle Starting 1 Adjust the driver s seat for the proper driving posture 2 Adjust the rear view mirror so as to obtain the best possible rear view 3 Before moving off look forward and back to confirm safety 8 3 DRIVING TIPS AND SAFE DR...

Page 65: ... light and stop sign When moving into the intersection without any traffic lights or signs drive slowly to confirm safety 2 Always follow other vehicles at a safe distance in order to prevent a rear end collision should the car ahead make a sudden stop 8 4 DRIVING TIPS AND SAFE DRIVING 72F 08 004 72F 08 005 72F 08 006 ...

Page 66: ...ecelerate to a safe speed Don t apply brakes during cornering or a cornering skid may occur 5 When overtaking other cars watch out for the oncoming car and carefully confirm the safety 6 Don t attempt zigzag driving which will hinder your control over the car and cause an accident 8 5 DRIVING TIPS AND SAFE DRIVING 72F 08 007 72F 08 008 72F 08 009 72F 08 010 ...

Page 67: ... behind you 2 Gradually apply the brake 3 Bring the car to a halt 3 When driving on a downhill try not to apply the brake but use the engine brake effectively Overuse of the footbrake may result in total brake failure Braking 1 Use the parking brake when parking your car and shift the gear shift lever into the first gear or reverse gear position for the sake of safety 8 6 DRIVING TIPS AND SAFE DRI...

Page 68: ...ver s visual range becomes In such a state it is difficult to anticipate any hazard and the driver feels much fatigued 6 Never do sharp handling during high speed driving You will lose your control over your car 7 When overtaking or changing the lane while driving at a high speed keep an ample car to car distance 8 7 DRIVING TIPS AND SAFE DRIVING 72F 08 014 72F 08 015 72F 08 016 72F 08 017 ...

Page 69: ...a trip 2 Take rest at certain intervals to prevent an accident which may occur when you are sleepy or tired Night time driving 1 Drive more slowly at night than in the daytime for the visual range is restricted at night 8 8 DRIVING TIPS AND SAFE DRIVING 72F 08 018 72F 08 019 72F 08 020 ...

Page 70: ... drivers For that observe the following Drive at a safe speed Maintain a sufficient distance between your car and the vehicle ahead Don t force yourself to overtake other vehicles Don t make quick start hard steering or sudden stops Allow an ample time in the driving schedule Observe traffic rules and regulations CONCLUSION A perfect driver does not exist The endeavour of every motorist should be ...

Page 71: ...edule 9 2 Water Pump Belt 9 7 Engine Oil and Filter 9 8 Gear Oil 9 12 Automatic Transmission Fluid 9 13 Engine Coolant 9 14 Windscreen Washer Fluid 9 16 Air Cleaner 9 16 Spark Plugs 9 17 Brakes 9 18 Steering 9 20 Clutch Pedal 9 20 Tyres 9 21 Battery 9 24 Fuses 9 24 Bulb Replacement 9 27 Wiper Blades 9 31 ...

Page 72: ...or Park for automatic transmission vehicles 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 hot exhaust components such as the manifold pipes and mufflers Do not allow smoking sparks or flames around gasoline or the battery Flammable fumes are present Do not get under yo...

Page 73: ...ehicle is required This table shows in kilometres and months when inspections adjustments lubrication and other services should be performed Maruti recommends that maintenance on your Maruti vehicle be performed by Maruti Authorised Dealer Service Station Whenever it becomes necessary to replace parts on your vehicle it is recommended that you use MARUTI GENUINE PARTS MGP INSPECTION AND MAINTENANC...

Page 74: ... R I I I R I I I R 3 Engine oil level leakage API GRADE SF SG SH R I R I R I R I R I R I R I R I R 4 Cooling system hoses and connections leakage damage I I I I I I I I I I I I I I I I I 5 Engine oil filter leakage R I R I R I R I R I R I R I R I R 6 Engine bolts All cylinder head and manifold fixings T T T T T T T T 7 Engine mounting loose damage T T T T T T T T 8 Valve clearance A A A A A 9 Cams...

Page 75: ... 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 I I I I I I I 3 Manual Transmission Transfer and Differential oil level leakage I I I I R I I I R I I I R I I I R 4 Automatic Transmission Fluid level replacement I I I I I I I I I I I I I I I I R 5 Hose Automatic Transmission Fluid I I I I I I I I I I I I I I I I R DRIVE SHAFTS 1 Drive shafts boots bent of boots d...

Page 76: ...s oil leakage damage I I I I I I I I I I I I I I I I I 5 All bolts and nuts loose I T I T I T I T I T I T I T I T 6 Suspension arms and Tension rods I I I I I I I 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 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 I I I I I I I ELECTRICAL 1 Battery electrolyte level leakage I I I I I I I I I I I I I I I...

Page 77: ...I I I I 2 Check Receiver Drier bubbles I I I I I I I I I I I I I I I I I 3 Tighten compressor mounting bolts T T T T T T T T T T T T T T T T T 4 Check all hose joints tighten if necessary I I I I I I I I I I I I I I I I I 5 Check functioning of Recirc flap I I I I I I I I I I I I I I I I I 6 Clean condenser with high pressure water C C C C C C C C C C C C C C C C 7 Check belt for frayed edges chan...

Page 78: ...he belt needs to be replaced or adjusted have it done by your MARUTI dealer When the engine is running keep hands hair clothing tools etc away from the fan and water pump belt Even though the fan may not be moving it can automatically turn on without warning Make sure the water pump belt tension is correct If the belt is too loose insufficient battery charging engine overheating or excessive belt ...

Page 79: ...ther before starting the engine or at least five 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 Specified oil Be sure that the engine oil you use comes under the API classification of SF SG or S...

Page 80: ...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 two or three 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 ...

Page 81: ...eve 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 gasket Tighten the plug to a torque of 3 0 4 0 kg m 22 0 28 5 lb ft Replace the oil filter 1 Using an oil filter wrench turn the o...

Page 82: ...e and install the filler cap 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 t...

Page 83: ...ler and level plug 1 Tightening torque 3 6 5 4 kg m 26 5 39 0 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 or 80W 90 gear oil Type of oil Gear oil API GL 4 After driving the vehicle the transmission oil temperature may be high enough to burn you Wait until the oil fil...

Page 84: ...s in the HOT range on the dipstick Specified Fluid Use an automatic transmission fluid equivalent to DEXRON IIE or DEXRON III Fluid Level Check Driving with too much or too little fluid can damage the transmission You must check the fluid level with the automatic transmission fluid at normal operating temperature To warm up the transmission fluid drive the vehicle or idle the engine until the temp...

Page 85: ...dding or replacing coolant use a high quality ethylene glycol antifreeze and anticorrosion Non Amine type diluted with distilled water If the lowest ambient temperature in your area is expected to be 150 C 50 F or above make the antifreeze concentration of the mixture you use at least 30 but no more than 50 If 160 C 30 F or below make the concentration at least 50 If the 50 concentration does not ...

Page 86: ...wn out under pressure Wait until the coolant temperature has lowered before removing the cap 2 Remove the reservoir tank cap Remove the reservoir by lifting it up and drain the reservoir completely by pouring the coolant in to a suitable container 3 Loosen the drain plug attached to the lower part of the radiator and drain the coolant into a suitable container 4 Tighten the drain plug on the radia...

Page 87: ... 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 AIR CLEANER w w w w w WARNING w w w w w CAUTION 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...

Page 88: ... holes when the plugs are removed Never use spark plugs with the wrong thread size or length 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 INSPECTION AND MAINTENANCE 9 17 w w w w w CAUTION 70F 07 025E 70F 07 026E When replacing spark p...

Page 89: ... SAE J1703 or DOT 3 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 INSPECTION AND MAINTENANCE 9 18 w w w w w WARNING w w w w w WARNING 70F 07 028E 70F 07 029 ˇ ˇ ˇ ˇ ˇ ˇ ˇ ˇ ˇ ˇ Do not use any fluid ...

Page 90: ...th your vehicle s brake system have the vehicle inspected immediately by your MARUTI 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 INSPECTION AND MAINTENANCE 9 19 w w w w w WARNING 70F 07 030 Parking brake Check the parking brake for proper adjustment by c...

Page 91: ...lowly 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 dealer 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...

Page 92: ... 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 dealer The fro...

Page 93: ...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 as standard or optional equipment for your vehicle Replacing the original tyres with tyres of a different size may result in false speedometer or odomet...

Page 94: ...CE section in this manual 4 Remove the wheel nuts and wheel 5 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 6 Lower the jack and fully tighten the nuts 4 0 7 0 kg m 28 9 50 5 lb ft in a crisscross fashion with a wrench as shown in the illustration INSPECTION AND MAINTENANCE ...

Page 95: ...h 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 FUSES 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 negat...

Page 96: ...r extensive electrical damage and a fire can result Fuse Box The fuse fox is located under the driver s side of the dashboard Remove the fuse box cover by pushing in at both ends and pulling off the cover To identify the amperage and location refer to the fuse list shown on the back of the fuse box cover To remove a fuse hook the fuse with the end hook on the fuse box cover and pull out the fuse I...

Page 97: ...wn 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 dealer NOTE Make sure that the fuse box always carries three spare fuses 5A 15A and 30A INSPECTION AND MAINTENANCE 9 26 w w w w w WARNING 70F 07 044E 70F 07 045E 70F 07 046E 70F 07 047 ...

Page 98: ...ure that the contact springs are holding the bulb securely Headlights Open the bonnet Remove the socket and rubber cover Then unhook the bulb holding spring and replace the bulb Note Your vehicle is provided with two spare headlight bulbs for replacement in emergency Frequent replacement of a bulb indicates the need for an inspection of the electrical system This should be carried out by your MARU...

Page 99: ...e used for these lights To remove and install a small oval bulb simply pull out or push in the bulb 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 Front clearance light TYPE 1 Open the bonnet and support it with the prop rod TYPE 2 Zen Classi...

Page 100: ...screw driver covered with a soft cloth Rear combination light tail stop turn signal etc Undo the two screws that secure the housing and remove the housing by sliding in the direction of the white arrow in the illustration The wiring grommet may come off during bulb replacement Ensure that the grommet is in place before refitting the housing INSPECTION AND MAINTENANCE 9 29 70F 07 053 70F 07 054 72F...

Page 101: ...ight Undo the two screws and remove the light housing INSPECTION AND MAINTENANCE 9 30 70F 07 056 72F 09 010E 70F 07 057 Rear fog light if equipped Detach the light housing by removing the nuts and remove the lens by undoing the screws ...

Page 102: ...nt from the ones described here depending on vehicle specifications If so consult your 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 70F 07 058 High mount stop la...

Page 103: ...E 2 Squeeze lock lever A towards wiper arms B and remove the wiper frame from the arm as shown INSPECTION AND MAINTENANCE 9 32 For windshield wipers 1 Hold the wiper arm away from the window 70F 07 060 72F 09 008 ...

Page 104: ...104 72F 74E MEMO ...

Page 105: ...105 72F 74E EMERGENCY SERVICE 10 EMERGENCY SERVICE Jacking Instructions 10 1 Jump Starting Instructions 10 2 Towing 10 4 Emergency Remedies 10 4 ...

Page 106: ...least 2 inches 51 mm before it contacts the vehicle Use of the jack when it is within 2 inches of being fully collapsed may result in failure of the jack 1 Park the vehicle securely on hard level ground 2 Choke the front and rear wheel diagonally opposite the wheel to be changed 3 Switch on the hazard warning flasher if your vehicle is in or near traffic 4 Slacken but do not remove wheel nuts on t...

Page 107: ... certain that your hands and the jump leads remain clear from pulleys belts or fans 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 If the booster battery you use for jump starting is installed in another vehicle make sure the two vehicles are not touching each other If your batt...

Page 108: ... those necessary for safety reasons for example headlights or hazard lights 3 Make jump lead connections as follows a Connect one end of the first jump lead to the positive terminal of the flat battery b Connect the other end to the positive terminal of the booster battery c Connect one end of the second jump lead to the negative terminal of the booster battery d Make the final connection to an un...

Page 109: ...e speed for a few minutes until the indicator is within the normal acceptable temperature range between H and C If you see or hear escaping steam stop the vehicle in a safe place and immediately turn off the engine to let it cool Do not open the bonnet when steam is present When the steam can no longer be seen or heard open the hood to see if the coolant is still boiling If it is you must wait unt...

Page 110: ...ator cap when the water temperature is high because scalding fluid and steam may be blown out under pressure The cap should only be taken off when the coolant temperature has lowered To help prevent personal injury keep hands tools and clothing away from the engine cooling fan and air conditioner fan if equipped These electric fans can automatically turn on without warning EMERGENCY SERVICE 10 3 w...

Page 111: ...111 72F 74E BODY WORK CARE 11 BODY WORK CARE Corrosion Prevention 11 1 Vehicle Cleaning 11 2 ...

Page 112: ... the painted surfaces Should you find any chips or scratches in the paint touch them up immediately to prevent corrosion from starting If the chips or scratches have gone through to the bare metal have a qualified body shop make the repair Keep Passenger and luggage compartments clean Moisture dirt or mud can accumulate under the floor mats and may cause corrosion Occasionally check under these ma...

Page 113: ...can be removed from vinyl with water or mild soap Use a brush to help loosen dirt After the dirt is loosened rinse the mat thoroughly with water and dry it in the shade Carpets Remove dirt and soil as much as possible with a vacuum cleaner Using a mild soap solution rub stained areas with a clean damp cloth To remove soap rub the areas again with a cloth dampened with water Repeat this until the s...

Page 114: ...e or brush Do not use hard materials which can scratch the paint 3 Wash the entire exterior with a mild detergent or car wash soap using a sponge or soft cloth The sponge or cloth should be frequently soaked in the soap solution When using a commercial car wash product observe the cautions specified by the manufacturer Never use strong household detergents or soaps BODY WORK CARE 11 3 w w w w w WA...

Page 115: ...115 72F 74E GENERAL INFORMATION 12 GENERAL INFORMATION Vehicle Identification 12 1 ...

Page 116: ...is and or engine serial numbers are used to register the vehicle They are also used to assist your dealer when ordering or referring to special service information Whenever you have occasion to consult your MARUTI dealer remember to identify your vehicle with this number Should you find the number difficult to read you will also find it on the identification plate GENERAL INFORMATION 12 1 70F 10 0...

Page 117: ...117 72F 74E SPECIFICATIONS 13 SPECIFICATIONS ...

Page 118: ...mission DIMENSIONS UNIT mm Overall length 3 495 Overall width 1 495 Overall height 1 405 Wheelbase 2 335 Tread front 1 335 rear 1 305 Ground clearance 165 MASS WEIGHT UNIT Kg Kerb mass weight M T 740 755 A T 778 793 Gross vehicle mass weight rating M T 1160 A T 1190 Seating Capacity 5 persons 13 1 SPECIFICATIONS ...

Page 119: ...on timing 100 10 B T D C at 800 r min Standard spark plug NGK BP5EY MICO W8DC CHAMPION N10YC Battery 38B20R 28AH 5HR Fuses See INSPECTION AND MAINTENANCE section Headlight 12V 60 55W Turn signal light 12V 21W Side turn signal light 12V 5W Clearance light 12V 5W Tail brake light 12V 5 21W Registration plate light 12V 5W Reversing light 12V 21W 18W Zen Classic SPECIFICATIONS 13 2 ...

Page 120: ...7 kg cm2 Suspension type front strut rear Coil spring STEERING Toe in 0 1 mm CAPACITIES Coolant M T 4 0 L Including reservoir tank A T 3 8 L Fuel tank 35 L Engine oil 3 3 L Replacement with Oil Filter Transmission oil M T 2 4 L A T 4 9 L Replacement quantity approximately 1 5 L 13 3 SPECIFICATIONS ...

Page 121: ...This Owner s manual service booklet applies to the following models produced by MARUTI UDYOG LIMITED ZEN LX VX VXi AX ZEN CLASSIC ...

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