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MARUTI SUZUKI Maruti 800 User Manual

MARUTI SUZUKI Maruti 800
644 pages
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IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special mean-
ings. Pay special attention to the messages high-
lighted by these signal words.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
This service manual is intended for autho-
rized Maruti dealers and qualified service
mechanics only. Inexperienced mechanics
or mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the
mechanic and may render the vehicle un-
safe for the driver and passengers.

Table of Contents

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MARUTI SUZUKI Maruti 800 Specifications

General IconGeneral
BrandMARUTI SUZUKI
ModelMaruti 800
CategoryAutomobile
LanguageEnglish

Summary

General Information

How to Use This Manual

Instructions on navigating and utilizing the service manual for effective information retrieval.

Precautions

General safety and handling precautions applicable to various service procedures.

Metric Information

Details on metric fasteners, strength identification, and tightening torque specifications.

Engine Mechanical (F8B Engine)

General Description

Overview of the F8B engine, its configuration, and valve mechanism operation.

Engine Lubrication

Explanation of the engine's internal oil pump system and lubrication pathways.

Inspection of Engine Components

Procedures for inspecting critical engine parts like cylinder head, valves, and pistons.

Piston and Piston Rings

Detailed inspection and measurement of piston diameter, cylinder bore, and ring clearance.

Brake System Service and Diagnosis

Diagnosis Table

A table outlining common brake system problems, their possible causes, and suggested corrections.

Front Disc Brake

Detailed information on the front disc brake system, including caliper, pads, and disc components.

Rear Drum Brake

Explains the components and service procedures for the rear drum brake system.

Bleeding Brakes

Step-by-step instructions for removing air from the hydraulic brake system.

Steering, Suspension, and Wheel Systems

Front End Alignment

Procedures and specifications for adjusting front wheel alignment, including toe, camber, and caster.

Manual Rack and Pinion

Detailed information on the manual rack and pinion steering system, including diagnosis and overhaul.

Front Suspension

Components and service procedures for the front suspension system, including struts and control arms.

Rear Suspension (Coil Spring Type)

Procedures for servicing the rear suspension system, focusing on coil spring components.

Wheels and Tires

Information on tire specifications, replacement, maintenance, and balancing procedures.

Ignition System Service and Diagnosis

Components

Identifies key components of the vehicle's ignition system, including ECM, sensors, and coils.

Diagnostic Flow Table

A troubleshooting guide for common ignition system issues, linking symptoms to possible causes and corrections.

High-Tension Cords

Procedures for removing, inspecting, and installing high-tension cords and their resistance specifications.

Ignition Timing

Instructions for checking and adjusting ignition timing using a scan tool or timing light.

Engine Fuel System Service

Fuel Tank

Details on fuel tank removal, inspection, and installation procedures.

Fuel Filter

Procedures for removing and installing the fuel filter, emphasizing replacement as an assembly.

Fuel Pump

On-vehicle inspection and removal/installation procedures for the fuel pump assembly.

Engine Cooling System Maintenance and Service

Coolant Level

Guidelines for checking and maintaining the correct engine coolant level in the reservoir tank.

Cooling System Flush and Refill

Step-by-step instructions for flushing and refilling the cooling system with the proper coolant mixture.

Thermostat

Procedures for removing, inspecting, and testing the thermostat's functional specifications.

F8B Engine Mechanical Services

Engine Lubrication

Explanation of the engine's internal oil pump system and lubrication pathways.

Dismounting Engine

Detailed steps for removing the engine from the vehicle, including draining fluids and disconnecting components.

Inspection of Engine Components

Procedures for inspecting critical engine parts like cylinder head, valves, and pistons.

Piston and Piston Rings

Detailed inspection and measurement of piston diameter, cylinder bore, and ring clearance.

F8D Engine Mechanical Services

Engine Lubrication

Explanation of the engine's internal oil pump system and lubrication pathways.

Compression Check

Procedures for measuring compression pressure across all three cylinders.

Valve Lash (Clearance)

Instructions for checking and adjusting valve clearance with the engine mounted.

4-Speed Manual Transmission Service

Diagnosis Table

Troubleshooting guide for common transmission issues like slipping, hard shifting, and noise.

Transmission Oil

Procedures for checking transmission oil level, leakage, and oil change, including specifications.

Gear Shift Control

Details on the gear shift mechanism components and their adjustment.

Dismounting/Remounting

Steps for removing and reinstalling the transmission assembly from the engine.

Clutch System Service

Diagnosis Table

Common clutch problems, their causes, and corrective actions.

Clutch Pedal

Procedures for adjusting clutch pedal height and checking pedal free travel.

Clutch Cable

Instructions for removing, inspecting, and installing the clutch cable, including free travel adjustment.

Clutch Cover, Clutch Disc and Flywheel

Procedures for removing and installing the clutch cover, disc, and flywheel assembly.

Body Electrical System Service

Cautions in Servicing

Essential safety precautions for working with electrical systems, including battery and connector handling.

Diagnosis

Troubleshooting tables for common body electrical system faults like headlights, turn signals, and brake lights.

Headlight

Procedures for inspecting the headlight switch, removing, and installing headlight assemblies.

Wiper and Washer Systems

Inspection procedures for the front wiper/washer switch and motor.

Body Service Procedures

Front Door Glass and Window Regulator

Steps for removing, inspecting, and installing the front door glass and window regulator mechanism.

Rear Door Glass and Window Regulator

Procedures for removing, inspecting, and installing the rear door glass and window regulator assembly.

Door Lock

Exploded views and removal/installation procedures for front and rear door lock components.

Door

Procedures for removing the door assembly and adjusting latch striker alignment.

Vehicle Restraint System Service

Seat Belt with ELR

General description and service precautions for seat belts with Emergency Locking Retractor (ELR) systems.

Front Seat Belt

Procedures for removing, inspecting, and installing front seat belts, including anchor bolt torque.

Rear Seat Belt

Instructions for removing and installing rear seat belts, emphasizing precautions and anchor bolt tightening.

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