DIRECTOR
GENERAL BORDER ROADS
GENERAL
MAINTENANCE INSTRUCTION NO 226
OF
MARUTI GYPSY KING MPFI
Introduction
1. Maruti
Gypsy King MPFI 4WD 1298 CC RHD petrol driven with hard top/6 gear/ speed with
standard accessories Bharat stage III (Eqvt EURO III) competent.
2. To
prolong the life of your vehicle and reduce maintenance cost, the periodic
maintenance must be carried out according to the ‘periodic maintenance schedule
described in ‘inspection and maintenance’ section of this GMI. Periodic
maintenance is essential for preventing trouble and accident to ensure yore
satisfaction and safety. Daily care and inspection is essential for prolonging
the operating life of the vehicle and for safe driving, it also reduce the wear
and tear on your vehicle, prolongs its life, give more mileage, if failure of
the guide lines below can result in personal injury or serious damage to the
vehicle. All information and instruction in this GMI is based on the latest
Owner’s manual and service booklet.
AIM:-
The
instruction are issued as guide lines for schedule of preventive maintenance,
lubrication of Maruti Gypsy King MPFI manufactured by Maruti Udhyog Ltd for
regular attention to keep the vehicle in good mechanical condition and it must
be strictly followed.
Action
by
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a)
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User Unit:-
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To carry out periodic inspection and
monitor regular/periodical maintenance as laid down in this instruction and record the
tasks done in the log book.
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b)
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Field Wksp (GREF):-
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i)
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To carry out and monitor, maintenance
schedule and oil changes as per periodical maintenance laid down in the
maintenance instructions and to check the record of maintenance including
lubrication.
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ii)
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To advise the user unit in respect of any
lapses noticed.
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c)
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Mobile maintenance team:-
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To ensure that proper maintenance is
carried out and report accordingly to Task Force Commander and OC Fd Wksp for
necessary action.
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4. Details: The
details of maintenance and lubrication with their periodicity are as under :-
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a)
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Periodical
maintenance schedule
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Appx
‘A’
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b)
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Driving
tips and safe driving
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Appx
‘B’
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c)
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Safety
precaution
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Appx
’C’
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d)
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Lubricants
and coolant
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Appx
‘D’
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e)
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Tech
specifications
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Appx
‘E
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5. Please
ack receipt.
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(Hari Prakash)
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SE (E&M) FS
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Dir (Tech)
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Distribution
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for Dir Gen Border Roads
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Normal
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Appx’A’
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PERIODIC
MAINTENANCE:-
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|||||||||
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A----Adjust
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C---- Clean
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T---- Tighten
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O---- Rotate
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||||||||
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R---- Replace or change
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L---- Lubricate
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I----- Inspect
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||||||||
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This interval should be judged by odometer reading or
months, whichever comes first
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Periodic maintenance service at
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|||||||||
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Kms
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1,000
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5,000
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10,000
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20,000
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30,000
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40,000
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|||||
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Months
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1
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6
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12
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24
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36
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48
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ENGINE
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1.
Water pump drive belt (tension, wear)
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A
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I
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I
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I
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I
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R& A
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|||||
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2.
Engine coolant (level, leakage)
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I
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I
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I
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R
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I
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R
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|||||
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3.
Engine oil and oil filter
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R
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I
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R
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R
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R
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R
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|||||
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4.
Cooling system hoses and
connection.(leakage, damage)
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I
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I
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I
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I
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I
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I
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|||||
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5.
Engine bolt (All cyl head & manifold fixing)
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-
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-
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T
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-
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T
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-
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|||||
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6.
Engine mounting (loose, damage)
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-
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-
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T
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-
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T
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-
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|||||
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7.
Valve clearance
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-
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A
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-
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A
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-
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A
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|||||
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8.
Cam shaft timing belt (damage, wear)
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-
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-
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-
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I
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-
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I
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|||||
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9.
Exhaust system. (noise, leakage or defective)
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-
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I
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-
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I
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-
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I
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|||||
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10.
Positive crank case ventilation system (hoses, connections and valve)
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-
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I
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-
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I
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-
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I
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IGNITION
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1.
Ignition wiring (damage, deterioration)
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-
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-
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-
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I
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-
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I
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|||||
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2.
Spark plugs (clean & adjust the gap)
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-
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-
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I
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R
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I
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R
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|||||
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|||||
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1.
Air cleaner
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Clean
every 5,000 Kms& replace every40,000 Kms
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||||||||||
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2.
Accelerator cable and throttle shafts
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-
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I&L
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I&L
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I&L
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I&L
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I&L
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|||||
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3.
Fuel tank cap, fuel line &connections(leakage and damage)
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-
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I
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-
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-
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-
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I
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|||||
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4.
Fuel filter (leakage)
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I
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I
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I
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I
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I
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R
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CLUTCH &
TRANSMISSION
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1.
Clutch pedal (play)
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I
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I
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I
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I
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I
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I
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2.
Clutch slipping(dragging or excessive play)
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I
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I
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I
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I
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I
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I
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|||||
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3.
Manual transmission/transfer & differential oil(level, leakage)
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I
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I
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I
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R
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I
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R
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|||||
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PROPELLER SHAFTS
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1.
Propeller shafts (Play)
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-
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-
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I
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I
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I
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I
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|||||
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2.
Universal joints (slack)
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-
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-
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I
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I
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I
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I
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|||||
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WHEEL
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1.
Tyres(Air pressure, abnormal wear, crack, rotation)
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Rotate
and inspect every 5,000 Kms
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||||||||||
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2.
Wheel (damage)
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I
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I
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I
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I
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I
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I
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3.
Front wheel bearings(loose, damage)
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-
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I
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I
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I
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I
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I
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|||||
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4.
Rear wheel bearings(loose, damage)
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-
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I
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I
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I
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I
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I
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BRAKE
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1.
Brake fluid(level)
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I
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I
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I
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R
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I
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R
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|||||
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2.
Brake pedal (pedal-to-wall clearance)
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I
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I
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I
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I
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I
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I
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|||||
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3.
Parking brake lever and cable(play & damage)
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I
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I
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I
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I
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I
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I
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|||||
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4.
Brake discs & pads(wear)
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-
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I
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I
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I
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I
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I
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|||||
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5.
Master cylinder& wheel cylinder(oil leakage)
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I
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I
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I
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I
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I
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R
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|||||
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6.
Brake hoses and pipes (leakage ,damage)
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I
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I
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I
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I
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I
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I
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|||||
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FRONT AND REAR
SUSPENTION
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1.
Suspension strut (leakage, damage)
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I
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I
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I
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I
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I
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I
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|||||
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2.
Suspension arms and knuckle supports(loose, damage)
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-
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I
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I
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I
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I
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I
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|||||
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3.
Rear spring (damage)
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-
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I
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I
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I
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I
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I
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|||||
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4.
Shock absorber(leakage ,damage)
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I
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I
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I
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I
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I
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I
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|||||
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5.
All bolts and nuts(loose)
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-
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T
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T
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T
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T
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T
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|||||
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6.
Suspension arms and tension rods
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-
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I
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I
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I
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I
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I
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|||||
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STEERING
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1.
Steering wheel (Play, loose)
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I
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I
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I
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I
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I
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I
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|||||
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2.
Steering gear box(loose, damage)
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I
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I
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I
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I
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I
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I
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|||||
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3.
All rods and arms(loose, damage, wear)
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I
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I
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I
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I
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I
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I
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|||||
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ELECTICAL
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|||||
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1.
Battery electrolyte(level, leakage)
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I
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I
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I
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I
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I
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I
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|||||
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2.
Wiring harness connection(looseness, damage)
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-
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I
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I
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I
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I
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I
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|||||
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3.
Lighting system(operation, stains, damage)
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I
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I
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I
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I
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I
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I
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|||||
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4.
Horn (operation)
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I
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I
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I
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I
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I
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I
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|||||
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5.
System voltage
|
-
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I
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I
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I
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I
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I
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|||||
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BODY
|
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|||||
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1.
All chassis bolts and nuts(tighten)
|
-
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I
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T
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T
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T
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T
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|||||
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2.
All latches, hinges & locks (function)
|
I
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I&L
|
I&L
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I&L
|
I&L
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I&L
|
|||||
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3.
Wash your vehicle frequently
|
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|||||
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|||||
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1.
Operation of brakes, Gear shifting& speedometer
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I
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I
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I
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I
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I
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I
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|||||
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2.
Body and chassis noise
|
I
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I
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I
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I
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I
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I
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|||||
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Appx-
’B’
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(1) DRIVING TIPS AND SAFE DRIVING:
|
|||
|
a)
|
Wear seat belts at all times while you
drive the vehicle.
|
||
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b)
|
Never drive while under the influence of
alcohol or other drugs. Alcohol and drugs can seriously impair your ability
to drive safely, greatly increasing the risk of injury to yourself and
others.
|
||
|
c)
|
You
should avoid driving when you are tired, sick, irritated or under stress.
|
||
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d)
|
Don’t attempt to take curves at the same
speeds that you would in a vehicle with a lower gear center of gravity.
|
||
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e)
|
The stability of any vehicle will be
affected by strong gusting cross winds. This is an especially true with small
four wheel drive vehicles, because of the higher center of gravity to
minimize the effects of cross winds on your vehicle you should drive slower
under such condition.
|
||
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HIGH SPEED DRIVING:-
|
|||
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When
driving at a high speed, pay attention to the following.
|
||
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|
Stopping distance
progressively increase with vehicle speed. Apply the brakes for enough ahead
of the stopping point to allow for the extra stopping distance.
|
||
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|
On rainy day, ”Aquaplaning can occur”. Aquaplaning
is the loss of direct contact between the road surface and the vehicle tyres
due to the water film forming between them. Steering or braking the vehicle
while ”Aquaplaning” can be very difficult, and loss of control can occur.
Keep speed down when the road surface is wet.
|
||
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At high speeds, the vehicle may be affected
by side winds. Therefore, reduce speed and be prepared for unexpected buffer
ting, which can occur at the exits of tunnels, when passing by a cut of a
hill, or when being over taken by large vehicles etc.
|
||
|
DRIVING
ON HILL:-
|
|||
|
a)
|
When climbing steep hills, the vehicle may
begin to slow down and show a lack of power, if this happens, you should
change to a lower gear so that the engine will be operating in its normal
power range.
|
||
|
b)
|
When driving a downhill, the engine should
be used for braking by shifting to next lower gear.
|
||
|
c)
|
When descending a downhill, never turn the
ignition key to the ‘OFF’ position. Result emission control system may not damage.
|
||
|
DRIVING
ON SLIPPERY ROAD:-
|
|||
|
a)
|
Under wet road condition you should drive
at a lower gear speed than on dry roads due to possible slippage of tyres
during braking. When driving on Icy, snow covered, or muddy roads reduce your
speed and avoid sudden acceleration, abrupt braking or sharp steering
movement, use 4-wheel drive high range (4H) for better traction.
|
||
|
|
|||
|
If you use snow chains to increase tyre
traction, observe the following precautions
|
|||
|
a)
|
Choose a safe place away from traffic to
install the chains.
|
||
|
b)
|
When installing the chains carefully follow
the manufacturer instructions.
|
||
|
c)
|
With the chains on drive only at slow and
moderate speeds.
|
||
|
d)
|
Use 4- wheel drive high range (4H) for
better traction and directional stability.
|
||
|
OFF
|
|||
|
When
you are driving on off-road for different driving techniques is used than
from paved roads.
|
|||
|
STEEP
INCLINE REQUIRES CAUTION:-
|
|||
|
a)
|
Never drive your vehicle up and extremely
steep incline. Coming down a steep hill can be trickery than getting up one.
|
||
|
b)
|
Keep vehicle heading straight down to the
hill on low gear.
|
||
|
c)
|
Don’t lock the brakes, if the vehicle
begins to slide, accelerate slightly to regain steering control
|
||
|
d)
|
Do not drive across the side of hill
|
||
|
e)
|
Avoid sudden reaction in mud, Ice, or snow.
Make sure your vehicle tyres in
good condition and always maintain the specified tyre pressure.
|
||
|
DO
AND DON’TS FOR SAFE DRIVING:-
|
|||
|
Exercise care in handling your vehicle. Be
conscious of not only your safety but also the safety of other on the road,
and thus enjoy the best and most comfortable driving experience. Please read
this section carefully.
|
|||
|
a)
|
Adjust the driver’s seat for the proper
driving posture.
|
||
|
b)
|
Adjust the rear view mirror so as to obtain
the best possible rear view.
|
||
|
c)
|
Before moving off, look forward and back to
confirm safety.
|
||
|
d)
|
Don’t start quickly, for it is dangerous
and wastes fuel.
|
||
|
e)
|
Always follow other vehicles at a safe
distance in order to prevent a rear end collision, should the vehicle ahead
make a sudden stop.
|
||
|
f)
|
Turn on the turn signal at least 30 meters
before making a turn or change the lane so as not to be hit from behind.
|
||
|
g)
|
When over taking other vehicle’s, watch out
for the oncoming vehicle and carefully confirm the safely.
|
||
|
h)
|
Don’t attempt zig- zag driving which will
hinder your control over the vehicle and cause an accident
|
||
|
j)
|
Use the parking brake when parking your
vehicle and shift the gear in to 1st gear or reverse gear position for the
sake of safety.
|
||
|
k)
|
When driving on a downhill, try not to
apply the brake but use the engine brake
effectively. Over us the foot brake may result in brake failure.
|
||
|
l)
|
Avoid reckless high speed driving and try
to drive at a safe speed suitable for
the road conditions while maintaining a constant speed.
|
||
|
m)
|
Never do sharp handling during high speed
driving. You will lose your control over your vehicle.
|
||
|
n)
|
When over taking or changing the lane while
driving at a high speed, keep a sample vehicle distance.
|
||
|
LONG
DISTANCE DRIVING:-
|
|||
|
a)
|
Be sure to perform safety checks before
starting a trip.
|
||
|
b)
|
Take rest at certain intervals to prevent
an accident which may occur when you are sleepy or tired.
|
||
|
NIGHT
TIME DRIVING:-
|
|||
|
a)
|
Derive more slowly at night than in the day
time, for the visual range is restricted at night
|
||
|
b)
|
Don’t over take other vehicles at night,
darkness bothers your sense of speed and hinders your judgment on the
vehicle- to-vehicle distance. .
|
||
|
c)
|
Always keep the window glasses clean.
|
||
|
d)
|
Don’t operate the wiper motor when the wind
shield glass is dry, it may damage the glass and blades.
|
||
|
|
|
||
|
|
|
Appx-
’C’
|
|
|
SAFETY
PRECAUTION:-
|
|||
|
You should
take extreme care when working on your vehicle to prevent accidental
injury. Some precautions that you should be especially careful to observe:-
|
|||
|
a)
|
Don’t leave the engine in running
condition.
|
||
|
b)
|
When the engine is running, keep hands,
clothing, tool and other objects away from the fan and water pump belt.
|
||
|
c)
|
Don’t touch ignition wires or other
ignition system parts when starting the engine
or engine is in running condition.
|
||
|
d)
|
Be careful not to touch hot exhaust
components such as the manifold, pipes and mufflers.
|
||
|
e)
|
Don’t allow smoking, sparks or flames
around gasoline or the battery.
|
||
|
f)
|
Keep used oil, coolant and fluids away from
children and pets. Dispose of used fluids properly.
|
||
|
g)
|
Rear shock absorber is filled with high
pressure gas. Never attempt to disassemble it or through it in to a fire.
Avoid storing it near a heater or heating device.
|
||
|
h)
|
All maintenance should be carried out with
the ignition switch in the “OFF” position.
|
||
|
j)
|
When the engine is in running condition.
Keep hands, hair, clothing, tools away from the fan and drive belt.
|
||
|
k)
|
Spark plug should be checked periodically
for carbon deposit. 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.
|
||
|
l)
|
Never use spark plugs with the wrong thread
sizes or length.
|
||
|
m)
|
Brake fluid should be replace every 2 year
or 20,000 Kms
|
||
|
n)
|
Check the parking brake for proper
adjustment.
|
||
|
o)
|
Check the play of the steering wheel by
gently turning it from left to right and turn easily/ smoothly. If find any
things else to be wrong rectify it timely.
|
||
|
p)
|
Battery produces flammable hydrogen gas.
Keep flames and sparks away from the battery or an explosion may occur.
|
||
|
q)
|
Use the jack only to change wheels
|
||
|
r)
|
Never jack up the vehicle with inclined
surface.
|
||
|
s)
|
Never run the engine when the vehicle is
supported by the jack.
|
||
|
t)
|
Vehicle equipped with electronic fuel
injection system will not start by pushing or towing as the fuel pump will
not work in this condition. This starting method could also result in
permanent damage to the catalytic converter. Use jump lead to start a vehicle
with a weak or medium charge battery.
|
||
|
u)
|
Air pressure should be checked when the
tyre are cold, or you may get inaccurate reading.
|
||
|
v)
|
Check inflation, time to time while
inflating the tyre gradually.
|
||
|
w)
|
Check that, the treads groove of tyres is
found less than 1.6mm (0.06 in), tyre should be replaced with new one.
|
||
|
x)
|
Hitting curbs and running over rocks can
damage tyres and affects wheel alignment. Be sure to have tyres and wheels
alignment checked periodically.
|
||
|
y)
|
It is important to ensure proper steering
and handling of the vehicle. Never mix tyres of different size or type, may
result in false speedometer reading.
|
||
|
z)
|
To avoid uneven wear of tyres and to
prolong their life, rotate the tyres as illustrated. Tyre should be rotated
every 5,000 Kms as recommended in the periodic maint schedule.
|
||
|
aa)
|
To avoid damage to your vehicle during towing,
proper equipment and towing procedures must be used. Safety chain should
always be used.
|
||
|
|
|
||
|
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Appx- ’D’
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LUBRICANTS
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Engine
oil – 20W-40/20W-50
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Gear
oil - SAE 90,75W-90 or 80W-90
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Coolant - High quality ethylene glycol
antifreeze coolant.
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Appx- ’E’
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TECHNICAL SPECIFICATIONS
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Overall length
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:
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4010 mm
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Over all width
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:
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1540 mm
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Over all height
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:
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1875 mm (Soft top)
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1845 mm (Hard top)
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Wheel base
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:
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2375 mm
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Tread - Front
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:
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1300 mm
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Rear
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:
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1310 mm
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Ground
clearance
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:
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210 mm
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Gross
Weight
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:
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1585 kg (Soft top)
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1620 kg (Hard top)
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Seating
capacity
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:
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8 persons
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Engine
type
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:
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G13 B- Four stroke
cycle,16 valve, water cooled (SOHC)
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Number
of cylinders
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:
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4
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Bore
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:
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74.0 mm
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Stroke
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:
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75.5 mm
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Piston
displacement
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:
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1298 cm³
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Compression
ratio
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:
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9.2:1
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Standard
spark plug
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:
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NGK-
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Battery
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:
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12 V 28 AH
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Head
light
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:
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12 V 45/40 W
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Turn
signal light
|
:
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12V 21 W
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Side
turn signal light
|
:
|
12V 5 W
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Clearance
light
|
:
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12V 5 W
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Tail
brake light
|
:
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12V 5/21 W
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Registration
plate light
|
:
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12V 10W
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Reversing
light
|
:
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12V 21 W
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Tyre
size front & rear
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:
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F78-15-$ PR
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Tyre
pressure - Front
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:
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1.4 Kg/cm²
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Rear
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:
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1.4 Kg/cm²(light load)1.8
Kg/ cm²(full load)
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CAPACITY
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Coolant(Including
reservoir tank)
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:
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4.8 L
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Fuel
tank
|
:
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40 L
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Engine
oil
|
:
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4.2 L(Replacement with oil
filter)
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Transmission
oil
|
:
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1.3 L
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Transfer
gear box oil
|
:
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0.8 L
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Differential
oil - Front
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:
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2.0 L
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Rear
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:
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1.5 L
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