1

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

CONTENTS INTRODUCTION TO CNG...................................................................................................... 3SAFETY PRECAUTIONS (Do’s & Don’ts) .......................................................................... 3LAYOUT OF THE CNG SYSTEM ......................................................................................... 4FUEL MODES ......................................................................................................................... 5SELECTOR SWITCH POSITION ........................................................................................... 5PETROL MODE ....................................................................................................................... 5AUTO MODE ........................................................................................................................... 5FORCED CNG MODE ............................................................................................................ 5CNG LEVEL INDICATOR....................................................................................................... 6CNG FILLER VALVE .............................................................................................................. 6CNG CYLINDER ...................................................................................................................... 6MANUAL SHUT-OFF VALVE ................................................................................................ 7LIST OF GOVERNMENT APPROVED CNG CYLINDER TESTING STATIONS ............. 8TYRE AND JACK REMOVAL ............................................................................................... 8INSTRUMENT CLUSTER ....................................................................................................... 9CNG MALFUNCTION WARNING LAMP .............................................................................. 9CNG KIT IDENTIFICATION ................................................................................................. 10CNG WARNING LABEL ....................................................................................................... 10FUSE BOX ............................................................................................................................. 10PERIODIC MAINTENANCE SCHEDULE ............................................................................ 11SPECIFICATIONS.................................................................................................................. 12FIRE EXTINGUISHER (if equipped) ........................................................................ 13PARTS DESCRIPTION ......................................................................................................... 13REMOVAL PROCEDURE (from front seat) .................................................................... 13PROCEDURE OF OPERATION ................................................................................. 13FITMENT PROCEDURE .............................................................................................. 14REFILLING SCHEDULES ........................................................................................... 14

2

3

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

INTRODUCTION TO CNG:

CNG (Compressed Natural Gas) is princi-pally constituted by methane. CNG isconsidered as clean burning fuel. Due tolow density of CNG, it is compressed at apressure of around 200 bars to enhance thevehicle on-board storage capacity.

CAUTIONIn case of any symptom of CNG leakageor releasing noise or any externaldamage to CNG piping or duringaccident, do not panic.• Stop the vehicle and switch off the

engine, roll down the windows andopen all the doors

• Ensure to close manual shut off valve.• Contact Maruti Suzuki authorized

workshop immediatly for furtherassistance.

SAFETY PRECAUTIONS (Do’s): SAFETY PRECAUTIONS (Don’ts):

1. If any service or body repair is to becarried out, turn the manual shut offvalve on CNG cylinder valve to closeposition prior to commencement of therepair work.

2. Get the CNG cylinder checked everyfive (5) years from the date of lasttesting / retesting of cylinder bygovernment authorized CNG cylindertesting agency.

3. If the vehicle does not changeover toCNG in AUTO MODE, then have yourvehicle checked by Maruti Suzukiauthorized workshop at the earliest.

4. Switch "OFF" engine while fuel filling(CNG/Petrol).

5. After refueling CNG or Petrol, ensurethat the fuel filler lid is closed. (Other-wise vehicle cannot be started)

6. In AUTO MODE, It is programmed tostart the vehicle in petrol and auto-matically shift to CNG based on theengine temperature etc. Do not pressthe accelerator pedal to change frompetrol to CNG.

1. Do not change/modify the configuration,settings or the components from CNGsystem.

2. The CNG cylinder should not berepaired under any circumstances, incase of any problem, consult with MarutiSuzuki authorized workshop.

3. Do not adjust setting of CNG system.

4. Never install LPG or any other gascylinder in place of CNG cylinder.

5. Avoid carrying inflammable material nearthe CNG cylinder.

6. Do not fill any other type of gas otherthan CNG.

7. Do not press the accelerator pedal tochange from petrol to CNG MODE.

4

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

1 Changeover switch2 High pressure pipe3 Receptacle4 Fuel lid switch5 CNG cylinder valve6 CNG cylinder

7 Vent hose8 CNG controller9 CNG injectors10 Low pressure & temperature sensor11 Engine12 Pressure regulator

13 Water hose14 High pressure sensor15 High pressure gauge16 Low pressure hose17 CNG filter

LAYOUT OF THE CNG SYSTEM

5

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

FUEL MODES

NOTE:

• Do not press the accelerator pedal tochangover from petrol to CNG mode.

• With ignition switch "ON" and engine notrunning, blinking of CNG malfunctionwarning lamp indicates that fuel lid isopen. Vehicle will not start in thiscondition.

There are three fuel modes in the vehicle(Petrol, Auto and Forced CNG) which areselectable by pressing the selector switch(1) located on the right side of the steeringwheel on the dashboard.

PETROL MODE

In this mode vehicle starts in petrol andcontinue running in petrol mode. In thismode, petrol indicator is continuouslydisplayed and CNG indicator will remain“OFF”.

Make sure that the parking brake isapplied fully and the transmission isin Neutral before attempting to startthe engine.

• Stop turning the starter immediatelyafter the engine has started or thestarter system can be damaged.

• Do not crank the engine for morethan 15 seconds at a time. If theengine doesn’t start on the first try,wait about 15 seconds before tryingagain.

CAUTION

wwwww WARNING

SELECTOR SWITCH POSITION AUTO MODE

In this mode engine starts in petrol modeand then automatically changes to CNGafter reaching programmed warming upcondition. With ignition switch ON andvehicle started in “AUTO MODE”, CNGindicator blinks on the display and PETROLindicator is displayed. After changeover toCNG, CNG indicator will be displayed andPetrol indicator will switch OFFautomatically.

NOTE:It is always recommended to start thevehicle in AUTO MODE or PETROL MODEto enhance the engine life.

FORCED CNG MODE

This is emergency mode and may be usedin cases where there is no petrol in petrol

6

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

CNG LEVEL INDICATOR

CNG level indicator (1) is built into thedisplay. When the ignition switch is in the“ON” position, this gauge gives anapproximate indication of the quantity of fuelin the fuel tank. “F” stands for full and “E”stands for empty.If the CNG level meter indicator shows onlyone segment to “E” refill the CNG tank assoon as possible.The mark (2) indicates that the fuel fillerdoor is located on the left side of thevehicle.

tank. In this mode vehicle starts in CNGmode and continues running in CNG mode.With ignition "ON" and engine not running,press and hold the changeover switch tillonly CNG indicator is displayed. In thismode, CNG indicator is displayed and Petrolindicator remains "OFF".

NOTE:It is recommended to keep sufficient amountof petrol in the petrol tank.

1

23

The CNG filler valve is integrated in fuelbox next to petrol filling area.

CNG filler valve (1) can be uncovered bypulling out the Filler valve cover (2) and itcan be covered by simply pushing it back.

Filling automatically gets cut off when thecylinder pressure becomes equal todispenser pressure. After CNG filling, ensurethat the filler valve cover (2) and fuel fillerlid (3) is closed.

NOTE:• If the Fuel filler lid (3) is kept open, you

will not be able to start the vehicle.• Engine will stop if the fuel filler lid (3)

is opened in vehicle stationary condition.

CNG CYLINDER

CNG cylinder (1) is installed in the luggagecompartment.

CAUTIONDo not place any luggage or load overcylinder as it may damage the cylinder,pipe, hose, valve etc.

CNG FILLER VALVE

7

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

CNG CYLINDER WARNING LABEL

You may find this label on the CNGcylinder.

MANUAL SHUT-OFF VALVE OPERATION

Open Close

2 2

MANUAL SHUT-OFF VALVE

Manual shut-off valve (2) is located on theleft hand side of the CNG cylinder.

OP

EN

OMBC

NG

on

lyCL

OS

E

2

CNG supply can be switched off by closingthe manual shut-off valve.

Valve closing: Turn the knob completely inclockwise direction to close the CNG supplyto Engine.

Valve opening: Turn the knob completelyin anti-clockwise direction to open the CNGsupply to Engine.

NOTE:• If the manual shut-off valve is not opened

fully, then the engine may not runproperly.

• If the manual shut-off valve is in closedcondition, it is not possible to fill CNG intothe cylinder.

NOTE:• As per Government regulation, CNG

cylinder needs to be checked andcertified every five (5) years from the dateof initial testing as mentioned on the CNGcylinder identification plate.

• Customer has to present the vehicle toa government approved testing agency.

• Failure to test the cylinder may result indenying of CNG filling by the CNGdispensing stations or may result inconfiscating the vehicle by enforcementauthorities.

8

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

• All the expenses for CNG cylinder testinghas to be borne by the customer.

• As per Government regulation, CNGcylinder has to be discarded at 20 yearsfrom the date of initial testing asmentioned in the CNG cylinderidentification plate.

• Customer has to discard the cylinder athis / her expense through governmentapproved scrap agencies.

• No person shall refill any cylinder, whichhas been repaired under sub-rule (2) withany gas unless a full report on the repairsand test carried out on the cylinder,accompanied by the repairer's certificateof testing are furnished to the ChiefController and his permission is obtainedfor its refilling.

wwwww WARNING

LIST OF APPROVED CNG CYLINDERSTESTING STATIONS

To obtain testing stations infromation visitthe following internet website address :“www.peso.gov.in”

TYRE AND JACK REMOVAL(For CNG vehicles)

• Fold the rear seat by pulling the knob1 and 2 together as shown, in order toaccess the spare wheel.

wwwww WARNING

• Unscrew spare wheel screw in anticlockwise direction.

• Remove spare wheel (3) from the frontside of vehicle as shown in the figure.

• Unscrew the jack from its holder andremove.

• Reverse the above procedure for fittingthe spare wheel and jack.

Note :• Spare wheel can only be removed from

the front side of the vehicle.• It is recommended to remove the spare

wheel first before removing the jack.

• Never remove the cylinder valvefrom the cylinder assembly. For anyassistance consult Maruti Suzukiauthorized workshop.

• Never try to clean the cylinder. Incase of any problem, contact MarutiSuzuki authorized workshop.

• Do not reuse the cylinder valve,once it is replaced / removed fromcylinder assembly.

• Even if the CNG from the cylinderis consumed till engine stops, someamount of CNG will be left out inthe tank under pressure.

VehicleFront

9

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

1) Speedometer2) Odometer / Tripmeter3) Odometer / Tripmeter selector knob4) Fuel indicator (Petrol)5) Fuel indicator (CNG)6) CNG malfunction warning Indicator lamp7) Other warning and indicator lamps

INSTRUMENT CLUSTER

EXAMPLE

When the ignition switch is turned "ON", thisCNG malfunction warning lamp comes onbriefly, to check that the CNG malfunctionlamp is troublefree.

• If CNG malfunction warning lamp glowscontinuously, with ignition "ON" there issome problem with the CNG system.Immediately get your vehicle checked byMaruti Suzuki authorized workshop.

• If CNG malfunction warning lamp blinksduring engine running, it means there issome problem in CNG system in whichvehicle cannot continue running in CNGMODE and automatically switchover topetrol mode. Have your vehicle checkedat Maruti Suzuki authorized workshop.

CNG MALFUNCTION WARNING LAMP

NOTE:With ignition switch "ON" and engine notrunning, blinking of CNG lamp indicates thatfuel lid is open. Vehicle will not start in thiscondition. Close the lid in order to start thevehicle.

10

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

KIT IDENTIFICATION

CNG cylinder identification number and CNGkit installation date is located above the fuelfilling area.

CNG WARNING LABEL

CNG warning label is located on front andrear Right doors.

Front Driver DoorFUSE BOX

9) CNG 7.5A

21) CNG Valve 7.5A

For other fuses, refer "Inspection andmaintenance" section in the main owner'smanual.

11

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

PERIODIC MAINTENANCE SCHEDULE

Kms (1 x 1000) 1 5 10 20 30 40 50 60 70 80 90 100Month 1 6 12 24 36 48 60 72 84 96 108 120

All Joints (Gas leakage) I I I I I I I I I I I I

Coolant Hoses(Leakage, Damage) I I I I I I I I I I I I

All Fasteners Torque values T T T T T T T T T T T T

CNG reducer filter cartridgewith O-Ring - - - - - R - - - R - -

CNG low pressure filtercartridge with O-Ring - - - R - R - R - R - R

CNG cylinder leak testing andcertification Every 5 years from the date of initial testing by govt. approved testing agency

CNG filler receptacle O-Ring Replace every 4 years or 300,000 Km, whichever comes earlier

T ........ Tighten to Specified Torque

I ......... Inspect and correct or replace if necessary

R ....... Replace

Note:

• This table includes services as scheduled up to 100,000 km mileage. Beyond 100,000 km, carry out the same services at thesame intervals respectively.

• For other maintenance details refer “Inspection & Maintenance” section in main Owner’s Manual.

12

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

NOTE:1) It is recommended to run the vehicle on petrol mode for 5~10 kms after every 300~500 km run in CNG mode to keep fuel system

in good condition.2) Always keep minimum 5 litres of petrol in your petrol tank.

SPECIFICATIONS

NOTE:Specifications are subject to change without notice.

Mass (Weight) (Kgs)

Kerb Weight 785-815 Kgs

Gross Weight 1185 Kgs

Seating Capacity 4 persons

Fuel Capacity (litres)

Petrol 35 L

CNG (Water Filling Capacity) 60 L

13

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

FIRE EXTINGUISHER (if equipped)Do's and Don'ts

Do's1. Check pressure gauge periodically. Max

charging pressure is 15Kgf/cm2 (in greenzone (2)).

2. When pressure drops, indicator needle (1)will shift to the red zone (3). Immediatelycontact Maruti Suzuki authorized work-shop for inspection / refilling.

3. Get the fire extinguisher serviced, onlythrough Maruti Suzuki authorized work-shop.

4. Ensure that the Fire extinguisher isalways kept at its prescribed position inthe vehicle.

5. Refill the fire extinguisher immediatelyafter use.

Don't• Do not use water for cleaning fire

extinguisher. (Use clean cloth forremoving dust)

• Do not rely on used or discharged fireextinguisher.

Fire extinguisher is located below co-passenger's seat.

LOCATION

PARTS DESCRIPTION

REMOVAL PROCEDURE (from front seat)

Lift Lever (1) of fire extinguisher slightlyupwards and pull the fire extinguisher in thedirection as shown in the figure, in orderto disengage it from clamps (2).

1) Fire extinguisher cylinder

2) Seal3) Safety Pin

4) Lever5) Nozzle

PROCEDURE OF OPERATION

1. Hold the fire extinguisher (1) upright.

2. Break seal (2) by rotating the safety pin(3).

14

FOR VEHICLES FITTED WITH CNG FUEL SYSTEM

FITMENT PROCEDURE

3. Pull Safety pin (3)

4. Squeeze lever (4) and direct the jet fromnozzle (5) towards the near edge of thefire with a rapid (fast) sweeping motion.

5. Drive the fire towards the far edge untilflames are extinguished.

NOTE:Fire extinguisher is only meant for small firecaused in vehicle by external source only.

Insert the body of fire extinguisher (1) in tothe clamps (3) and place the nozzle (2)carefully downwards, on the clamp

NOTE:Ensure that the nozzle of fire extinguisheris properly seated on the clamp.

REFILLING SCHEDULES

1. Refilling is necessary after every use.

2. Fire extinguisher needs refilling afterevery 3 years even if it is not used.

15

79F-74E

MEMO

16

79F-74E

MEMO