[Ajayabd]

Originally Posted by jinojohnt

At least my Alto doesn't have this issue (2008 model). I think it has something to do with the pressure plate, release fork or the clutch cable.

I had to replace the clutch every 12000 km (three times), and some trial and error settings change done by the local mechanic seems to have fixed the issue (running fine for the past 40000 km). Even he doesn't know what fixed the issue

Below are my opinions on the basis of my experience:
1. The problem with the clutch is that there are not many mechanics who are knowledgeable or capable of adjusting the settings. Most of them say 'there is nothing much we can change in the clutch settings because everything is set at the factory.
2. You have no way of ensuring that all the parts have been indeed replaced as claimed, because it is difficult to unmount and check. Since there are too many parts, you need to understand each part and stay with your car at a local garage to ensure that the parts are changed. I replaced the Clutch plate, pressure plate, release bearing, release fork and clutch cable at Popular Automobiles Trivandrum (at least got billed), but when the clutch failed again in 12000 km, I got it opened at a local garage to find that the release fork was still the factory fitted one (you can make out from the robotic welding). When I raised this with the CRM, the reply I get is "We cannot bill a part that was not replaced, because everything is computer"

At least in my case, the (trial and error) adjustment of the clutch cable adjuster nut multiple times across clutch failures seems to have done the trick.

Thank you very much for your reply.

The garage where I changed the clutch is very experienced. I was there during the disassembly and assembly. Moreover I personally bought the clutch assembly consisting of cover assembly, plate and release bearing. The clutch cable is also new.
So there is no room for parts being billed without actually being replaced.

I still have with me the old clutch parts. The old release bearing was shot. Clutch plate had more life in it because it was replaced 30k back.

If clutch fork is the problem, then the new clutch should also show this thud sound from first km after replacement. But the thud sound came back only after few hundred km.

One more thing I noticed is when I press and release the clutch pedal during idle in neutral, I get tuk tuk sound from clutch area. Don't know what to do now because mechanic is suggesting that this sound may be from driveshaft.

Please advice.

[Aroy]

Originally Posted by Ajayabd

..........
If clutch fork is the problem, then the new clutch should also show this thud sound from first km after replacement. But the thud sound came back only after few hundred km.

One more thing I noticed is when I press and release the clutch pedal during idle in neutral, I get tuk tuk sound from clutch area. Don't know what to do now because mechanic is suggesting that this sound may be from driveshaft.

Please advice.

If the sound is from drive shaft, then there will be a play, which can be checked as follows
. Find an open road with none or very little traffic.
. Get the speed upto 40/50 km/h and drive at this speed in 4th gear for 1 minute or so.
. Put the gear on neutral.
. After a some distance put it back into 4th gear.

If there is a play in the transmission, then there will be a jerk and a sound when either engaging or disengaging from neutral .

You can also check for play by putting the car in neutral, jacking the front up and rotating the front wheels. If there is a play then initially the wheel will be easy to move and once it engages it will be slightly tighter.

[ard1955]

Originally Posted by ash22

Update on this issue.
For Welding, the quoted price was 500 INR. Since its already rusted, Welder was not sure if the Welding will hold for longer duration.
As suggested by our members, I replaced the complete muffler set from my FNG for 3,200 INR. Inquired at Vishnu cars Chennai and they quoted 6,500 INR for the same muffler change. Car is super silent now.Didnt have pics as of now. Will post accordingly.

Thanks.

Hi Ash22! I have a similar issue with my Alto. Looks like the leak is near the Exhaust manifold for me. If you don't mind, could you please forward the contact information of the FNG so that I can take it there and get it done?

[urbanzameendar]

Good day!

My Alto has developed a strange problem recently. The car by default sees a heavy highway usage due to the nature of my work and has crossed 1.92 lac kilometers in 11 years.

I recently did some major work on the car, got the clutch kit, timing belt, all 3 engine mounts changed. Also did a complete suspension overhaul, basically changed the entire suspension setup with MGP Parts. Immediately after the work was done, I drove the car for 5000 kms across Gujarat and Rajasthan. While on the way to Udaipur, continuous driving through the hilly roads lead to the failure of Thermostat Valve which started throwing the coolant out of the reserve tank. Which was fixed later by a road side garage by removing the kaput valve itself.

As advised by that mechanic as well my FNG where the car gets taken care of back home, most Alto owners remove the Thermostat Valve, therefore I drove the car for a good 2 months without the valve. I was alarmed when my fuel efficiency suffered big time due to it (came to know by reading about it on various sites), immediately got a new valve installed.

Now coming back to the problem, since driving back from Udaipur, the car started giving out a strange rattling sound (a metallic Ghrrrrrr) somewhere from the engine bay or the chassis mostly in 2nd and 3rd gears, during cold start. This is an on and off issue, sometimes there is no rattling sound at all and then there is suddenly this nasty ghrrrrrrrrrr sound popping up. This happens sometimes during highway drives as well while gaining speed after slowing down.

Totally confused with it. Any help would be highly appreciated.

[stallmaster]

Originally Posted by urbanzameendar

the car started giving out a strange rattling sound (a metallic Ghrrrrrr) somewhere from the engine bay or the chassis mostly in 2nd and 3rd gears, during cold start. This is an on and off issue, sometimes there is no rattling sound at all and then there is suddenly this nasty ghrrrrrrrrrr sound popping up. This happens sometimes during highway drives as well while gaining speed after slowing down

This definitely sounds like a transmission issue. Hard to diagnose over the internet, but I know this sound from the early gearbox days, when there used to be no synchros and we had to double-clutch. Maybe there's some issue with your 2nd/3rd gear synchros or shift forks.

[urbanzameendar]

Originally Posted by stallmaster

This definitely sounds like a transmission issue. Hard to diagnose over the internet, but I know this sound from the early gearbox days, when there used to be no synchros and we had to double-clutch. Maybe there's some issue with your 2nd/3rd gear synchros or shift forks.

Hi thanks for your reply. I had this doubt since the issue cropped up after a few days post clutch overhaul. Will seek the advice of the FNG.

Also forgot to mention, the gear lever vibrates a lot nowadays. The play has increased quite a bit, more than ideally it should be.

[urbanzameendar]

Good day T-Bhpians!

Another issue cropped up in the Alto thanks to the incessant rainfall recorded in Gujarat this week.

The dreaded Water Seepage inside the car! After all the diagnosis, took the car to the fng bodywork shop to cut open the cowl section above the fresh air manifold suspecting a hole due to rust. Found no holes there. Totally confused how it the water seeping inside from the dashboard somewhere near the glovebox.

Any suggestions would be welcome.

[jinojohnt]

Originally Posted by jinojohnt

My Alto Lxi is 13.5 months old, and has clocked 11900 km. Today I heard a 'thud' from the engine compartment while driving in 3rd gear, and the clutch almost immediately tightened up. (It was a good level road, and no debris on the road to hit the under body of the car). The guy at the workshop says the pressure plate is gone, and I need to replace the Pressure Plate + Clutch.

I am surprised, because only I have driven this car - I also feel that I am a healthy clutch user. No clutch riding, not even bumper to bumper traffic, and no reversing up a slope. I drive only at the manual-recommended speeds in each gear (Guess mileage of 17.25 per liter with a/c is testimony to this). Moreover, my Cielo's clutch (also driven by only me) is still fine after clocking 45,000 km.

Question 1: Do you think I can fight for a warranty?
Question 2: Do I need to service at the dealer itself or any Maruti authorized would do? If I don't get warranty, I wouldn't like to get the dealer service because I am not happy with them.

I guess the ordeal is finally over. I had to change the clutch at my expense every 12000 km for 4 times, even after complaining to Maruti multiple times. Finally got it fixed at an FNG, and I have clocked another 40000 km after this. Not sure what adjustment the FNG did - I think the mechanic adjusted the nut that changes the play of the clutch by rotating the nut multiple times.

1. Contrary to the popular image of Maruti, I got zero support from the company.
2. I gave the car to a MASS in Trivandrum (Popular) as per advise from Maruti, and they changed everything except the clutch pedal (had a bill of 10k rather than the normal clutch assembly replace bill of 4k). Next time the clutch failed, I got it inspected at an FNG and found that Popular had changed only the pressure plate (which may cost just 1.5k, if available separately). Even the release fork was the original factory fitted one with factory robotic welding.
3. Most MASS do not know a thing about even the simple mechanicals of a car like Alto, and they are not bothered as long as they fill their coffers at the customers expense. First two clutch replacements were done by Eminent (MASS) in Trivandrum, and their suggestion was that I have to change the clutch at my expense every 10000 km or so, and nothing can be done.
4. Though I had bought the car from Indus Motors at Trivandrum, I didn't give them my car for the clutch issue because of two reasons - The odo was disconnected when my car was delivered, and they had exchanged the wipers with an old set from another car when I gave for 6 months first service (Trust issues).

[Blooming Flower]

Originally Posted by jinojohnt

. Not sure what adjustment the FNG did -

Did your FNG mechanic adjust anything with the release bearing setup?

[Aroy]

Originally Posted by jinojohnt

I guess the ordeal is finally over. I had to change the clutch at my expense every 12000 km for 4 times, even after complaining to Maruti multiple times. Finally got it fixed at an FNG, and I have clocked another 40000 km after this. Not sure what adjustment the FNG did - I think the mechanic adjusted the nut that changes the play of the clutch by rotating the nut multiple times.

.................).

Abnormal clutch wear can be due to
. Cluct slipping - bad adjustment
. Riding the clutch - very normal with new drivers especially in B2B traffic.

I have been a Maruti customer since 1991 and in none of my 5 cars bought new did the clutch need replacement before 50K km. Yes, in my son's cars the clutch needs replacement within 30k. So I guess it is how you drive.

It is normal to keep the clutch slightly loose, that is it will engage only after the pedal is depressed a cm or so. Adjustting clutch to "hair trigger" will invariable result in a slipping clutch = abnormal wear = frequent replacement.

[jinojohnt]

Originally Posted by Blooming Flower

Did your FNG mechanic adjust anything with the release bearing setup?

The release bearing was not adjusted, only locknut/adjuster nut was adjusted for several revolutions

Originally Posted by Aroy

Abnormal clutch wear can be due to
. Cluct slipping - bad adjustment
. Riding the clutch - very normal with new drivers especially in B2B traffic.

The above two points usually result in worn off clutch disc. For me the clutch disc was fine, it was the diaphragm set up that gave away.
See my post at the start of this thread.
https://www.team-bhp.com/forum/techn...ml#post1513304 (Maruti Alto - Issues)

Originally Posted by Aroy

I have been a Maruti customer since 1991 and in none of my 5 cars bought new did the clutch need replacement before 50K km. Yes, in my son's cars the clutch needs replacement within 30k. So I guess it is how you drive.

May not be always the case. Another car in my family has clocked 75000 km without clutch replacement (single driven by me, driven almost during the same time period). And this car needed clutch replacement every 12000 km, four times (single driven by me). I have clocked 40000 km without issues after this fix.

[urbanzameendar]

Hi everyone!

A a lineup of strange issues cropped up today with my Alto (type 2).

There has been an oil leak issue since a week below the engine bay, I suspected a worn out oil filter or a drain plug, since the car is due for PMS, I took it to my FNG for an inspection, the FNG diagnosed it to probably be a case of oil chamber seal leakage. No work done since it was late in the evening.

While returning from the FNG the speedometer stopped working all of a sudden after a couple of kms. The speedo & odo is stuck only the digital fuel gauge is working. A few kms later, the CHECK ENGINE LIGHT glows up and is permanently glowing now.

I consulted the FNG on phone, he was pretty sure that the CEL is due to the now non functioning Speedo and ODO. Asked me to bring the car for an OBD2 scan and need not worry.

But I am quite worried

Any ideas or advice why would it have happened?

Thanks...

[saket77]

Originally Posted by urbanzameendar

Hi everyone!

A a lineup of strange issues cropped up today with my Alto (type 2).

There has been an oil leak issue since a week below the engine bay, I suspected a worn out oil filter or a drain plug, since the car is due for PMS, I took it to my FNG for an inspection, the FNG diagnosed it to probably be a case of oil chamber seal leakage. No work done since it was late in the evening.

While returning from the FNG the speedometer stopped working all of a sudden after a couple of kms. The speedo & odo is stuck only the digital fuel gauge is working. A few kms later, the CHECK ENGINE LIGHT glows up and is permanently glowing now.

I consulted the FNG on phone, he was pretty sure that the CEL is due to the now non functioning Speedo and ODO. Asked me to bring the car for an OBD2 scan and need not worry.

But I am quite worried

Any ideas or advice why would it have happened?

Thanks...

Yes, a bad speedo will light up the CEL. Your FNG is right. Before touching anything else, first get the speedo cable checked. This will be the most likely cause. Once the speedo starts working, the CEL will go away. If not, just reset the system by removing battery terminal (negative) for a while.

As for the engine oil leak, make sure that you are not driving on low oil in any case.

Regards,
Saket.

[urbanzameendar]

Originally Posted by saket77

Yes, a bad speedo will light up the CEL. Your FNG is right. Before touching anything else, first get the speedo cable checked. This will be the most likely cause. Once the speedo starts working, the CEL will go away. If not, just reset the system by removing battery terminal (negative) for a while.

As for the engine oil leak, make sure that you are not driving on low oil in any case.

Regards,
Saket.

Hi thanks for the input. I check the oil dip stick regularly and topup with the same grade and brand of oil I keep in stock at home, did this for a couple of times.

As for the speedo, will get the cable checked as a first step.

[BensonTom401]

Does anyone have a service manual for the Alto (2010 BSIV) or even the Alto K10 1st gen (2010-2014)? I just need the details of the pins of the instrument cluster. Trying swap to the Alto 1.1 cluster (which has a different wiring). I do have the pinouts of the 1.1 cluster. I did find out like half of the wiring with a multimeter but I would like to complete it. Hope someone can help out. Thanks