Maruti Zen Maintenance

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Engine Clutch & Gearbox Suspension Steering Brakes Pit Stop

Maruti

Zen cent motorist in India tasted blood with this small car , which provided much more tha just basic transportation. Vivek Bhat tries to solve whatever few problems you could come across in this refined car.

The Maruti Zen has been one of the successful performers in the small car segment due to its contemporary design and engine performance. An upgraded version of the Maruti 800, the refined packaging of the Zen was an appealing factor to the Indian buyer; it still is if one goes by sales figures. Add to it Maruti's extensive service network and the Zen is quite a winner. If the 800 provided basic transportation for the middle-class Indian, the Zen did it in style.
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ENGINE:

The Zen's heart is as big as the Esteem, dimensionally speaking, though the latter has an additional 300cc input capacity. The 997cc engine sports electronic ignition, which not only saves a lot of time in the tune-up process, but also aids engine performance whilst keeping emissions down. The engine is fitted with a Mikuni carburettor which, for some strange reason, has a stranger trait. This can be seen in Zens running in big metros where traffic is dense and liberal use of the accelerator is not allowed. In such cases, the secondary butterfly of the Mikuni carb remains unused and gets jammed due to the gumming of fuel. This is more common in cars that are used only for short hops and cars driven by elderly people (no offence meant) who drive at a sedate pace, seldom revving their set of wheels hard. Spraying the carburettor butterfly with WD-40 from the outside often eases this problem. If that does not work, then manually removing the carb for cleaning can solve the problem.
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CLUTCH & GEARBOX:

If the Zen's 1-litre all-aluminium engine is similar to the Esteem's 1.3-litre, the clutch is not too different either. Your only headache with this diaphragm-type clutch will be to correct the pedal's free play. A soft mushy clutch that presents problems while engaging gears is an indication of a worn-out one. The clutch in the Zen normally lasts for at least 30,000km, but with careful use the figure could double. The least one can do to ensure this is not to use the clutch pedal as a footrest. Extra pressure on the pedal only depresses the pressure plate tines causing the clutch plate to slip which, in turn, results in premature wear. The Zen is also available as a 3-speed automatic variant, which is a boon in bumper-to-bumper traffic. It is a wonderful feeling when you don't have to move your left hand and foot while driving (for obvious reasons of course). More wonderful is the fact that the automatic transmission needs relatively less attention. The transmission housing could be monitored once in a while for oil leaks. If the oil level is fine, check its

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Maruti Zen Maintenance

http://www.indiacar.com/maintain/zen.htm

consistency (every 10,000km). Replacement of the automatic transmission fluid every 40,000km is recommended. The oil level in the automatic is critical since even a slight drop could starve the clutch plate clusters of lubrication, causing them to run dry. Remember, excessive wear to the clutch plates only means an expensive overhaul.
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SUSPENSION:

The Zen employs lower arms and MacPherson struts up front for cushioning purposes. When the suspension is new, the steering geometry is perfect and the tyres remain well balanced. No big deal. But with use, the damping of the struts weaken closing the gap between the car's front end and terra firma. Reduced clearance between the wheel and the fender is a confirmation of weakened struts. This gives the tyres a negative camber and they tend to wear from the inside. Replacing the struts alleviates all these problems. The rear suspension has a three-link rigid axle. The isolated springs and shock absorbers give an independent suspension-like ride, much better than the rigid axle and leaf spring ride of the Maruti 800. Check the links' bushes for wear. No other trouble here. Touch wood. Our roads need sturdy wheels and the Zen's wheels are known to bend under severe driving conditions. Always check the wheel rims and request immediate corrective attention from the mechanic.
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STEERING:

The steering problems found in the Esteem can also be found in the Zen, the primary irritant being development of play in the steering rack. Thankfully, this occurs only over a period of time. Often, this can be taken care of by tightening the damper nut. In extreme cases, the rack bushes need to be replaced. As the rubber steering boot is not made by 'Nike', it may be prudent to ask your mechanic to check its condition at every service. If he appears reluctant, tell him to 'Just Do It'. The most vulnerable component in the steering is the set of tie-rod ends. These may need to be replaced every 40,000km.
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BRAKES:

The Zen was the first small car which could be brought to a halt with vacuum-assisted brakes. These power-assisted brakes with discs in front and drums in the rear reduce braking effort considerably. The Zen's brakes are very reliable and give it a good, positive feel. They have to be checked regularly though for brake pad wear. The ideal time for this business is when the car is being serviced and put up on a ramp. Another indication of worn brake pads is a grinding sound under braking. Radial scoring on the disc is an indication of metal- to-metal contact. This is caused when the brake pad material is worn out and the metal back of the pad gets too close to the brake disc for comfort. Replacement of brake oil every 40,000km and brake pads in half that period are the only service issues. Maruti recommends that the rubber parts of the master cylinder and wheel cylinders be changed every two years. Parking brake is manual and rarely needs adjustment. Unlike the Ambassadors and Padminis, the parking brake is self-adjusting and only the cable needs to be tightened, once in a while.
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Pit Stop - What, When & How Much

Part Clutch overhaul

Approximate Life
40,000km

Labour (Rs)
1015

Cost of Parts (Rs)

Cover assembly: 890 Disc: 1055 Release bearing: 2160 Cable: 157 Front: 438 (one side) (1 set) Rear: 370 (one side) (1 set)

Wheel bearings Suspension O/H Lower arms Struts

40,000km 40,000km 30,000km 60,000km

Front: 385 each Rear: 208 each

411 each 350 each

Front: 768 (2 pcs) Rear trailing arm: 885 (each) Kits: 1794 (2 pcs) Strut: 1546 (each) Rear shock absorber: 1305 (2 pcs) Ball joint: 475 (2 pcs) Tie rods: 254 (2 pcs) Rack bush: 90 Steering boot: 195 (2 pcs) 520( 2 pcs) 190 per litre

Steering rack O/H Drive shaft boot Coolant Brake O/H Wheel alignment

30,000km - 40,000km 30,000km 20,000km or 1 year

684 340

726 10,000km 550

Brake pad: 360 (1set - 4pcs) Brake shoes: 30 (1set - 4pcs)

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Maruti Zen Maintenance

http://www.indiacar.com/maintain/zen.htm

Wheel balancing

5,000km

74 each + weights Back to top Back

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