FEB 2021

1
1.
2.
SERVICING …..3
COOLANT/BATTERY/WIPERS ……4
TRIP DETAILS
3. IMPORTANT PARTS LIST……….5
4. WHEELS / ALIGNMENT…….5
5. TIRES / IMPORTANT PARTS LIST………6
6. BRAKES ……….7
7. CLUTCH……. 8
8. CEL ERRORS, MID WARNINGS ……9-10
9. TURBO HOSE LEAKAGE……11
10. EGR nozzle cap damage (Rat Bite)……12
11. ENGINE MOUNT FAIL….13
12. KYB SHOCKERS MOD…….14
13. REAR TORSION BEAM ISSUE…….15
14. TIMING/AUX BELT …………16-17
15. LIGHTING UPGRADE………..18-19
16. STEERING WHEEL COVER AND STEERING COLUMN…….20
17. GEAR KNOB ISSUES…….21-22
18. CAR RATTLES/NOISES……23
19. KEY FOB BATTERY & SPOILER……….24
20. ACCESSORIES (GRILL, SUN SHADE, SPOILER ETC)……..25
21. HARDWIRING & FUSES……….26
22. OEM PARKING CAMERA……27
23. ENGINE SILENCING PARTS…..28
24. REMAP & MODS……29-31
25. FACELIFT UPGRADE………….32
26. MUSIC SYSTEM…………..33-36
27. EXTERIOR PARTS COST…..37

2
 SERVICING
1.6 EGR valve
Rs. 600/LITRE cleaning
NOT required
DOT 3

16510 M 62M00 (Rs.840/-)

15411M55KD0 Rs.1150/- (common with 1.3 DDIS)
95850M79M00 Rs.360/- by MANN (common with swift/ciaz)
13780-62M00 Rs.900/- (scross 1.3 filter is compatible)
OIL FILTER 16510 M 62M00 FUEL FILTER 15411M55KD0 AIR FILTER CABIN AC FILTER
13780-62M00 ENGINE OIL
95850M79M00

ENGINE OIL 5.25 Litre (ACEA-C2)

4500/4lt.

4300/- 4300/-

1000/-

Liqui Toptec 4200 Addinol 5W30. SHELL HELIX ULTRA

5W30 Rs.950/lt Rs.700/litre ECT C2/C3 -0W30
Few trying mobil 0w40/ Mobil ESP 5w30

There is appx 600-700 ml oil

between Level 1 to 2

Maximum Level recommended 1

by service manual. (oil more
than this level may be fatal for
engine)

Average level after refill

during service. 23
Minimum level to be
maintained. (oil level not
touching dip-stick may be fatal)

Cold engine may show slightly higher oil level. When

engine is started after a long interval (say overnight)
the oil level in sump drops by appx. 300 ml. 3
So, there may be variation in oil level (depending on
whether engine is cold or warmed up)
 THERMOSTAT BLEEDING PROCEDURE:
COOLANT 5.5 Ltr

1
2
Best time to check the coolant level is in the morning
(When the engine is cooled) . level should be VENTILATION
between ‘full’ and ‘low’ marks. CAP

BLEEDING : When coolant is re-filled after

draining, there are chances of air being
1
trapped inside and coolant may not
circulate properly (leading to overheating of Before refilling the
engine). Bleeding procedure allows the coolant, blue colored
VENTILATION cap is
trapped air to escape and ensures proper loosened for bleeding.
circulation of coolant. (BLEEDING procedure This allows the trapped
is not required while simply topping up air to escape, allowing
coolant.) proper coolant
circulation.

BATTERY AMARON-DIN 65 (4500/- onwards, warranty 30+25 months)

If your car is taking
long time to
crank/start! do not
wait for it to die. Get
it checked and
replace with new
one. If battery is
dead, its Not
advisable to push
the car in gear.

WIPERS (stock FRONT 26” X 14”, REAR 10”) REAR REAR

(Frameless recommended size 24”x16”) WIPER
WIPER
In case of ‘frameless’ wipers, its better to choose smaller
size for RHS (24”) and bigger for LHS (16”). Few members
have faced issues like wipers hitting ‘A’ pillar with longer
RHS blade size. Frameless wipers are very flexible. Hence
bigger size (RHS) leads to more elasticity during fast wiping
mode, hitting A pillar. myTVS and BOSCH are popular. TVS
has better results and longer life. The rear wiper blade can
be easily replaced just by changing the rubber bead of wiper 4
DIY. Easily available online. How to remove rear wiper
blade: https://youtu.be/4NFoib_QgiM
 STOCK WHEEL SPECIFICATIONS
6”
5 studs

M12x1.5
ET 50 mm

114.3 mm

16”
60.1 mm

Centre bore diameter: 60.1 mm Most of the after market alloys will have bigger diameter.
So one must install ‘hub centric rings’ to fill in the gap. Absence of hub centric rings can be
dangerous, You may feel vibrations in steering etc.

WHEEL ALIGNMENT
FRONT WHEELS NOTE: Camber, caster and FRONT
kingpin inclination angle are not
FRONT
adjustable. If they are out of specification,
repair vehicle body or replace related part.

Front camber “a”

: -0° 10’ ± 1° 00’

Front caster “b”

: 3° 35’ ± 2° 00’

Front kingpin inclination angle “c”

: 12° 04’ ± 2° 00’

REAR WHEELS NOTE: Rear toe & camber are not adjustable. If out of specification, replace reference part.

Rear toe (Total) Rear camber

: IN 4.5 ± 2.6 mm (IN 0.18 ± 0.10 in.) : -1° 00’ ± 0° 30’

If measured value is not as specified, check the following parts for damage, deformation and crack:
1. Rear axle (torsion beam) 2. Spindle, wheel hub or wheel bearing, 3. Vehicle body

Reference Information (Toe angle) 5

Reference rear toe angle when measured with total wheel alignment tester or the like, is as follows.
Rear toe angle (each wheel)
: 0° 15’ ± 0° 13’
 Wheel
Diameter

Upgrade choices (popularity in group as per number of users): Popular size upgrade* :
• Michelin primacy P4ST – decent grip levels, low noise, • 215/60/R16 (performs better
comfort, long life with alloy width 6.5”/ 7”/7.5”)
• Continental MC5 – better grip levels & steering feel • 225/50/R17 (need to upgrade
• Yokohama Blue earth – overall value for money alloy wheels dia-17”, minimum
• Bridgestone Turanza T001– All rounder, little tougher suited width - 7”)
for bad roads

IMPORTANT PARTS LIST

6
FRONT BRAKES OIL-DOT3
MGP SCROSS: 2830/- (OEM by TVS, common SX4 / BREZZA)
EBC GREEN STUFF: 6800/- (Model no. DP21636)
TVS HI-PER: 1500/- (boodmo Part Number: 29932903)
HI-Q (HYUNDAI OEM): 1300/- (part no. SP4247)

Front brake pads of Nissan 350Z are

direct fit (but shims wont fit).

1. While replacing the front pads, make sure that Front Caliper pin (1 set)
CALIPER PISTONS have been fully compressed.
(55840M55K00)
2. CALIPER PINS must be greased. After fitting the
wheels should rotate freely/easily using one
finger. Its advised to replace both side caliper pins
(two sets required. 250/- each set)

REAR BRAKES
MGP SCROSS: 6000/- (OEM imported NBK-JAPAN)
MGP BALENO-RS: 2000/- (OEM 55910M68P01 by TVS)
EBC Ultimax2: 4000/- (model no. DPX2120)

Rear brake caliper PISTON is different from front brakes. The piston has to be rotated in
clockwise direction in order to push it inside caliper and make space for new pads:
Rear caliper piston
being rotated clockwise
Rear caliper piston to with the help of nose
be rotated clockwise plier

7
 CLUTCH ASSEMBLY (VALEO)
CLUTCH OVERHAUL = CLUTCH SET + SLAVE CYLINDER + LABOUR = 12800+3200+6500=22500/-

FINGERS

SLAVE CYLINDER
(THROWOUT BEARING)
CLUTCH DISC PRESSURE PLATE
Common with ddis 1.3

Clutch pedal malfunction (becoming dead, Getting stuck in depressed position).

Mostly its because of faulty SLAVE CYLINDER also known as ‘throw-out bearing’. In few cases
it was due to MASTER cylinder leakage or hydraulic pipeline damage/leakage. !!! In case of
slave cylinder the labour cost is 6500/-. So its better to go for clutch overhaul.

DEAD CLUCTH PEDAL = FAULTY SLAVE CYLINDER FAULTY SLAVE CYLINDER

In few cases it may be because of leaking pipes or

faulty MASTER CYLINDER. But so far all the cases
have been due to slave cylinder malfunction

• Clutch hardness (1. pressure plate

fingers made of cast iron become hard
with passage of time. 2. air bubbles
trapped in hydraulic lines)
• Clutch slipping, Reduced pickup, engine
revving but speed not increasing
proportionally (faulty clutch disc)
• Clutch judder/vibration (faulty clutch
disc/pressure plate)
• Vibration in clutch pedal (bent/faulty
fingers of pressure plate/failing flywheel)

FLYWHEEL FAILING FLYWHEEL: Few members have reported

noise from clutch (when car begins to move
25900/- from stationary position). And vibration in car.
CEL-P0504 (BRAKE SWITCH MALFUNCTION) PARKING
Car can be driven slowly SENSOR
REPLACE STOP LAMP SWITCH ASSEMBLY. Rs. 955/piece
(PART - 37740-M-83K-00) Rs.200/- 37735M79M00-5PK
SYMPTOMS:
• SDT shows following CEL- P0504 (Powertrain) MID will keep showing message.
• Cruise control does not work. No issue with driving car.
• When you press brake pedal the cruise control You can switch off parking sensor .
does not disengage. It resumes as soon as you In some cases the fault disappeared
release brake pedal. itself and working fine.

CLUTCH SWITCH CEL- B1504-H (SUNLOAD

MALFUNCTION
Car can be driven.
SYMPTOMS:
Service start system error starts showing on MID.
replacing clutch switch is the solution. (in One case
this error showed up because of blown FUSE-
HU didnt work, mirrors didnt adjust, and the error
kept coming up. In that case a replacing the blown
fuse removed this error)
SENSOR MALFUNCTION)
Car can be driven normally
SYMPTOMS: No particular physical symptoms. Its
just that SDT shows sun load sensor malfunction in
routine checkup. The moment you take the car
under sun, it goes away. If you park the car under
9
shade it would show again. It is considered normal.
Nothing to do.

GLOW PLUG MALFUNCTION (total 4 nos.) –

car can be driven normally KEY FOB
(If CEL P0671- to- P0674 shows up without battery issue
MID warning- Its related to plug circuit or
plug module)
May be troublesome to start engine in
Car does not start.
extreme cold weather conditions.
Key FOB battery has to be replaced.
Otherwise, car can be driven normally.
Some members also tried to
(MID would keep on showing warning)
disconnect/reconnect car battery to restart
Although its recommended to replace all
the car. (it worked)
the plugs together. But replacing faulty
plug is sufficient 1000/- per piece
WATER IN FUEL
SYSTEM
This has shown up
in many cars, but it
goes away of its own
after some time. If it persists than car
needs to be checked for fuel
contamination

OBD READER (500/- plug n play via Bluetooth)

*Its different for
apple and android
devices.
‘Torque pro’ app Socket is
can be downloaded right above the
via bar code hood release knob
 CEL-P1541 (OIL PRESSURE SWITCH-2 MALFUNCTION)
CEL-P0520 (OIL PRESSURE SWITCH-1 MALFUNCTION)
CEL P1541 SYMPTOMS: Primary symptom is loss of power at higher rpm (car going to limp
mode). If you push car to limits in 3rd and 4th gear, car goes to limp mode. In most of the cases oil leakage
was also observed from switch 2. all cases were resolved by replacing switch2.

OIL COOLER has two oil pressure switches (1&2). Switch 2 is located on the traverse side of cooler (check
yellow arrows in pictures). Switch-1 is located in front side (check the RED arrows in above photos)

SWITCH 2 (GREY)
(Part no. 16582M62M00)
1.95-2.40 bar

SWITCH 1 (BLACK)
(part no. 16582M79J50)
0.2-0.5 bar

SWITCH 1
(BLACK) OIL
SWITCH 2 COOLER
(GREY)

CEL P1541 could be because of malfunction

of following :
SWITCH 2
1. OIL PRESSURE SWITCH 2 (Rs. 650/-)
(part no. 16582M62M00)
or
2. VDOP solenoid valve/ Regulator Exhaust
(part no. 16111M62M00) 4494/- pipe
Gear
VDOP is located near crank pulley. box
or
3. FAULTY ECU

(so far all cases for P1541 were resolved by

replacing only switch2)

CEL P0520 could be because of malfunction of following:

1. OIL PRESSURE SWITCH 1 (Rs. 250/-)

(part no. 16582M79J50)
or
2. Faulty ECU. NOTE: VDOP solenoid valve has not
malfunctioned in any case
10(till date).
INTERCOOLER INLET LEAKAGE SYMPTOMS: SOLUTION:
HOSE LEAKAGE • Hissing sound from engine bay Maruti 800 AC pipe
• Black smoke during engine idling INSULATION (DLVM)
• RPM not exceeding above 1500 . Part No: 95711M84000
Connects turbo to intercooler inlet • Car going to limp mode again and (Rs. 63/-)
2200/- part no. 13661M62M00 again without any MID notification.
• Few members got this OBD error:

CONDENSOR FAN MOTOR COMPATIBLE WITH TURBO HOSE

PAJERO- 065000-7121 (4000/-)
AC
PIPE

REASON OF LEAKAGE
The turbo hose expands and contracts regularly due to turbo spool at
higher RPM’s. During this phase of expansion the turbo hose becomes
bigger in size and starts rubbing with aluminum joints of AC pipeline
(suction hose). During normal idling the turbo hose contracts to its actual
size and there is no rubbing contact. Hence its very difficult to diagnose Metal rubbing with turbo hose

BEFORE AFTER

TURBO
HOSE

AC pipe
metal
AC pipe
without
with DLVM
insulation
INSULATOR
TURBO
HOSE

DLVM
Slit

Fevibond or quickfix
is applied along slit portion.
(Insulation tape is wrapped)
 Rat bite (nozzle cap on EGR COVER damage)

TURBO stops working. CEL shows on MID

EGR

Nozzle 1: Turbo to Nozzle 2: covered Nozzle 3: Nozzle 2

EGR hose with rubber cap connected with CAP
another hose missing

Nozzle 1

Nozzle 3
EGR

EGR

SOLUTION: plug the nozzle no. 2 with a cap

made from brezza vacuum hose.
DIY: 2 inch piece of vacuum hose is required.
One end needs to be closed (air tight) by
inserting screw/ball pen click button/electrical
plug pin etc :
BREZZA vacuum hose 45/-
(18351M55KD0)
NOZZLE 2 plugged with
DIY cap

2 inches
One end closed
piece
with female
type screw

DIY Nozzle cap

zip tied
 LHS ENGINE MOUNT MALFUNCTION

Leads to damage of bolt

BRACKET
MOUNT

Lubricant leakage
from damaged
driveshaft

This mount helps in

Rotisserie movement of
engine. Puts a lot of stress
on BOLT (acting as a pivot))

13
 KYB SUSPENSION UPGRADE STABILIZER BAR
Front pair 9700/- 42420M55K02 (485/-)
(kyb part no. RHS/LHS: 3358007 / 3358008) by TALBROS-BLACK COLOR

Rear pair 5800/-

(kyb part no. 3438005)
FRONT STRUTS (10kg pair)

REAR SHOCKS
4.5 KG pair
• Better handling/maneuvering, quick steering response, Better braking, less body roll
• Less nose dive (better for sump protection while off-roading)
IMPORTANT for front shock installation:
Inner diameter (14mm)
of the MGP plastic
bearing has to be 14 mm
increased to 16mm. so
that it can firmly fit
around KYB front shock
shaft. KYB shaft is
wider than MGP shaft. 16 mm
BEARING (KYB shaft)
MOUNT Also, while putting the
mount in place make
sure that bearing is
fitted around shaft in
MGP Mount and bearing 2pcs each place. After increasing
14
required for front shock installation inner dia of bearing
 FAULTY REAR TORSION BEAM SYMPTOMS:
• Rear wheel alignment figures are out of reference range.
• Uneven tyre wear due to mis-alignment of rear wheels.
• KAT-KAT noise from rear beam.
The kat-kat noise is due to breaking/fracturing of the welding spots. The
microscopic fractures are difficult to spot. When the vehicle is in twisted
position like climbing a roadside footpath, when one of the rear tyres is
on footpath and remaining three tyres are on lower surface.- This
position puts pressure on beam arms in opposite direction, causing the
WELDING
beam to twist and make noise at the welded joint locations. SPOTS
Symptoms can be resolved by replacing TYPE1 beam with TYPE2
You can see this video to see how rear beam is subjected to pressure in driving conditions:
https://www.youtube.com/watch?v=_gBB8nMr8vI https://www.youtube.com/watch?v=w2V4KWEk7QI

TORSION BEAM ‘TYPE-2’

introduced in 1.3 FL version

TORSION BEAM ‘TYPE-1’

installed in pre-FL version

TYPE-2 TYPE-1
Type-2 may have new
Technically its called ‘CRUSHED TYPE TORSION BEAM’. You designing of the crest
shape or the general
can see the curvature/crest. (see the cross section drawing) curvature. There was a
difference of appx. 1.5 cm
between type1 & 2
curvature (height
measured from floor to top
of the beam curvature).
We do not know whether
its relevant to difference
between the beams.
 TIMING BELT INSPECTION @ 1,40,000 KMS / 5 yrs (LABOUR 5000/-)
Timing belt, idler pulley, tensioner and Water pump should be replaced together.

TIMING BELT
3250/-

PRESSURE CAM 705/-

PUMP

ALTERNATOR WATER PUMP

Timing
2750/-
IDLER
PULLEY
OIL
FILTER Timing
TENSIONER
CRANK

16 4135/-

TIMING BELT TENSIONING BELT TOO TIGHT

Automatically adjusts belt tension. But (PIN pointing above hole)
initially manual setting of PIN (pointer) is
required while installing.. PIN

TOO LOOSE or
TOO TIGHT
PIN
tensioner may
BELT TOO LOOSE
lead to failure
(PIN pointing below hole)
of accessories
driven by it.

PIN
while tensioning the timing belt, the
pointer pin of tensioner must point
exactly towards the center of hole.

TENSIONING
PROCEDURE :
 AUX BELT
Slipping aux belt may cause fluctuation in idling RPM
TOP VIEW ENGINE BAY
(BRACKET MOUNT attached)

MOUNT BRACKET
MOUNT BRACKET

AUX TENSIONER
AUX IDLER

RHS VIEW
17 Timing tensioner & timing
AUX AUX idler are hidden behind
ALTERNATOR TENSIONER IDLER COMPRESSOR
MOUNT BRACKET

TIMING TENSIONER

TIMING
IDLER

hidden behind MOUNT BRACKET

TIMING BELT
(COGGED TYPE)

AUX BELT
(Multi V-Groove type)
 LAMPS
DOME (FESTOON 5W)
W5W
SPOT/MAP (W5W)

BAU15S
(PY21W)
H4 (zeta/delta)
D5S (Alpha) W5W W16W

W5W

BAY15D
(PY21/5W)
BAU15S
(PY21W)

H8

W16W
 PROJECTOR FOG LIGHTS (appx 6900/-)
Best VFM head light upgrade for S-cross by BLAZE INDIA – Mr. Amit (watsapp- 9871490280)

Alignment process: Keeping it below

knee level at 20-25 ft distance
(reference the number plate)

PROJECTOR FOG RALLY LIGHT UPGRADE 6000/-

HID COMBINATION:
HELLA BLACK MAGIC
100w bulbs (relay required)

ZETA/DELTA
head lamp upgrade:
90/100 w H4 bulbs (400/-) RALLY LIGHTS THROW
RELAY with ceramic
holders (1000/-)

19
STEERING WHEEL COVER ALI EXPRESS (appx $35)
installation
without
removing
steering
wheel 800/-
Alcantara and
perforated
leather.
For zeta/alpha,
this cover goes
straight
on without
removing the
existing factory
fitted cover.

Installation after removing

steering wheel may cost up to
1500/- .

STEERING COLUMN ISSUE

Many members complained about steering
making noise or becoming sticky while making ‘U’
turn etc. In most of the cases, due to stickiness.
Normally, after turning steering to extreme
right/left, the steering wheel tends to come back
in its original position with ease. But faulty
column resists this normal movement (stickiness)
and the steering has to be pulled back with more
than usual force.
MARUTI has increased the warranty on STEERING
COLUMN by 3yrs. Means: 2yrs standard warranty
+ 3 yrs steering extended. Total 5yrs from the date
of purchase. (only for steering column VIN range
mentioned below)

One of the member faced rare

issue with the steering:

It's a component within the

column which holds the assembly..
20
it's glued in there. It gave up. The
steering fell down (collapsed).
Replaced column under warranty
 GEAR KNOB REPLACEMENT
Gear knob of CIAZ 1.5 DDIS is suitable replacement for 1.6 gear
knob. But the gear pattern badge is different for both. Therefore
1.6 badge has to be re-used on CIAZ knob.
Screw pattern
threads

CIAZ KNOB 500/-

(28113M72R20-C48)

REMOVAL: rotate the knob

ANTI-CLOCKWISE.
INSTALLING: place the knob on Gear knob bottom view
lever so that, the odd gears are after removing from lever
pointing at 9’O clock. And than
start rotating CLOCKWISE.
Use a plastic flat tool to pull out the badges from knobs

Gear pattern of 1.6 is different from ciaz

1.6 CIAZ
10mm
10 mm depth for reverse goes
Backside of BADGES are not similar. knob to slide in. Inside

CIAZ 5mm
1.6 Remains
outside

CLIP
1.6 Badge has two clips. These clips must to be broken/
removed (very easy) in order to fit 1.6 badge on CIAZ knob
ADHESIVE
FEVIBOND
1.6 CLIPS
removed
1.6 CIAZ CIAZ knob
KNOB BADGE With 1.6 badge
CIAZ
1.6
 NOTCHY GEAR GEAR KNOB HARD GEAR SHIFT
SHIFT LEVER WEARING OUT Normally gear oil is replaced after
1,60,000 kms. Few members have
replaced after 40,000 kms and
found noticeable smoothness in
gear shift.

using both hands on opposite sides ,

grip the silver cladding from inside,.

Pull the silver panel upwards

Remove all
the hooks

MGP does not sell gear knob

separately. One has to purchase
the complete gear lever assembly
costing 5000/-. There are few
options available on aliexpress but
expensive appx. 2000/-
Best option is to use CIAZ ddis 1.5
gear knob (500/-) as an OEM
replacement.

22
Lubricate the ball joint. Use normal
grease or WD40, Rust smash etc
 GETTING RID OF
CABIN NOISES

Speaker box SUNGLASS HOLDER

carpet
(adhesive)

Adhesive carpet

ARMREST BOTTLE HOLDER

CONSOLE

Adhesive carpet

Adhesive carpet

FOR PARCEL TRAY:

3M double sided adhesive
pads are applied on the four 3M PAD
specific locations (rubber
knobs of the parcel tray rest
here all the time and make
noise while car is moving).

Do not remove the sticker

cover on opposite side of
the pads.
PARCEL TRAY

PARCEL
PARCEL TRAY TRAY
FOOT RESTING RESTING
ON 3M TAPE SLAB 23
 ALPHA / ZETA KEY FOB BATTERY (appx life 2 yrs.)
1. remove the metal key. 2. Insert screwdriver in groove & rotate
3. replace battery CR2032 H (3 volt).

For DELTA
1. Unscrew the cap
2. Insert screwdriver in groove & rotate
3. replace battery CR1620 (3 volt).

REAR SPOILER (INDIAN DESIGN) 5000-7000/- with paint

NEW INTERNATION DESIGN (IMPORTED)

INDIAN DESIGN
NEW DESIGN

NEW DESIGN
Adhesive tape and screws to hold the spoiler on rear door

Spoiler screwed after fitting on

top of panel

Holes are drilled from inside and outside 24

of rear door panel
 WINDOW SHADES (LINX brand on amazon 500/- 4pcs)
Window glass can be scrolled up/down without removing shade

Perfect fit and finish Rear side, rear quarter and rear windshield.

IMPORTED
SGP SUN SHADE
4700/- + shipping

SUN 3M CR 70 used for front 6000-9000/- SUN

FILM FILM

Rear and sides, 3M MR 70, 8000/-

SPORTY PEDAL GRIPS

2015 MODEL EURO-GRILL
ebay/ali appx 3900/-

Sports alloy pedals from AliExpress, $25.

These are not covers, proper bolt on fit.

REAR GARNISH
DONE AT NEXA
Looks nice and different from
stock logo. But normally its
done by applying a layer of
black vinyl sticker coat on
stock plate. You can clearly
see the previous ‘S’ logo
impression emerging out of 25
vinyl coating.
25
 DASHBOARD FUSE-BOX FUSES IN THE ENGINE
MICRO-BLADE TYPE - No. 26 is ‘BLANK’ for
accessories. For more than one accessory, you COMPARTMENT
need to check ‘*’ fuses which could be available.
E.g. 36 is also available via fuse tap. 26 & 36 are
activated when ignition in turned ‘ON’

DASHBOARD FUSE-BOX
MICRO BLADE TYPE

FUSE -BOX

MICRO blade fuses only

DASHBOARD FUSE TAPPING FOR HARDWIRING ACCESSORIES

FUSE TAP can be used for powering accessories like dash cam, TPM’s,
radio, charger etc. you can insert this fuse tap in any blank fuse or
existing fuse:

This plugs Insert Existing Insert new

in to fuse FUSE if any accessory
box FUSE

Use
MLC based card FUSE
FUSE
(Transcend/Lexar) (micro blade type)
TAP

RANDOM
DASHBOARD
This end connects to accessory adaptor (+VE) FUSE BOX
terminal. The other terminal of accessory
adaptor is connected to chassis for earthling

26
 REVERSE PARKING CAMERA FOR ZETA
OEM camera 5675/- Customized wire 4000/-

We need OEM camera & customized

wiring. This wiring is specially prepared
by group member Mr. Ravinder. Not
BOSCH HU available at maruti or outside market.

Although the camera is simple plug n play with BOSCH HU. But it needs experienced installer to pull across
the wiring from HU to CAMERA. As it’s a single piece wiring without any joints/connections in between.

Glove box removed.

Wire pulled

‘Wire pulled along ‘A’ pillar,

taken towards roof rail.

Stereo is
removed ‘A’ pillar cover removed.
Wire pulled along ‘A’ Pulled along ‘A’ pillar towards
pillar roof rail

Pulled along roof, towards rear door. Roof

carpet should not be stretched much.
Otherwise it could sag/hang permanently

Most tricky part is to insert and pull

the wire across this rubber
shield/cover (connecting rear door
with roof)

Needs lot of patience.

Inside cover of rear door panel is

removed. Camera is installed in
garnish plate. Connected to HU.
27
 ENGINE SILENCER FUEL RAIL
355/-

SILENCING
PARTS
ENGINE
COVER
3800/-

SILENCER VACCUM PUMP

500/-

SILENCER
CHAIN CASE
425/- appx
28

TIMING BELT COVER (outer side)

TIMING
VELCRO COVER

SILENCER

SILENCER (inner side)

With passage of time
Inner side of SILENCER gets the Velcro patches
attached to outer side of become ineffective
COVER by VELCROS VELCRO and the SILENCER
keeps falling off in
aux belt area
 MOD - 200 HP CLUB BUFFET!
REMAP DOWNPIPE/FULL INTERCOOLER TURBO INTAKE
(25-40K) EXHAUST (25K) (22-30+12K) (65+5K) (14.5K)

INTAKE MOD
STAGE 1 is optional.
REMAP
(25K)

STAGE 2
REMAP DOWNPIPE/FULL INTAKE
(30K) EXHAUST (25K) (14.5K)

STAGE 3
REMAP DOWNPIPE/FULL INTERCOOLER TURBO INTAKE
(40K) EXHAUST (25K) (22-30+12K) (65+5K) (14.5K)
Stage 2 is the best in terms of money spent vs gains. It just needs downpipe and stage 2 remap and the car
is almost 3.5 seconds faster than stock to 100 kmph. Stage 2 drives like a naturally aspirated petrol (Point
and shoot). A killer combo for city and medium highway use would be stage 2 + IC.

Stage 3 is Highway monster. Stage 3 gains don't look much on paper wrt 0-100 timings. But, this is a top end
diesel monster. There are huge gains in timings at higher speeds. It would be a proper setup after
intercooler and intake mods. Every stage 3 build is different in terms of Intake mod, types of IC.

WOLF-REMAPPING REMAP 1:
• Very good Low end
• Lesser turbo kick
• Linear power delivery
• Mid range has lots of gain
• Top end was improved
REMAP 1 – (25 K) • EGR off0-100 : 9.0 seconds
REMAP 2 – (30 K)
REMAP 3 – (40 K)
REMAP 2 :
•Very good improvement in low end
•Turbo kick was minimal
ECU is removed from engine bay •very linear power delivery
ECU is connected to PC via flashing tool •Mid range has good punch
ECU maps are updated within few minutes. •Decent gains in top end
•EGR Off for all S-Cross 1.6 remaps.
•0-100 : 7.9 seconds

REMAP 3 :
• low end is slight better in Stage 2.
•Still it's much better than stock map.
•Mental mid range.
•Top end is brutal too.
•The car loves to redline 29
•0-100 : 6.9 seconds
 DOWNPIPE STOCK CATALYTIC
FULL EXHAUST (25K) CONVERTER
Fitted with
stock heat
shield

Complete
silencer is replaced including CAT

DOWN PIPE (15K)

Only CAT is replaced with this

Most of the members have done only down pipe. 30

Turbo spools better. Improvement in mid and top end, no drop or slightly better low end.

Downpipe: Only catalytic converter is removed and replaced with downpipe. Remaining portion of the stock
silencer is fitted back as it is.

Full exhaust: complete Stock silencer is removed and replaced along with catalytic converter. Custom made
silencer including downpipe is installed connecting directly with exhaust manifold. Full exhaust adds a
different character to exhaust sound.

Both downpipe or full exhaust mod gives almost equal gains. It’s a matter of personal choice to go for full
exhaust, giving a different sound character to your car. Otherwise downpipe is sufficient for gains. Most of
the members have gone for DOWNPIPE only (blackworks). Costing of full exhaust may go up to 33000/-

INTER-COOLER MOD
(KSM/FMIC/GARRET 22-30K) (PLUMBING 12K)

MODIFIED IC
(FMIC.eu)
Diameter of IC inlet/outlet is different from
other pipes. Silicon reducer is used to align.

STOCK IC

Stock IC performs better at lower rpm, but at higher rpm it IAT shoots up like crazy. With intercooler upgrade
you would notice better top end without any remap.

Modified IC offers significant drop in IAT. Max IAT in stage 3 cars doesn't go above 50-55 degrees. Stock IC
hits 70+ degrees. With new IC there won't be major increase in power, but there wont be much drop while
doing back to back WOT high speed runs. Cooler air to the engine, more efficient too.

IC dimensions may be different as per your requirement. Some members have used bigger size but they had
to cut off the front member (impact bar) for proper fitting. Few used smaller size to fit without cutting the
front member. Plumbing of the IC is most important part. Proper sealed fittings are necessary in order to get
peak performance.
 GARRET TURBO
MOD 65K
labor 5-7K
MODIFIED
VERY SIMPLE GARRET
PLUG N PLAY

STOCK
TURBO
MODIFIED
GARRET

AIR INTAKE MOD BMC DIA (14.5K)

Stock intake is directly

behind the radiator
Feeding it hot air. This
intake pipe is directed
in a different manner,
away from radiator etc.
this helps in more cool
air intake.
Minimize the loss of air flow pressure passing through the air filter. ensures that aspirated air is carried to
the engine at a higher speed and capacity in respect to traditional systems, thus providing significant
31 gains
in engine performance. better low end, better throttle response. Colder air - up to 20 degrees colder than
stock. Filter serves life long, needs only cleaning every 10000 kms.
FACE LIFT

Full body
RED Paint
32
by MASS,
@45,000/-
 BOSCH HU FIRMWARE UPDATE
Default factory security PIN for BOSCH SLDA: ‘0123’

LATEST STABLE VERSION- 1770:

https://drive.google.com/uc?id=18ZMOrR1hNqSiXqII91oVPWozqzkwDI8w&export=download

OLD STABLE VERSION-1760.2:

www.dropbox.com/s/1lu818suwfg4wk1/1760.2.zip?dl=0

Long press the ‘setting’ button for 10-15 sec. it would show you the latest version. If its not
1770, than you need to download latest update firmware copy the content of the main
folder on a pen drive. Insert the pen drive in HU. It should begin installation in few seconds
(as mentioned in above screen). Do not switch off HU while installation or do not pull out
pen drive (it may damage your HU permanently ). Once the update is finished, the system
would reboot itself. (in between also it may reboot many times.) It will probably hang the
first time around and has to be restarted and second time is the charm as a lot of members
reported.

CAR AUDIO & DAMPING BASICS

Scross Stock HU:
Bosch [Touch model] & Panasonic [Non-Touch Model]
RMS power output 18 watts per channel (one 4-ohm speaker per channel) which can power 4 speakers.
STOCK Speakers:
4 x 6.25 inch round dual cone paper diaphragm coaxial Speakers, 25watts
@ 4 Ohm and 2 x Tweeters 1-inch paper dome from Nippon Audiotronix.
These speakers and tweeters specially made for Maruti and these models
cannot be procured outside.
General Observations on S cross Stock Audio Setup:
1. Factory fitted head unit’s output is low and has limited digital sound processing capabilities.
2. The stock Nippon speakers which is paper diaphragm coaxial speakers has less than 75w peak output
and has no proper enunciation.
3. Placement of tweeters in dashboard facing up makes no music impact to listeners as high frequency
waves travel upwards to windshield.
4. S cross door panel is not the best environment for quality sound as the vibration from the engine, road
noise and hollow doors makes audio output below average. 33
5. Scross car door is not designed for bass elocution and hence causing the waves to distort resulting in
losing clear notes.
 DAMPING & SPEAKERS INSTALL
Application of Standard Package
Step 1:
Dampening increases speaker output, while absorbing annoying squeaks, rattles, and vibrations. The result
would be enhanced sound reproduction inside the cabin with increased audio acoustic characteristics which
includes improved frequency response and better bass reproduction.
Areas to be damped: 4 Doors, Floor Panel, Wheel Arches, Engine bonnet [ under the insulation material]
Recommended Sound Dampening Material: Butyl Rubber with aluminum foil.
Scross door interior panels have big
holes resulting in much more sound
distortion from speakers. The thin layer
of metal provided vibrates if aftermarket
high sensitive speakers are installed
without dampening.
Picture showing full underbody
dampening from inside. It approximately
takes 12 sheets of dampening material.
Dampening Material Used : Dr Artex
Earth Gold HD

Step 2:
Installation of Speakers, Amplifiers & Subwoofers.

High sensitivity speakers are advised for quality music and distortion free sound production. The tweeters are to
be placed facing the users so that high frequency waves would create perfect sync to the music notes along with
low frequency waves from woofer component.
•Pre installation check: Amplifier RMS output should always be in acceptable range of Speaker/Subwoofer RMS
input.
•Post Installation check: Speaker/woofer cones should resonate at the same time during test play

Front Co driver passenger door:

New speakers installed with plywood
ring bushes to avoid speaker vibration.
Speaker Type : High Sensitive
component speakers. Model: Focal
Access 165AS
Front Driver side door:
New speakers installed with plywood
bushes to avoid speaker vibration.

Tweeter speakers which produce high Backdoors: High Sensitive

frequency notes should be placed Speakers - Coaxial Type. Model:
towards the front seats to have clear Focal Access 165AC
listening experience. Using tweeter
mounts or wave guides, direct the
tweeter’s high frequencies so they
have a more direct path to your ears
from the driver and co passenger 34
seats.
 AMPLIFIER, SUB & TUNING
Step 3 Tune the frequencies of the equipment installed to set the high notes, midrange notes, base and
treble boosts with appropriate balance as below:
Adjust Tweeters: Try aiming the tweeters in different directions facing seats to find the best sound. Be sure
to adjust the tweeter level settings on your component crossovers until you find the perfect sound.
Adjust Rear Fill: Front speakers should give the best mid- and high-range frequencies, one should be hardly
aware of your rear speakers. Rear speakers should add depth to the sound coming from the front speakers.
Adjust Subwoofer: Set the high-pass filters for your front speakers to the lowest frequency speakers can
handle. Then raise the crossover point until you hear the bass notes clearly..
Tuning results should be as below
 The bass note should always produce
tight quality bass note.
 Highs should be crisp but not shrill.
 Midrange should be smooth and clear.

Amplifier used for speakers:

Midrange Pioneer GM A6704
which provides 60W RMS
output for 4 Speakers.
Subwoofer: 12 Inch Kenwood
KFC PS3016W – 400W input
and 2000W output.
Amplifier used for Subwoofer: Midrange
Box: Local made square type JBL Club 5501 Mono Amplifier which
concealed box. provides 370 RMS output for Subwoofer.

Recommended audio enhancement options for S cross.

Option 1: Basic [Very economical].
•Basic 4ch amplifier [ Class A/B] for
stock speakers and
•Basic Mono amp
•10 Inch Subwoofer
This combination brings stock system
to life making far better experience
than stock version. This is ideal for
those who are fine with the stock
setup but require some low
frequency base notes.
Recommended Brands:
Amplifier: JBL, Pioneer
Subwoofer: Pioneer, JBL
Option 2: Standard [Economical]
•Midrange component Speakers for
front doors and Co axials in the rear
door.
•4 Ch Amplifier for speakers + Mono
amplifier for subwoofer
•12 Inch Subwoofer
•4 Door dampening
•Digital sound processing unit
This option is for the people who are
active music listeners who simply
wants decent acoustic details with
distortion free sound re production.
Recommended Brands:
Speakers: Midrange Series - Infinity,
Focal, Alpine X series, Sony
Amplifier: Midrange Series – Alpine,
Pioneer, JBL Class D
Subwoofer: Pioneer, Kenwood, Sony,
Kicker, Alpine Xseries
Option 3: Advanced [Expensive]
•Powerful Head unit
•Performance series component
speakers for all 4 doors
•5 Ch Class D Amplifier
•12 Inch Subwoofer
•4 Door dampening
ultimate musical experience
with exceptional acoustic
qualities. makes you feel like you
are cruising in your own
personal concert venue with
crystal clear low/high end notes.
Recommend Brands:
Amplifier: Alpine, Kenwood,
Pioneer
Speakers: Focal
Performance/elite Series, Infinity
Kappa,
Subwoofer: Rockford, MTX
 ALPINE MP 6400
16000/-
SOME HEAVY ICE
ALPINE BT
SERIES
18000/-
LBM sub
RAINBOW
COMPS
15000/-

INFINITY KAPPA
8000/- POLK CO-AXIAL
8000/-

LBM sub
40,000/-

3 way speaker:
1. Tweeter
2. Mid range
3. Woofer
25000/-

SUB-WOOFER inside SPARE WHEEL

custom made fiber-glass housing
7500/- (including subwoofer)

36
36
 EXTERIOR PARTS COST
8054/-

4470/- 4680/-
3600/-
350/-

230/-
1025/- 7000/-
1610/-
2060/-

1500/-
3990/- 1055/-
1355/-

1110/- 225/- 2240/- 2210/- 455/- 1210/- 1620/- 1460/-

525/- 925/- 1040/-

350/- 230/- 2060/-

9465/- 1025/-
1014/-
8705/- 4470/-
270/-
315/-

320/- 325/- 1485/-

345/-