Engine Cooling System: Removal & Installation Suzuki Aerio I

Cooling Water Pipes or Hoses Removal and Installation

Reference: COOLING SYSTEM COMPONENTS

Removal

1. Drain cooling system.
2. To remove these pipes or hoses, loosen clamp on each hose and pull hose end off.

Installation

Reverse order of removal procedure noting the following.

Scheme 12

1. Tighten each clamp securely.
2. Be sure to align matching mark (5) to stopper (3).
3. For heater inlet and outlet hoses, be sure to position the hoses so that each marking (4) faces upward.
4. Refill cooling system with proper coolant referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .

Scheme 13

1. Drain coolant and tighten drain plug.
2. Remove radiator outlet hose at thermostat cap.
3. Remove thermostat cap (1).
4. Remove thermostat.

Reference: THERMOSTAT INSPECTION

Scheme 14

1. When positioning thermostat (1) on water pump case, be sure to position it so that air bleed valve (2) comes at match mark (3) and into the recession of water pump case.
2. Install thermostat cap to water pump case.
3. Install radiator outlet hose to thermostat cap referring to «COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION»(ref-251063-S42109225762007032000000) .
4. Fill cooling system referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
5. After installation, check each part for leakage.

Radiator Cooling Fan Removal and Installation

Reference: RADIATOR COOLING FAN ON-VEHICLE INSPECTION

Scheme 15

1. Disconnect negative cable at battery.
2. Remove condenser cooling fan (if equipped with A/C).
3. Disconnect connector of radiator cooling fan motor.
4. Remove radiator cooling fan motor (1) from radiator (2).

Reverse removal procedure for installation.

Note. Add proper coolant and check coolant level referring to COOLANT LEVEL CHECK .

Radiator Removal and Installation

Reference: RADIATOR ON-VEHICLE INSPECTION AND CLEANING

Scheme 16

1. Disconnect negative cable at battery.
2. Drain cooling system by loosening drain plug of radiator.
3. Disconnect connector of cooling fan motor.
4. Remove condenser cooling fan (if equipped with A/C).
5. Remove reservoir (1).
6. Disconnect radiator inlet (2) and outlet hoses from radiator.
7. Disconnect A/T fluid hoses from radiator, if equipped with A/T vehicle.
8. Remove radiator cooling fan assembly (3).
9. Remove radiator.

Reverse removal procedures, noting the following.

1. Refill cooling system with proper coolant referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
2. After installation, check each joint for leakage.
3. Check automatic fluid level referring to «A/T FLUID LEVEL CHECK»(ref-251085-S32130992962007032000000) (for A/T vehicle).

Water Pump Removal and Installation

Reference: WATER PUMP COMPONENTS

Scheme 17

Scheme 18

1. Disconnect negative cable at battery.
2. Drain coolant and tighten drain plug.
3. Remove condenser cooling fan (if equipped with A/C).
4. Remove radiator outlet hose from thermostat cap (2).
5. Remove heater outlet pipe bolt (1).
6. Remove generator belt referring to «GENERATOR DRIVE BELT REMOVAL AND INSTALLATION»(ref-251067-S00664805372007032000000) .
7. Remove compressor from its bracket with hoses still attached (if equipped with A/C).
8. Remove water pump assembly (1) by removing its 4 bolts (2). NOTE: Do not lose dowel pins when removing water pump.

Reference: WATER PUMP INSPECTION

Scheme 19

Scheme 20

1. Install new O-ring to water pump. NOTE: Do not forget to install dowel pins on water pump side before mounting water pump to cylinder block.
2. Install heater outlet pipe to water pump, then install water pump (1) by using new bolts (2) to cylinder block and tighten to specified torque. CAUTION: Use NEW bolts (2) to install water pump (1) to cylinder block. Failure to do so may result water leakage. Tightening torque Water pump mounting bolt a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
3. Install compressor to its bracket (if equipped with A/C).
4. Tighten heater outlet pipe bolt (1).
5. Install radiator outlet hose to thermostat cap referring to «COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION»(ref-251063-S42109225762007032000000) .
6. Install generator belt referring to «GENERATOR DRIVE BELT REMOVAL AND INSTALLATION»(ref-251067-S00664805372007032000000) .
7. Fill cooling system referring to «COOLING SYSTEM FLUSH AND REFILL»(ref-251063-S04981760882007032000000) .
8. Connect negative cable at battery.
9. Check each part for leakage.