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Engine Cooling System (QR25DE): Removal & Installation Suzuki Equator I

Cooling System (Mechanical) 10 illustrations ~1273 words

Radiator: Removal and Installation

WARNINGDo not remove radiator cap when engine is hot. Serious burns could occur from high-pressure engine coolant escaping from radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.

Scheme 10

Scheme 10: REMOVAL
Scheme 10: REMOVAL

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13
  1. Remove engine under cover. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000) .
  2. Drain engine coolant from radiator. Refer to [ «CHANGING ENGINE COOLANT»(ref-375740-S19773137712010102800000) ]. CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
  3. Remove air duct and resonator assembly and air duct brackets. Refer to [ «AIR CLEANER AND AIR DUCT: EXPLODED VIEW»(ref-375720-S11578578132010102800000) ].
  4. Remove reservoir tank hose.
  5. Removal (upper and lower) radiator hoses. CAUTION: Be careful not to allow engine coolant to contact drive belts.
  6. Disconnect A/T fluid cooler hoses. (A/T models) Install blind plug to avoid leakage of A/T fluid.
  7. Remove lower shroud.
  8. Remove upper shroud.
  9. Remove front grille. Refer to «FRONT GRILLE: REMOVAL AND INSTALLATION»(ref-375738-S40643390202010102800000) .
  10. Remove the upper radiator mounting bracket bolts.
  11. Remove the two A/C condenser bolts. (if equipped)
  12. Remove radiator as follows: CAUTION: Do not damage or scratch A/C condenser and radiator core when removing. With lifting and pulling radiator in a rear direction, disassemble mounting rubber (lower) from radiator core support center. CAUTION: Because A/C condenser is attached to the front-lower portion of radiator, moving it in the rear direction should be at a minimum. Lift A/C condenser up and remove radiator after disengaging the fitting at front-bottom surface. CAUTION: Lifting A/C condenser should be minimum to prevent a load to A/C piping. After removing radiator, put A/C condenser on radiator core support center to prevent a load to A/C piping, and temporarily secure it with rope or by similar means.

INSTALLATION

Installation is in the reverse order of removal.

REMOVAL

  1. Remove the engine front under cover. Refer to [ «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000) ].
  2. Partially drain engine coolant.
  3. Remove air duct and resonator assembly and air duct mounting brackets. Refer to «AIR CLEANER AND AIR DUCT: EXPLODED VIEW»(ref-375720-S11578578132010102800000) .
  4. Remove upper radiator hose.
  5. Disconnect reservoir tank hose from upper shroud and radiator.
  6. Remove the upper and lower shrouds. Refer to «RADIATOR: EXPLODED VIEW»(ref-375740-S23526455702010102800000) .
  7. Remove drive belts. Refer to [ «DRIVE BELTS: REMOVAL AND INSTALLATION»(ref-375720-S17652607302010102800000) ]
  8. Remove cooling fan.
  9. Remove fan coupling, if necessary.
  10. Remove water pump pulley, if necessary.

Installation is in the reverse order of removal.

  1. Install cooling fan with its front mark "F" facing front of engine.
  1. Remove engine front under cover. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000) .
  2. Drain engine coolant from radiator. Refer to [ «CHANGING ENGINE COOLANT»(ref-375740-S19773137712010102800000) ]. CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belt.
  3. Remove cooling fan and water pump pulley. Refer to [ «COOLING FAN: REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE)»(ref-375740-S12168416692010102800000) ].
  4. Remove water pump with power tool. CAUTION: Handle water pump vane so that it does not contact any other parts. Water pump cannot be disassembled and should be replaced as a unit. NOTE: Engine coolant will leak from cylinder block, so have a receptacle ready below.

Scheme 14

Scheme 14: INSPECTION AFTER REMOVAL
Scheme 14: INSPECTION AFTER REMOVAL
  1. Visually check if there is no significant dirt or rusting on water pump body and vane.
  2. Make sure that there is no looseness in vane shaft, and that it turns smoothly when rotated by hand.
  3. Replace water pump, if necessary.

Installation is in the reverse order of removal.

  1. When inserting heater pipe end into water pump and thermostat housing, apply a neutral detergent to O-ring. Then insert it immediately.
  1. Drain engine coolant from radiator. Refer to [ «CHANGING ENGINE COOLANT»(ref-375740-S19773137712010102800000) ] and [ «ENGINE UNIT: EXPLODED VIEW»(ref-375720-S17311883202010102800000) ] CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belt.
  2. Remove the air duct. Refer to «AIR CLEANER AND AIR DUCT: EXPLODED VIEW»(ref-375720-S11578578132010102800000) .
  3. Disconnect radiator hose (lower) at water inlet side. Refer to [ «RADIATOR: EXPLODED VIEW»(ref-375740-S23526455702010102800000) ].
  4. Remove water inlet and thermostat.

Scheme 15

Scheme 15: INSPECTION AFTER REMOVAL
Scheme 15: INSPECTION AFTER REMOVAL
  1. Place a thread so that it is caught in the valve of the thermostat. Immerse fully in a container filled with water. Heat while stirring.
  2. The valve opening temperature is the temperature at which the valve opens and falls from the thread.
  3. Continue heating. Check the full-open lift amount. NOTE: The full-open lift amount standard temperature for water control valve is the reference value.
  4. After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.

Standard

ItemsThermostat
Valve opening temperature80.5 - 83.5°C (177 - 182°F)
Full-open lift amount8 mm/95°C (0.315 in/203°F)
Valve closing temperature77°C (171°F)

THERMOSTAT REFERENCE CHART

  1. If out of the standard, replace thermostat.

Installation is in the reverse order of removal.

Scheme 16

Scheme 16: Thermostat
Scheme 16: Thermostat

Scheme 17

Scheme 17
Scheme 17
  1. Install thermostat with making rubber ring groove fit to thermostat flange with the whole circumference.
  2. Install thermostat with jiggle valve (A) facing upwards. The position deviation may be within the range of 20° (b).
  1. Drain engine coolant from radiator. Refer to [ «CHANGING ENGINE COOLANT»(ref-375740-S19773137712010102800000) ].
  2. Remove water pump. Refer to «Water Pump: Exploded View»(ref-375740-S05875966512010102800000) .
  3. Remove radiator hose (lower) at water inlet.
  4. Remove thermostat. Refer to «Thermostat Removal and Installation»(ref-375740-S09299308542010102800000) .
  5. Remove exhaust manifold cover. Refer to [ «EXHAUST MANIFOLD AND THREE WAY CATALYST: EXPLODED VIEW [QR25DE]»(ref-375741-S09879295812010102800000) ]
  6. Remove oil level gauge and oil level gauge guide. Refer to [ «ENGINE UNIT: EXPLODED VIEW»(ref-375720-S17311883202010102800000) ] CAUTION: Plug the oil level gauge guide opening to prevent foreign materials from entering oil pan.
  7. Remove A/C compressor, if equipped, and position aside. Refer to [ «COMPRESSOR: REMOVAL AND INSTALLATION»(ref-375746-S15025359182010102800000) ]
  8. Disconnect electric throttle control actuator, oil cooler and heater hose from heater pipe.
  9. Remove bolt for heater pipe at water pump and thermostat housing.
  10. Disconnect heater pipe from water pump and thermostat housing.
  11. Remove water pump and thermostat housing.

Installation is in the reverse order of removal.

  1. When inserting heater pipe end into water pump and thermostat housing, apply a neutral detergent to O-ring. Then insert it immediately.

Water Control Valve: Removal and Installation

WARNINGNever remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator.
CAUTIONPerform when the engine cold.
  1. Partially drain the engine coolant from the radiator. Refer to [ «CHANGING ENGINE COOLANT»(ref-375740-S19773137712010102800000) ].
  2. Disconnect the heater hose and water hoses from the heater outlet.
  3. Remove the heater outlet.
  4. Remove the water control valve.
  5. Remove the engine coolant temperature sensor, if necessary. CAUTION: Be careful not to damage engine coolant temperature sensor.

Scheme 18

Scheme 18: INSPECTION AFTER REMOVAL
Scheme 18: INSPECTION AFTER REMOVAL
  1. Place a thread so that it is caught in the valve of the water control valve. Immerse fully in a container filled with water. Heat while stirring.
  2. The valve opening temperature is the temperature at which the valve opens and the falls from the thread.
  3. Continue heating. Check the full-open lift amount. NOTE: The full-open lift amount standard temperature for the water control valve is the reference value.
  4. After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.

Standard values

Water Control ValveStandard Value
Valve opening temperature93.5° - 96.5°C (200° - 206°F)
Full-open lift amountMore than 8 mm / 108°C (0.315 in / 226° F)
Valve closing temperature90°C (194°F) or higher

STANDARD VALUES

Installation is in the reverse order of removal.

Water Control Valve

  1. Install water control valve by making rubber ring (1) groove fit to water control valve flange (A) around the whole circumference. see scheme 22: Installing Thermostat With Making Rubber Ring Groove Fit To Thermostat Flange With Whole Circumference
  2. Install water control valve with jiggle valve facing upwards. The position deviation may be within the range of 20°. see scheme 23: Installing Thermostat With Jiggle Valve Facing Upwards
  3. Install the engine coolant temperature sensor if removed. Use Genuine RTV Silicone Sealant or equivalent.

Scheme 19

Scheme 19: Water Outlet and Water Piping: Exploded View
Scheme 19: Water Outlet and Water Piping: Exploded View
  1. Partially drain engine coolant from the radiator. CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
  2. Remove the air duct. Refer to «AIR CLEANER AND AIR DUCT: EXPLODED VIEW»(ref-375720-S11578578132010102800000) .
  3. Disconnect radiator hose (upper) at water outlet side. Refer to [ «RADIATOR: EXPLODED VIEW»(ref-375740-S23526455702010102800000) ].
  4. Remove water outlet.

Note the following, and install in the reverse order of removal.

  1. Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.

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