Engine Cooling System (VQ40DE): Other Suzuki Equator I

CHECKING COOLING SYSTEM HOSES

Check hoses for the following

1. Improper attachment
2. Leaks
3. Cracks
4. Damage
5. Loose connections
6. Chafing
7. Deterioration

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1. Check if the engine coolant reservoir tank level is within MIN to MAX when the engine is cool.
2. Adjust engine coolant level as necessary.

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system using Tool.

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Tool number: EG17650301 (J-33984-A)

Testing pressure: 137 kPa (1.4 kg/cm 2 , 20 psi)

Note. In case that engine coolant decreases, replenish cooling system with engine coolant.

If any concerns are found, repair or replace damaged parts.

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1. Inspect the reservoir cap. Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket. Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer. NOTE: Thoroughly wipe out the reservoir filler neck to remove any waxy residue or foreign material.
2. Pull the negative-pressure valve to open it and check that it closes completely when released. Check that there is no dirt or damage on the valve seat of the reservoir cap negative-pressure valve. Check that there are no abnormalities in the opening and closing conditions of the negative-pressure valve.
3. Check reservoir cap relief pressure using suitable tool and Tool. Tool number: EG17650301 (J-33984-A) Standard: 78 - 98 kPa (0.8 - 1.0 kg/cm 2 , 11 - 14 psi) Limit: 59 kPa (0.6 kg/cm 2 , 9 psi) NOTE: Apply engine coolant to the cap seal surface. Replace the reservoir cap if there is any damage in the negative-pressure valve, or if the open-valve pressure is outside of the limit.

CHECKING RADIATOR CAP

Inspect the radiator cap.

Note. Thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material.

1. Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket.
2. Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer.

CHECKING RADIATOR

Check radiator for mud or clogging. If necessary, clean radiator as follows.

1. Apply water by hose to the back side of the radiator core, with the hose pointed vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core, with the air hose pointed vertically downward. Use compressed air lower than 490 kPa (5 kg/cm 2 , 71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
6. Check for leaks.

Changing Engine Coolant

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1. Turn ignition switch ON and set temperature control lever all the way to HOT position or the highest temperature position. Wait 10 seconds and turn ignition switch OFF.
2. Remove the engine front undercover using power tool. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000)
3. Open the radiator drain plug at the bottom of the radiator, and remove the reservoir cap. This is the only step required when partially draining the cooling system (radiator only). CAUTION: Do not allow the coolant to contact the drive belts.
4. When draining all of the coolant in the system for engine removal or repair, it is necessary to drain the cylinder block. Remove the cylinder block drain plugs (A), (B), (C), (D) and block heater if equipped, to drain the cylinder block as shown. NOTE: For Canada, the (D) cylinder block drain plug as shown, is not a cylinder block drain plug but a block heater.
5. Remove the reservoir tank to drain the engine coolant, then clean the reservoir tank before installing it.
6. Check the drained coolant for contaminants such as rust, corrosion or discoloration. If the coolant is contaminated, flush the engine cooling system. Follow the "Flushing Cooling System" procedure.

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1. Close the radiator drain plug. Install the reservoir tank, cylinder block drain plugs (A), (B), (C), (D) and block heater if equipped, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. Apply sealant to the threads of the cylinder block drain plugs (A), (B), (C), (D). Use Genuine High Performance Thread Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) Tighten each plug to the specified torque. Refer to «ENGINE UNIT: DISASSEMBLY AND ASSEMBLY»(ref-375720-S27006757312010102800000)
2. Set the vehicle heater controls to the full HOT and heater ON position. Turn the vehicle ignition ON with the engine OFF as necessary to activate the heater mode.
3. Remove the vented reservoir cap and replace it with a non-vented reservoir cap before filling the cooling system.
4. Install the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attach the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. Tool number: KV991J0070 (J-45695)
5. Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed position. Use recommended coolant or equivalent. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-375712-S04876022172010102800000) . Cooling system capacity (with reservoir): Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-375712-S04876022172010102800000) .
6. Install an air hose to the venturi assembly, the air pressure must be within specification. Compressed air supply pressure: 5.7 - 8.5 kPa (5.6 - 8.4 kg/cm 2 , 80 - 120 psi) CAUTION: The compressed air supply must be equipped with an air dryer.
7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process open the ball valve on the refill hose slightly. Coolant will be visible rising in the refill hose. Once the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose.
8. Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations, use the vacuum specifications based on the altitude above sea level. Altitude above sea level Vacuum gauge reading 0 - 100 m (328 ft): 28 inches of vacuum 300 m (984 ft): 27 inches of vacuum 500 m (1,641 ft): 26 inches of vacuum 1,000 m (3,281 ft): 24 - 25 inches of vacuum
9. When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses any vacuum. If the vacuum level drops, perform any necessary repairs to the system and repeat steps - to bring the vacuum to the specified amount. Recheck for any leaks.
10. Place the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero. CAUTION: Do not allow the coolant container to get too low when filling, to avoid air from being drawn into the cooling system.
11. Remove the Tool from the radiator neck opening and install the radiator cap.
12. Remove the non-vented reservoir cap.
13. Fill the cooling system reservoir tank to the specified level. Run the engine to warm up the cooling system and top up the system as necessary before installing the vented reservoir cap.

Check radiator for mud or clogging. If necessary, clean radiator as follows.

1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces.
3. Stop washing when dirt and debris no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downward. Use compressed air lower than 490 kPa (5 kg/cm 2 , 71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces until no water sprays out.
6. Check for leaks.

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1. Remove engine front undercover using power tool. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000)
2. Partially drain engine coolant from radiator. CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
3. Remove the engine room cover. Refer to «ENGINE ROOM COVER: REMOVAL AND INSTALLATION»(ref-375721-S37910005862010102800000)
4. Remove air duct. Refer to «AIR CLEANER AND AIR DUCT: REMOVAL AND INSTALLATION»(ref-375721-S30855040562010102800000)
5. Remove reservoir tank hose from shroud.
6. Removal radiator hose (upper) from radiator. CAUTION: Do not spill engine coolant on drive belts.
7. Release the radiator shroud (lower) (2) from the radiator shroud (upper) (1) and position aside. Release the tabs, pull radiator shroud (lower) (2) rearwards and down.
8. Remove the radiator shroud (upper) bolts and remove the radiator shroud (upper). Refer to «RADIATOR: EXPLODED VIEW»(ref-375748-S03099360622010102800000) .
9. Remove the engine cooling fan (Motor driven type). Refer to «Engine Cooling Fan: Removal and Installation (Motor driven type)»(ref-375748-S15830116222010102800000)
10. Remove the drive belt. Refer to «DRIVE BELTS: REMOVAL AND INSTALLATION»(ref-375721-S39771743322010102800000)
11. Remove the engine cooling fan.
12. Remove the fan coupling, if necessary.
13. Remove the cooling fan pulley, if necessary.
14. Remove the drive belt auto-tensioner, if necessary.
15. Remove the fan bracket, if necessary.

Fan Coupling

Inspect fan coupling for oil leakage and bimetal conditions.

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1. Visually check that there is no significant looseness in the fan bracket shaft, and that it turns smoothly by hand.
2. If there are any unusual concerns, replace the fan bracket assembly.

RADIATOR

RADIATOR SPECIFICATIONS

THERMOSTAT

THERMOSTAT SPECIFICATIONS

Special Service Tool

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL SERVICE TOOL Tool number (Kent-Moore No.) Tool name Description KV10111100 (J-37228) Seal cutter Removing chain tensioner cover and water pump cover WS39930000 (-) Tube presser Pressing the tube of liquid gasket EG17650301 (J-33984-A) Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator filler neck 28 (1.10) dia. 31.4 (1.236) dia. 41.3 (1.626) dia. Unit: mm (in) KV991J0070 (J-45695) Coolant refill tool Filling cooling system KV991J0010 (J-23688) Engine coolant refractometer Checking concentration of ethylene glycol in engine coolant

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Commercial Service Tool

COMMERCIAL SERVICE TOOL Tool name Description Power tool Loosening bolts and nuts Radiator cap tester Checking radiator and radiator cap Coolant system tester adapter Adapting radiator cap tester to reservoir filler neck Coolant system tester adapter Adapting radiator cap tester to reservoir cap

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