Engine Cooling System (VQ40DE): Removal & Installation Suzuki Equator I

Radiator: Removal and Installation

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1. Remove engine undercover using power tool. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000)
2. Drain engine coolant from radiator. CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
3. Remove engine room cover. Refer to «ENGINE ROOM COVER: REMOVAL AND INSTALLATION»(ref-375721-S37910005862010102800000)
4. Remove air duct and air cleaner case assembly. Refer to «AIR CLEANER AND AIR DUCT: REMOVAL AND INSTALLATION»(ref-375721-S30855040562010102800000)
5. Remove reservoir tank hose.
6. Remove radiator hoses (upper and lower). CAUTION: Be careful not to allow engine coolant to contact drive belts.
7. Disconnect A/T fluid cooler hoses, if equipped. Install blind plug to avoid leakage of A/T fluid.
8. Remove radiator shroud (lower).
9. Remove radiator shroud (upper).
10. Remove radiator cooling fan assembly. Refer to «Engine Cooling Fan: Removal and Installation (Motor driven type)»(ref-375748-S15830116222010102800000)
11. Remove front grille. Refer to «FRONT GRILLE: REMOVAL AND INSTALLATION»(ref-375738-S40643390202010102800000)
12. Remove the upper radiator mounting bracket bolts.
13. Remove the two A/C condenser bolts.
14. 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 fix it with rope or similar means.

INSTALLATION

Installation is in the reverse order of removal.

Installation is in the reverse order of removal.

1. Install cooling fan with its front mark "F" facing front of engine. Refer to «ENGINE COOLING FAN: EXPLODED VIEW»(ref-375748-S23201541072010102800000) .

Installation is in the reverse order of removal.

1. Cooling fan is controlled by ECM. For details, refer to «P1217 ENGINE OVER TEMPERATURE»(ref-375704-S22541282342010102800000)

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Water Pump: Removal and Installation

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1. Remove engine front undercover using power tool. Refer to «FRONT BUMPER: REMOVAL AND INSTALLATION»(ref-375736-S25592846052010102800000)
2. Drain engine coolant. CAUTION: Perform this step when engine is cold. Do not spill engine coolant on timing chain and drive belt.
3. Remove the engine room cover. Refer to «ENGINE ROOM COVER: REMOVAL AND INSTALLATION»(ref-375721-S37910005862010102800000)
4. Remove air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT: REMOVAL AND INSTALLATION»(ref-375721-S30855040562010102800000)
5. Remove drive belt. Refer to «DRIVE BELTS: REMOVAL AND INSTALLATION»(ref-375721-S39771743322010102800000)
6. Remove radiator hose (upper).
7. Remove coolant reservoir hose from the radiator.
8. Remove engine cooling fan (Motor driven type). Refer to «Engine Cooling Fan: Removal and Installation (Motor driven type)»(ref-375748-S15830116222010102800000)
9. Remove cooling fan (Crankshaft driven type). Refer to «ENGINE COOLING FAN: REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE)»(ref-375748-S25336598872010102800000) .
10. Remove chain tensioner cover and water pump cover from front timing chain case, using Tool. Tool number: KV10111100 (J-37228)
11. Remove timing chain tensioner (primary) as follows: Loosen clip of timing chain tensioner (primary), and release plunger stopper (1). Insert plunger into tensioner body by pressing slack guide (2). Keep slack guide pressed and hold plunger in by pushing stopper pin through the tensioner body hole and plunger groove (3). Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. Remove bolts and remove timing chain tensioner (primary). CAUTION: Be careful not to drop bolts inside timing chain case.
12. Remove water pump as follows: Remove three water pump bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley counterclockwise until timing chain looseness on water pump sprocket becomes maximum. Screw M8 bolts [pitch: 1.25 mm (0.049 in) length: approx. 50 mm (1.97 in) ] into water pumps upper and lower bolt holes until they reach timing chain case. Then, alternately tighten each bolt for a half turn, and pull out water pump. CAUTION: Pull straight out while preventing vane from contacting socket in installation area. Remove water pump without causing sprocket to contact timing chain. Do not spill engine coolant into timing chain case. Remove M8 bolts and O-rings from water pump. CAUTION: Do not disassemble water pump. NOTE: Do not reuse O-rings.

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1. Check for badly rusted or corroded water pump body assembly.
2. Check for rough operation due to excessive end play.
3. Replace water pump, if necessary.

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1. Install new O-rings to water pump. NOTE: Apply engine oil to O-rings. Locate O-ring with white paint mark to engine front side.
2. Install water pump. CAUTION: Do not allow timing chain case to pinch O-rings when installing water pump. Make sure that timing chain and water pump sprocket are engaged. Insert water pump by tightening bolts alternately and evenly.
3. Install timing chain tensioner (primary) as follows: Remove dust and foreign material completely from backside of timing chain tensioner (primary) and from installation area of rear timing chain case. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. Install timing chain tensioner (primary) with its stopper pin attached. CAUTION: Be careful not to drop bolts inside timing chain case. Remove stopper pin. Make sure again that timing chain and water pump sprocket are engaged.
4. Install chain tensioner cover and water pump cover as follows: Before installing, remove all traces of old liquid gasket from mating surface of water pump cover and chain tensioner cover using scraper. Also remove traces of old liquid gasket from the mating surface of front timing chain case. Apply a continuous bead of liquid gasket, to mating surface of chain tensioner and water pump cover, using Tool. Tool number: WS39930000 (-) Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) . CAUTION: Attaching should be done within 5 minutes after coating. Tighten bolts to specified torque. Refer to «FRONT TIMING CHAIN CASE: EXPLODED VIEW»(ref-375721-S39312088122010102800000)
5. Installation of the remaining components is in the reverse order of removal after this step. Refill engine coolant system. Refer to «CHANGING ENGINE COOLANT»(ref-375748-S18727906452010102800000) Apply liquid gasket to the thread of water drain plug (front). Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-375700-S13998640382010102800000) . After starting engine, let idle for three minutes, then rev engine up to 3,000 RPM under no load to purge air from the high-pressure chamber of chain tensioner. Engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

Installation is in the reverse order of removal, paying attention to the following.

1. Do not spill engine coolant in engine room. Use rag to absorb engine coolant.

REMOVAL

1. Drain engine coolant from radiator. Refer to «CHANGING ENGINE COOLANT»(ref-375748-S18727906452010102800000) . CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
2. Remove the intake manifold collector. Refer to «INTAKE MANIFOLD: REMOVAL AND INSTALLATION»(ref-375721-S36914482782010102800000)
3. Remove engine coolant temperature sensor as necessary. CAUTION: Be careful not to damage engine coolant temperature sensor.
4. Remove water outlet, heater pipe, water bypass hoses and water pipe.

Installation is in the reverse order of removal, paying attention to the following.

1. Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
2. When inserting water pipe into water outlet, apply neutral detergent to O-ring.