Engine Cooling System: Removal & Installation Suzuki Forenza I

Removal

Scheme 4

Scheme 5

Scheme 6

1. Drain the coolant. Refer to «Draining and Refilling the Cooling System»(ref-257072-S24557310622007062900000) .
2. Loosen the hose clamp on the upper radiator hose at the thermostat housing.
3. Disconnect the upper radiator hose from the thermostat housing.
4. Remove the mounting bolts that hold the thermostat housing to the cylinder head.
5. Remove the thermostat housing from the cylinder head.
6. Remove the seal ring from the thermostat housing.
7. Remove the thermostat from the thermostat housing by pressing the thermostat mounting flange downward and then rotating the flange clockwise.
8. Inspect the valve seat for foreign matter that could prevent the valve from sealing properly.
9. Inspect the thermostat for proper operation. Refer to «Thermostat Test»(ref-257072-S00969537432007062900000) .
10. Clean the thermostat housing and the cylinder head mating surfaces.

Installation

1. Install the thermostat into the thermostat housing by pressing the thermostat mounting flange downward and then rotating the flange counterclockwise. Rotate the thermostat mounting flange until it is seated in the thermostat housing recesses.
2. Coat the sealing surface of a new seal ring with Lubricator®.
3. Install a new seal ring into the recess in the thermostat housing.
4. Install the thermostat housing to the cylinder head.
5. Secure the thermostat housing to the cylinder head with the mounting bolts. Tighten: Tighten the thermostat housing mounting bolts to 15 N.m (11 lb-ft).
6. Connect the upper radiator hose to the thermostat housing.
7. Secure the upper radiator hose to the thermostat housing with a hose clamp.
8. Refill the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257072-S24557310622007062900000) .

Scheme 7

Scheme 8

1. Drain the engine cooling system to a level below the thermostat housing. Refer to «Draining and Refilling the Cooling System»(ref-257072-S24557310622007062900000) .
2. Remove the timing belt. Refer to «TIMING BELT REMOVAL AND INSTALLATION»(ref-257073-S15577769162007062900000) .
3. Remove the timing belt tension roller retaining bolt.
4. Remove the timing belt tension roller.
5. Remove the water pump mounting bolts.
6. Remove the water pump from the engine block.
7. Remove the ring seal from the water pump.

Scheme 9

1. Install a new ring seal to the water pump.
2. Coat the sealing surface of the ring seal with Lubricator®.
3. Install the water pump to the engine block with the flange aligned with the recess of the rear timing belt cover.
4. Secure the water pump to the engine block with the mounting bolts. Tighten: Tighten the water pump mounting bolts to 25 N.m (18 lb-ft).
5. Install the timing belt tension roller to the oil pump with the flange inserted into the recess of the oil pump.
6. Install the timing belt tension roller bolt. Do not tighten the bolt at this time.
7. Install the timing belt. Refer to «TIMING BELT REMOVAL AND INSTALLATION»(ref-257073-S15577769162007062900000) .
8. Refill the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257072-S24557310622007062900000) .

Scheme 10

1. Inspect the water pump body for cracks and leaks.
2. Inspect the water pump bearing for play or abnormal noise.
3. Inspect the water pump pulley for excessive wear. If the water pump is defective, replace the water pump as a unit.
4. Clean the mating surfaces of the water pump and the engine block.

Scheme 11

Scheme 12

Scheme 13

1. Disconnect the negative battery cable.
2. Disconnect the cooling fan electrical connector.
3. Remove the fan shroud mounting bolts.
4. Lift the fan shroud assembly upward, and remove the fan shroud assembly from the vehicle.
5. Remove the fan blade from the fan shroud assembly by removing the nut at the center of the fan hub.
6. Turn over the fan shroud assembly.
7. Remove the fan motor retaining screws.
8. Remove the fan motor from the shroud.

1. Install the fan motor to the shroud.
2. Secure the motor to the shroud with the retaining screws. Tighten: Tighten the fan motor retaining screws to 4 N.m (35 lb-in).
3. Turn over the fan shroud assembly.
4. Install the fan to the fan shroud assembly with the single nut in the center of the fan hub. Tighten: Tighten the fan motor nut to 3.2 N.m (28 lb-in).
5. Install the fan shroud assembly to the radiator.
6. Secure the shroud to the top of the radiator with the mounting bolts. Tighten: Tighten the fan assembly mounting bolts to 4 N.m (35 lb-in).
7. Connect the cooling fan electrical connector.
8. Connect the negative battery cable.

Scheme 14

Scheme 15

1. Drain the engine coolant to below the level of the surge tank.
2. Loosen the return hose clamp and disconnect the return hose from the top of the surge tank.
3. Loosen the throttle body hose clamp and disconnect the throttle body hose from the top of the surge tank.
4. Loosen the feed hose clamp and disconnect the feed hose from the bottom of the surge tank.
5. Remove the surge tank attaching bolt.
6. Remove the surge tank from the support mount.
7. Clean the inside and the outside of the surge tank and the surge tank cap with soap and water.
8. Rinse the surge tank and the cap thoroughly.

1. Install the surge tank to the support mount.
2. Secure the surge tank with the attaching bolt. Tighten: Tighten the surge tank attaching bolt to 5 N.m (44 lb-in).
3. Connect the return hose and the throttle body hose to the top of the surge tank.
4. Connect the feed hose to the bottom of the surge tank.
5. Secure the return hose, the throttle body hose, and the feed hose to the surge tank with the hose clamps.
6. Fill the surge tank with the coolant to the center ridge, or to the MAX mark.

Scheme 16

Scheme 17

1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257072-S24557310622007062900000) .
3. Remove the main and the auxiliary cooling fans. Refer to «Electric Cooling Fan - Main or Auxiliary Removal and Installation»(ref-257072-S06832511902007062900000) .
4. Remove the upper radiator retaining bolt.
5. Remove the upper radiator retaining bracket.
6. Remove the upper radiator hose clamp.
7. Disconnect the upper radiator hose from the radiator.
8. Remove the hose clamp from the surge tank hose at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Remove the lower radiator hose clamp.
11. Disconnect the lower radiator hose from the radiator.
12. Disconnect the transaxle cooler pipes from the lower radiator tank, if equipped.
13. Remove the bolt and the transaxle pipe support clamp from the radiator.
14. Remove the radiator from the vehicle.

1. Set the radiator into place in the vehicle with the radiator bottom posts in the rubber shock bumpers.
2. Connect the transaxle cooler pipes to the lower radiator tank, if equipped.
3. Install the transaxle pipe and support clamp to the radiator with a bolt.
4. Connect the surge tank hose to the radiator.
5. Secure the surge tank hose with a hose clamp.
6. Connect the upper radiator hose and the lower radiator hose to the radiator.
7. Secure each hose with a hose clamp.
8. Position the radiator retainers in place.
9. Install the upper radiator retainer bracket.
10. Install the upper radiator retaining bolt.
11. Install the main and the auxiliary cooling fans. Refer to «Electric Cooling Fan - Main or Auxiliary Removal and Installation»(ref-257072-S06832511902007062900000) .
12. Refill the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257072-S24557310622007062900000) .
13. Connect the negative battery cable. Tighten: Tighten the radiator retaining bolt to 8 N.m (71 lb-in).