Engine Cooling System Suzuki Grand Vitara I рестайлинг

Cooling System Introduction

The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan, and thermostat. The radiator is of tube-and-fin type.

Thermostat Description

1. Temperature at which valve begins to open: 82+/-2°C (179+/-3.6°F)
2. Temperature at which valve becomes fully open: 95°C (203°F)
3. Valve lift: More than 8 mm (0.315 in) at 95°C (203°F)

Scheme 1

Cooling Fan Clutch Description

Fluid is enclosed in the cooling fan clutch (2) and at its center front, there is a bimetal (3) whose thermal reaction and the engine speed control the cooling fan speed.

Scheme 2

Coolant Description

The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is collected in the reservoir.

When the system cools down, the coolant is drawn back into the radiator.

The cooling system has been filled at the factory with a quality coolant that is a 50/50 mixture of water and ethylene glycol antifreeze.

This 50/50 mixture coolant solution provides freezing protection to -36°C (-33°F).

Scheme 3

Scheme 4

1. Maintain cooling system freeze protection at -36°C (-33°F) to ensure protection against corrosion and loss of coolant from boiling. This should be done even if freezing temperatures are not expected.
2. Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than -36°C (-33°F). NOTE: Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any time as damage to cooling system could occur. Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethylene glycol antifreeze (Antifreeze/Anticorrosion coolant) should be used for the purpose of corrosion protection and lubrication. Coolant must be mixed with demineralized water or distilled water.

Scheme 5

Scheme 6

1. While the engine is warmed up (thermostat closed), coolant circulates as follows.
2. When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator core to be cooled as well as the above flow circuit.

Scheme 7

Cooling System Check

Cooling system should be serviced as follows.

Scheme 8

1. Check cooling system for leakage or damage.
2. Wash radiator cap and filler neck with clean water by removing radiator cap when engine is cold.
3. Check coolant for proper level and freeze protection.
4. Using a pressure tester, check system and radiator cap for proper pressure holding capacity 110 kPa (1.1 kg/cm 2 , 15.6 psi). If replacement of cap is required, use proper cap specified for this vehicle. NOTE: After installing radiator cap to radiator, make sure that its ear is aligned with reservoir hose as shown in the figure. If not, turn cap more to align its ear with hose.
5. Make sure that hose clamps are tightened securely and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise deteriorated.
6. Clean frontal area of radiator core.

Coolant Level Check

To check level, lift hood and look at "see-through" coolant reservoir.

It is not necessary to remove radiator cap to check coolant level.

When engine is cool, check coolant level in reservoir.

A normal coolant level should be between "FULL" and "LOW" marks on reservoir.

If coolant level is below "LOW" mark, remove reservoir cap and add proper coolant to reservoir to bring coolant level up to "FULL" mark.

Then, reinstall cap.

Note. If recommended quality antifreeze is used, there is no need to add extra inhibitors or additives that claim to improve system. They may be harmful to proper operation of system. When Installing reservoir cap, align arrow marks on reservoir and cap.

Scheme 9

Scheme 10

1. Remove radiator cap when engine is cool. Turn cap slowly to the left until it reaches a "stop" (Do not press down while turning it). Wait until pressure is relieved (indicated by a hissing sound) then press down on cap and continue to turn it to the left. WARNING: To help avoid danger of being burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon.
2. With radiator cap removed, run engine until upper radiator hose is hot (this shows that thermostat is open and coolant is flowing through system).
3. Stop engine and open radiator drain plug to drain coolant.
4. Close drain plug. Add water until system is filled and run engine until upper radiator hose is hot again.
5. Repeat Steps 3 and 4 several times until drained liquid is nearly colorless.
6. Drain system and then close radiator drain plug (1) tightly.
7. Disconnect hose from reservoir. Remove reservoir and pour out any fluid. Scrub and clean inside of reservoir with soap and water. Flush it well with clean water and drain. Reinstall reservoir and hose.
8. Add 50/50 mixture of good quality ethylene glycol antifreeze and water to radiator and tank. Fill radiator to the base of radiator filler neck and reservoir to "FULL" level mark. Reinstall reservoir cap, aligning the arrow marks on the reservoir and cap.
9. Run engine, with radiator cap removed, until radiator upper hose is hot.
10. With engine idling, add coolant to radiator until level reaches the bottom of filler neck. Install radiator cap, making sure that the ear of cap lines up with reservoir hose.

Scheme 11

1. Remove radiator cap.
2. Loosen drain plug on radiator to drain coolant.
3. After draining coolant, be sure to tighten drain plug (1) securely.
4. Fill cooling system. Refer to «Coolant Description»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__coolant-description) and «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 12

1. Drain coolant and tighten drain plug.
2. Remove fan shroud with cooling fan after disconnecting radiator inlet hose from radiator.
3. Remove thermostat cap (1).
4. Remove thermostat.

Scheme 13

1. When positioning thermostat (1) and O-ring on thermostat case, be sure to position it so that air bleed valve (2) comes at match mark (3) and into the recession of thermostat case.
2. Install thermostat cap to thermostat case.
3. Install cooling fan, fan shroud and connect radiator inlet hose to radiator.
4. Fill cooling system. Refer to «COOLANT DESCRIPTION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__coolant-description) and «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Connect negative cable at battery.
6. After installation, check each part for leakage.

Scheme 14

Scheme 15

1. Make sure that air bleed valve (1) of thermostat is clean. Should this valve be clogged, engine would tend to overheat.
2. Check to make sure that valve seat is free from foreign matters which would prevent valve from seating tight.
3. Check thermostat seal (2) and O-ring for breakage, deterioration or any other damage.
4. Check thermostatic movement of wax pellet as follows: Immerse thermostat (1) in water, and heat water gradually. Check that valve starts to open at specific temperature. Refer to «THERMOSTAT DESCRIPTION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__thermostat-description) . If valve starts to open at a temperature substantially below or above specific temperature, thermostat unit should be replaced with a new one. Such a unit, if reused, will bring about over cooling or overheating tendency.

Scheme 16

1. Disconnect negative cable at battery.
2. Drain engine oil.
3. Drain coolant referring to «COOLANT DRAINING»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove timing chain cover. Refer to «TIMING CHAIN COVER & FRONT OIL SEAL»(ref-159328-S03046697142003112600000) for H25 engine or «TIMING CHAIN COVER REMOVAL & INSTALLATION»(ref-159329-S35031340182005051200000) for H27 engine .
5. Remove water pump assembly (1).

Scheme 17

1. Install new O-rings (3) to water pump (1).
2. Install water pump (1) to cylinder block. Tightening torque Water pump bolt (a): 27 N.m (2.7 kg-m, 19.5 lb-ft)
3. Install timing chain cover. Refer to «TIMING CHAIN COVER & FRONT OIL SEAL»(ref-159328-S03046697142003112600000) for H25 engine or «TIMING CHAIN COVER REMOVAL & INSTALLATION»(ref-159329-S35031340182005051200000) for H27 engine .
4. Install oil pan referring to «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/i-2000-2006/remont/lubrication-system/#engine-lubrication-system) .
5. Install front differential housing referring to «FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/i-2000-2006/remont/differentials-drive-axles/#differentials) .
6. Install P/S system referring to «P/S PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/i-2000-2006/remont/manual-power-steering/#power-assisted-steering-system) .
7. Install cooling system referring to «THERMOSTAT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) , «COOLING FAN AND FAN CLUTCH REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) and «RADIATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Install intake manifold with throttle body. For H25 engine model, refer to «INTAKE MANIFOLD»(ref-159328-S26284738442003112600000) . For H27 engine model, refer to «THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION»(ref-159329-S26781429642005051200000) .
9. Refill cooling system with coolant, front differential with gear oil, P/S system with specified fluid and engine with engine oil.
10. Check wheel alignment referring to «SPECIFICATIONS & PROCEDURES»(/suzuki/grand-vitara/i-2000-2006/remont/wheel-alignment/#specifications-procedures) for H25 engine or «SPECIFICATIONS & PROCEDURES»(ref-161736) for H27 engine .
11. Verify that there is no fuel leakage, water leakage and oil leakage at each connection.
12. Connect negative cable at battery.

Water Pump Inspection

Note. Do not disassemble water pump. If any repair is required on pump, replace it as assembly.

Scheme 18

1. Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it.
2. Inspect water pump impeller for damage. Replace as necessary.

Scheme 19

Scheme 20

1. Disconnect negative cable at battery.
2. Drain coolant system by loosening drain plug (1) of radiator.
3. Disconnect radiator inlet hose from radiator.
4. Loosen cooling fan/clutch nuts.
5. Remove P/S fluid reservoir stay bolts (1) from radiator stay.
6. Remove radiator shroud securing clips.
7. Then remove cooling fan/clutch and radiator shroud.

Installation

Install removed parts in reverse order of removal procedure.

After installation, adjust belt tension for specification referring to COOLING FAN/GENERATOR BELT TENSION CHECK AND ADJUSTMENT and tighten each bolt and nut securely.

Tightening torque

1. Cooling fan/clutch nut (a): 25 N.m (2.5 kg-m, 18.0 lb-ft)

Scheme 21

Note. Refill cooling system with proper coolant referring to COOLANT DESCRIPTION and COOLING SYSTEM FLUSH AND REFILL . After installation, check each joint for leakage.

Cooling Fan and Fan Clutch Inspection

Inspect fluid coupling for oil leakage.

If necessary, replace fan clutch assembly. Do not disassemble clutch assembly.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. Disconnect negative cable at battery.
2. Drain cooling system by loosening drain plug (1) of radiator.
3. When servicing vehicle equipped with A/T (Automatic Transmission), place oil pan under radiator (1) and disconnect A/T fluid hoses (inlet hose (Outlet from oil cooler) (2), outlet hose (Inlet to oil cooler) (3)) from radiator (1).
4. Loosen cooling fan/clutch nuts (1).
5. Disconnect radiator inlet hose from radiator.
6. Remove P/S fluid reservoir stay bolts (1) from radiator stay.
7. Remove radiator shroud securing clips.
8. Then remove cooling fan/clutch and radiator shroud.
9. Disconnect water hoses (inlet hoe (1), outlet hose (2)) and reservoir hose (3) from radiator (4).
10. Remove radiator.

Reverse removal procedures for installation noting the following.

1. Refill cooling system with proper coolant referring to «COOLANT DESCRIPTION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__coolant-description) and «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Adjust cooling fan belt tension to specification. Refer to «COOLING FAN/GENERATOR BELT TENSION CHECK AND ADJUSTMENT»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__cooling-fangenerator-belt-tension-check-and) .
3. With A/T equipped vehicle, check A/T fluid level referring to «CHECKING FLUID LEVEL»(/suzuki/grand-vitara/i-2000-2006/remont/automatic-trans/#servicing-at) .
4. After installation, check each joint for leakage.

Inspection

Check radiator for leakage or damage. Straighten bent fins, if any.

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. Disconnect negative cable at battery.
2. Drain coolant referring to «COOLANT DRAINING»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove radiator inlet hose (1), outlet hose (2) and radiator outlet pipe (3).
4. Remove throttle body and intake manifold. For H25 engine model, refer to «INTAKE MANIFOLD»(ref-159328-S26284738442003112600000) . For H27 engine model, refer to «THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION»(ref-159329-S26781429642005051200000) .
5. Disconnect ECT sensor (4) coupler.
6. Disconnect heater inlet hose (5) from water outlet cap (3).
7. Remove water outlet cap (3) from cylinder heads.
8. Remove water outlet pipe (2) from thermostat case (1).
9. Remove thermostat case (1) from cylinder block.

Install removed parts in reverse order of removal procedure, noting the followings.

Scheme 32

Scheme 33

Scheme 34

1. Install thermostat case (1) to cylinder block with new O-ring (4).
2. Install water outlet pipe (2) to thermostat case (1) with new O-rings (4).
3. Install water outlet cap (3) to cylinder heads with new gaskets.
4. Connect heater hose (5) to water outlet cap (3).
5. Connect ECT sensor (4) coupler.
6. Install throttle body and intake manifold. For H25 engine model, refer to «INTAKE MANIFOLD»(ref-159328-S26284738442003112600000) . For H27 engine model, refer to «THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION»(ref-159329-S26781429642005051200000) .
7. Install radiator outlet pipe (3) to thermostat case with new O-ring.
8. Install radiator inlet hose (1) and outlet hose (2).
9. Refill cooling system with proper coolant, referring to «COOLANT DESCRIPTION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__coolant-description) and «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .

Cooling Fan/Generator Belt Tension Check and Adjustment

Scheme 35

Scheme 36

1. Inspect belt for cracks, cuts, deformation, wear and cleanliness. If it is necessary to replace belt, refer to «COOLING FAN/GENERATOR BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Check belt for tension. Belt is in proper tension when it deflects within specified value under thumb pressure (about 10 kg or 22 lb.). Cooling fan belt tension as deflection: 10 kg (22 lbs) "a": 9 - 11 mm (0.35 - 0.43 in.) NOTE: When replacing belt with a new one, adjust belt tension to 7 - 9 mm (0.28 - 0.35 in.).
3. If belt is too tight or too loose, adjust it to proper tension by displacing generator position.
4. Tighten generator adjusting bolt and pivot bolt.
5. Connect negative cable at battery terminal.

Scheme 37

1. Disconnect negative cable at battery.
2. Loosen P/S pump drive belt adjusting bolt and then remove P/S pump belt.
3. Loosen adjusting bolt (1) and pivot bolt.
4. Slacken belt by displacing generator and then remove it.

1. Install belt to water pump pulley, crankshaft pulley and generator pulley. Install P/S pump drive belt.
2. Adjust belt tension as specified. For adjustment of P/S pump drive belt tension, refer to «P/S PUMP DRIVE BELT INSPECTION AND ADJUSTMENT»(/suzuki/grand-vitara/i-2000-2006/remont/manual-power-steering/#power-assisted-steering-system) . For adjustment of cooling fan belt tension, refer to «COOLING FAN/GENERATOR BELT TENSION CHECK AND ADJUSTMENT»(/suzuki/grand-vitara/i-2000-2006/remont/cooling-system-mechanical/#engine-cooling-system__cooling-fangenerator-belt-tension-check-and) .
3. Tighten adjusting bolt and pivot bolt.
4. Connect negative cable at battery.

Tightening Torque Specifications

Torque Specifications

See also:
• OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
• FRONT DIFFERENTIAL DISMOUNTING AND REMOUNTING
• P/S PUMP REMOVAL AND INSTALLATION
• SPECIFICATIONS & PROCEDURES
• CHECKING FLUID LEVEL
• Coolant Description
• COOLING SYSTEM FLUSH AND REFILL
• THERMOSTAT DESCRIPTION
• COOLING FAN/GENERATOR BELT TENSION CHECK AND ADJUSTMENT