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Engine Cooling System Suzuki Grand Vitara II

Cooling System (mechanical) 20 illustrations ~1824 words

COOLING SYSTEM DESCRIPTION

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.

COOLANT DESCRIPTION

WARNINGDo not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary. As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal of the radiator cap while engine is hot and pressure is high will cause the solution to boil instantaneously and possibly with explosive force, spewing the solution over engine, fenders and person removing cap. If the solution contains flammable anti-freeze such as alcohol (not recommended for use at any time), there is also the possibility of causing a serious fire. Check to make sure that engine coolant temperature is cold before removing any part of cooling system. Also be sure to disconnect negative (-) cable from battery terminal before removing any part.

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

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

The cooling system has been filled 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).

  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. Coolant must be mixed with deminerated water or distilled water.

Anti-freeze proportioning table

Freezing temperature°C36
°F33
Anti-freeze/Anti-corrosion coolant concentration%50
Ratio of compound to cooling waterLtr.4.1/4.1
US pt.8.75/8.75
Imp pt.7.22/7.22

ANTI-FREEZE PROPORTIONING TABLE

Coolant capacity

Engine, radiator and heater: 7.4 liters (15.64/13.03 US/lmp pt.)

Reservoir: 0.8 liters (1.69/1.41 US/lmp pt.)

Total: 8.2 liters (17.49/14.43 US/lmp pt.)

Scheme 1

Scheme 1: COOLANT CIRCULATION
Scheme 1: COOLANT CIRCULATION

ENGINE COOLING SYMPTOM DIAGNOSIS

ConditionPossible CauseAction
Engine overheats (Radiator fan operates)Loose or broken water pump beltAdjust or replace .
Not enough coolantCheck coolant level and add as necessary .
Faulty thermostatReplace .
Faulty water pumpReplace .
Dirty or bent radiator finsClean or remedy .
Coolant leakage on cooling systemRepair .
Clogged radiatorCheck and replace radiator as necessary .
Faulty radiator capReplace .
Improper ignition timingRefer to IGNITION SYSTEM SYMPTOM DIAGNOSIS .
Dragging brakesAdjust brake .
Slipping clutchAdjust or replace .
Poor charge batteryCheck and replace as necessary .
Poor generation generatorCheck and repair .
ECT sensor faultyCheck and replace as necessary .
Radiator cooling fan relay No. 2 and/or No. 3 faultyCheck and replace as necessary .
Radiator fan motor faultyCheck and replace as necessary .
ECM faultyCheck and replace as necessary .
Wiring or grounding faultyRepair as necessary .
Equipped with too much electric load part(s)Dismount .
Engine overheats (Radiator fan does not operate)Fuse blownCheck radiator fan fuse of relay/fuse box and check for short circuit to ground .
Radiator cooling fan relay No. 1 faultyCheck and replace as necessary .
ECT sensor faultyCheck and replace as necessary .
Radiator cooling fan motor faultyCheck and replace as necessary .
Wiring or grounding faultyRepair as necessary .
ECM faultyCheck and replace as necessary .

ENGINE COOLING SYMPTOM DIAGNOSIS REFERENCE

Scheme 2

Scheme 2: COOLING SYSTEM COMPONENTS
Scheme 2: COOLING SYSTEM COMPONENTS

COOLANT LEVEL CHECK

WARNINGTo 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 radiator cap is taken off too soon.

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 (1).

A normal coolant level should be between "FULL" mark (2) and "LOW" mark (3) on reservoir (1).

If coolant level is below "LOW" mark (3), remove reservoir cap (4) and add proper coolant to reservoir to bring coolant level up to "FULL" mark (2).

Note. If proper 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, and are unnecessary expense.

Scheme 3

Scheme 3
Scheme 3
WARNINGTo 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.

Scheme 4

Scheme 4
Scheme 4
  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 (1), check system and radiator cap (2) for proper pressure holding capacity. If replacement of cap is required, use a proper cap for this vehicle. NOTE: After installing radiator cap to water outlet cap, make sure that the ear of cap lines is parallel to radiator. Cooling system and radiator cap holding pressure (for inspection) 110 kPa (1.1 kg/cm 2 , 15.6 psi)
  5. Tighten hose clamps and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise deteriorated.
  6. Clean frontal area of radiator core.

Scheme 5

Scheme 5: COOLING SYSTEM DRAINING
Scheme 5: COOLING SYSTEM DRAINING
  1. Remove radiator cap.
  2. Drain coolant from radiator drain plug (1).
  3. After draining coolant, be sure to tighten drain plug (1) securely.

COOLING SYSTEM FLUSH AND REFILL

WARNINGTo 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.

Note. For detail of coolant specification, refer to COOLANT DESCRIPTION .

Scheme 6

Scheme 6
Scheme 6
  1. Remove radiator cap as follows when engine is cool. Turn cap counterclockwise slowly 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 counterclockwise.
  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 drain coolant from radiator drain plug (1).
  4. Close radiator 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. Close radiator drain plug (1) tightly.
  7. Remove reservoir (1) and remove cap (2) from reservoir (1).
  8. Pour out any fluid, scrub and clean inside of reservoir with soap and water. Flush it well with clean water and drain, Reinstall reservoir.
  9. Fill reservoir with coolant up to "FULL" level mark (3).
  10. Install reservoir cap (2) on reservoir.
  11. Fill radiator with coolant up to bottom of water outlet cap filler neck and install radiator cap, making sure that the ear of cap lines is parallel to radiator.
  12. Run engine at idle speed.
  13. Run engine until radiator fan motor is operated.
  14. Stop engine and wait until engine comes cooled down to help avoid danger of being burned.
  15. Add coolant to radiator up to bottom of water outlet cap filler neck, and install radiator cap, making sure that the ear of cap lines is parallel to radiator.
  16. Repeat Step 12 through 15 .
  17. Confirm that reservoir coolant level is "FULL" level mark (3). If coolant is insufficient, repeat Step 9 and 10 .

Scheme 7

Scheme 7
Scheme 7

COOLING WATER PIPES OR HOSES REMOVAL AND INSTALLATION

Removal

  1. Drain coolant referring to «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. To remove these pipes or hoses, loosen clamp on each hose and pull hose end off.

Installation

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

  1. Tighten each clamp securely.
  2. Refill cooling system referring to Step 7 to 17 of «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-flush-and-refill) .

Scheme 8

Scheme 8: Removal
Scheme 8: Removal
  1. Drain coolant referring to «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. Disconnect radiator outlet hose (3) from water inlet pipe (1).
  3. Remove thermostat cap (2) with water inlet pipe.
  4. Remove thermostat from thermostat case.

Reverse removal procedure for installation noting the following points.

Scheme 9

Scheme 9: Installation
Scheme 9: Installation
  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. Use new O-ring when installing.
  3. Refill cooling system referring to Step 7 to 17 of «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-flush-and-refill) .
  4. Verify that there is no coolant leakage at each connection.

THERMOSTAT INSPECTION

Scheme 10

Scheme 10: THERMOSTAT INSPECTION
Scheme 10: THERMOSTAT INSPECTION

Scheme 11

Scheme 11
Scheme 11
  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 (2) is free from foreign matters which would prevent valve from seating tight.
  3. Check thermostat O-ring (3) 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. Temperature at which valve begins to open 80 - 84 °C (176 - 183 °F) Temperature at which valve become fully open 95 - 97 °C (203 °F) Valve lift More than 8 mm at 95 °C (203 °F) 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 12

Scheme 12: RADIATOR COOLING FAN MOTOR ON-VEHICLE INSPECTION
Scheme 12: RADIATOR COOLING FAN MOTOR ON-VEHICLE INSPECTION

Scheme 13

Scheme 13
Scheme 13
  1. Check main and/or sub fan operation of radiator cooling fan as follows. Connect battery to main fan motor coupler (coupler color: black) or sub fan motor coupler (coupler color: gray) as shown in figure. Check that radiator cooling fan rotates smoothly. If any abnormality is found, replace fan motor. Reference: Fan motor specified current at 12 V Main fan operation: 10.9 - 14.4 A Sub fan operation: 10.3 - 13.3 A

Scheme 14

Scheme 14: RADIATOR COOLING FAN RELAY INSPECTION
Scheme 14: RADIATOR COOLING FAN RELAY INSPECTION
  1. Disconnect negative (-) cable at battery.
  2. Remove radiator cooling fan relay No. 1 (1), No. 3 (2) and/or No. 2 (3) from relay box.
  3. Check radiator cooling fan relay No. 1 (1) and No. 3 (2) as follows. Check that there is no continuity between terminals "C" and "D". If there is continuity, replace relay. Connect battery positive (+) terminal to terminal "B" of relay. Connect battery negative (-) terminal to terminal "A" of relay. Check continuity between terminals "C" and "D". If there is no continuity, replace relay.
  4. Check radiator cooling fan relay No. 2 (3) as follows. Check that there is no continuity between terminals "G" or "H" and "F". If there is continuity, replace relay. Check continuity between terminals "I" and "H". If there is no continuity, replace relay. Connect battery positive (+) terminal to terminal "F" of relay. Connect battery negative (-) terminal to terminal "E" of relay. Check continuity between terminals "G" and "H". If there is no continuity, replace relay.

RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION

Scheme 15

Scheme 15: Removal
Scheme 15: Removal

Scheme 16

Scheme 16
Scheme 16
  1. Disconnect negative (-) cable at battery.
  2. Disconnect connectors (1) of cooling fan motors.
  3. With hose connected, detach P/S fluid reservoir with reservoir bracket.
  4. Remove air cleaner case and air cleaner suction pipe (2).
  5. Remove reservoir (1) from radiator.
  6. Remove cooling fan assembly.

Reverse removal procedure for installation noting the following.

  1. Refill cooling system referring to Step 7 to 17 of «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-flush-and-refill) .
  2. After installation, verify there is no coolant leakage at each connection.

Inspection

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

Cleaning

Clean frontal area of radiator cores.

Scheme 17

Scheme 17: Cleaning
Scheme 17: Cleaning

RADIATOR REMOVAL AND INSTALLATION

  1. Disconnect negative (-) cable at battery.
  2. For A/T, drain A/T fluid referring to «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2005-2008/remont/automatic-trans/#automatic-transmission) .
  3. Drain coolant.
  4. Remove cooling fan assembly referring to «RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system__radiator-cooling-fan-assembly-removal-and) .
  5. For A/T, remove A/T fluid cooler inlet and outlet hoses.
  6. Remove radiator outlet hose from radiator.
  7. Remove condenser bolts from condenser brackets.
  8. Remove radiator from vehicle.

Reverse removal procedures, noting the following.

  1. Refill cooling system referring to Step 7 to 17 of «COOLING SYSTEM FLUSH AND REFILL»(/suzuki/grand-vitara/ii-2005-2008/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-flush-and-refill) .
  2. After installation, verify there is no coolant leakage each connection.
  3. Refill A/T fluid referring to «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2005-2008/remont/automatic-trans/#automatic-transmission) .

Scheme 18

Scheme 18: Removal
Scheme 18: Removal
  1. Remove engine assembly from vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/mechanical/#engine-mechanical) .
  2. Remove timing chain cover referring to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/mechanical/#engine-mechanical__timing-chain-cover-removal-and-installation) .
  3. Remove water pump assembly (1) from cylinder block.

Scheme 19

Scheme 19: Installation
Scheme 19: Installation
  1. Install new O-rings (3) to water pump (1).
  2. Install water pump to cylinder block. Tighten water pump bolts to specified torque. Tightening torque Water pump bolt a: 25 N.m (2.5 kg-m, 18.0 lb-ft)
  3. Install timing chain cover referring to «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/mechanical/#engine-mechanical__timing-chain-cover-removal-and-installation) .
  4. Install engine assembly to vehicle referring to «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/mechanical/#engine-mechanical) .

WATER PUMP INSPECTION

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

Rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it.

Scheme 20

Scheme 20
Scheme 20

TIGHTENING TORQUE SPECIFICATIONS

Fastening partTightening torque
N.mKgf-mLb-ft
Water pump bolt252.518.0

TIGHTENING TORQUE SPECIFICATIONS

Note. The specified tightening torque is also found in COOLING SYSTEM COMPONENTS .