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Engine Cooling System (j24b) Suzuki Grand Vitara II рестайлинг

Cooling System (mechanical) 32 illustrations ~2599 words

Cooling System Description

WARNINGBe sure to check coolant level only on coolant reservoir (a translucent container) and add coolant only into the reservoir when replenishment is needed. Never remove radiator cap to check coolant level or add coolant, as doing so is very dangerous for the following reasons: Coolant in cooling system may be extremely high in temperature, even exceeding the boiling point as it is under pressure. If radiator cap is removed in this condition, high-temperature and high-pressure coolant will instantaneously boil up and gush out; you could then be seriously scalded by hot coolant and steam. Furthermore, as coolant contains flammable anti-freeze material, coolant splashing over engine and fenders can start fire. Be sure to check that engine coolant is cold before removing any part of cooling system. Be sure to disconnect negative (-) cable from battery before removing any part of cooling system.

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

Coolant Description

The coolant recovery system is a standard system, which allows part of coolant to flow from the radiator into the coolant reservoir when it is expanded by heat. When the cooling system cools down, the coolant in the coolant reservoir 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 a temperature as low as -36 °C (-33 °F).

  1. Freeze protection down to -36 °C (-33 °F) is also important to ensure protection against corrosion and loss of coolant from boiling. This level of protection should be maintained 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 temperatures lower than -36 °C (-33 °F).

Note. Ethanol 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 demineralized water or distilled water.

Antifreeze concentration table

M/T modelA/T model
Freeze protection temperature°C3636
°F3333
Concentration%5050
QuantityLtr.3.653.60
US pt.7.717.61
Imp pt.6.426.34

ANTIFREEZE CONCENTRATION REFERENCE CHART

Coolant capacity

M/T

  1. Engine, radiator and heater: 6.6 liters (13.95/11.61 US/Imp pt.)
  2. Reservoir: 0.7 liters (1.48/1.23 US/Imp pt.)
  3. Total: 7.3 liters (15.43/12.85 US/Imp pt.)

A/T

  1. Engine, radiator and heater: 6.5 liters (13.74/11.44 US/Imp pt.)
  2. Reservoir: 0.7 liters (1.48/1.23 US/Imp pt.)
  3. Total: 7.2 liters (15.22/12.67 US/Imp pt.)

Cooling Fan Description

Radiator cooling fan motors are controlled by ECM on the following conditions.

Note. Radiator cooling fan motors operate only while engine is running.

Cooling fan operation modeOFFLowMidHigh
Main fan motorOFFLow speedHigh speedHigh speed
Sub fan motorOFFLow speedOFFHigh speed

COOLING FAN DESCRIPTION

A/C switch: OFF

Note. The following table indicates cooling fan operation while engine is running at 1,250 RPM. It depends on engine revolution to determine temperature for changing proper fan motor speed.

Scheme 1

Scheme 1: A/C switch: OFF
Scheme 1: A/C switch: OFF

A/C switch: ON

Note. It depends on engine revolution to determine temperature for changing proper fan motor speed.

Low speed

Cooling fan operates at low speed when A/C refrigerant pressure is more than specified value 0.34 MPa (3.5 kgf/cm 2 , 49.3 psi).

Middle speed

Cooling fan operates at middle speed for a given time (0.3 sec.) when fan speed changes high from low.

High speed

Cooling fan speed changes at high speed from low when A/C refrigerant pressure is more than specified value 1.6 MPa (16.3 kgf/cm 2 , 232 psi).

Fail-safe

Cooling fan operates high speed on condition that malfunction is detected in ECT sensor.

Scheme 2

Scheme 2: Coolant Circulation
Scheme 2: Coolant Circulation

Engine Cooling System Symptom Diagnosis

ConditionPossible CauseAction
Engine overheats (Radiator fan operates)Loose or broken accessory driveCheck accessory drive belt , see ACCESSORY DRIVE BELT INSPECTION .
Not enough coolantCheck coolant level and add as necessary , see COOLANT LEVEL CHECK .
Faulty thermostatCheck thermostat , see THERMOSTAT INSPECTION .
Faulty water pumpCheck water pump , see WATER PUMP INSPECTION .
Dirty or bent radiator finsClean or remedy , see RADIATOR ON-VEHICLE INSPECTION AND CLEANING .
Coolant leakage on cooling systemCheck cooling system for leakage , see ENGINE COOLING SYSTEM INSPECTION .
Clogged radiatorReplace radiator , see RADIATOR REMOVAL AND INSTALLATION .
Faulty radiator capCheck radiator cap , see ENGINE COOLING SYSTEM INSPECTION .
Dragging brakesCheck brake , see BRAKES SYMPTOM DIAGNOSIS .
Slipping clutchCheck clutch , see CLUTCH (HYDRAULIC TYPE) SYMPTOM DIAGNOSIS .
Poor charged batteryCheck battery , see BATTERY INSPECTION .
Poor electricity generated by generatorCheck generator , see GENERATOR TEST .
ECT sensor faultyCheck ECT sensor , see ECT (ENGINE COOLANT TEMPERATURE) SENSOR INSPECTION .
Radiator cooling fan motor faultyCheck radiator cooling fan motor , see RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION .
ECM faultyCheck ECM and its circuit , see ECM (ENGINE CONTROL MODULE) REMOVAL AND INSTALLATION .
Wiring or grounding faultyRepair wiring .
Equipped with too many additional electrical part(s)Dismount them .
Engine overheats (Radiator fan does not operate)Fuse blownCheck fuse .
Radiator cooling fan relay faultyCheck radiator cooling fan relay , see RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION .
ECT sensor faultyCheck ECT sensor , see ECT (ENGINE COOLANT TEMPERATURE) SENSOR INSPECTION .
Radiator cooling fan motor faultyCheck radiator cooling fan motor , see RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION .
Wiring or grounding faultyRepair as necessary .
ECM faultyCheck ECM and its circuit , see INSPECTION OF ECM AND ITS CIRCUITS .

POSSIBLE CAUSE

Scheme 3

Scheme 3: Wiring Diagram
Scheme 3: Wiring Diagram

Troubleshooting

WARNINGKeep hands, tools, and clothing away from radiator cooling fan to prevent personal injury. This fan is driven by electric motor that can turn on whether or not the engine is running. The fan motor can start automatically in response to ECT sensor signal if ignition switch is at "ON" position.

Note. For details about engine cooling fan operation, refer to COOLING FAN DESCRIPTION . Before beginning troubleshooting, be sure to read PRECAUTIONS FOR ECM CIRCUIT INSPECTION . When measuring circuit voltage, resistance and/or pulse signal of ECM, connect the special tool between ECM and ECM connectors. See INSPECTION OF ECM AND ITS CIRCUITS .

StepActionYESNO
1DTC Check Turn OFF ignition switch and connect SUZUKI scan tool to data link connector (DLC). Turn ignition switch to ON position and check DTC. Is there DTC(s)?Go to applicable DTC flow and recheck.Go to Step 2.
2Radiator cooling fan low mode control check Check radiator cooling fan control for low mode. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION . Is it in good condition?Go to Step 3.Go to Step 6.
3Radiator cooling fan mid and high mode control check Check radiator cooling fan control for mid and high mode. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION . Is it in good condition?Radiator cooling fan control system is in good condition.Go to Step 4.
4Radiator cooling fan relay No. 2 power supply circuit (switch side) check Turn OFF ignition switch and remove radiator cooling fan relay No. 2 from relay box. Check for proper connection to radiator cooling fan relay No. 2 at each terminal. If OK, measure voltage between radiator cooling fan relay No. 2 power supply circuit (A2) and vehicle body ground. Is it 10 - 14 V?Go to Step 5.Repair or replace radiator cooling fan relay No. 2 power supply circuit (switch side).
5Radiator cooling fan relay No. 3 ground circuit check Turn OFF ignition switch and remove radiator cooling fan relay No. 3 from relay box. Check for proper connection to radiator cooling fan relay No. 3 at each terminal. If OK, measure resistance between radiator cooling fan relay No. 3 ground circuit (C1) and vehicle body ground. Is resistance 3ohms or less?Go to Step 6.Repair or replace radiator cooling fan relay No. 3 ground circuit.
6Radiator cooling fan relay No. 1 power supply circuit (switch side) check Turn OFF ignition switch and remove radiator cooling fan relay No. 1 from relay box. Check for proper connection to radiator cooling fan relay No. 1 at each terminal. If OK, measure voltage between radiator cooling fan relay No. 1 power supply circuit (A1) and vehicle body ground. Is it 10 - 14 V?Go to Step 7.Repair or replace radiator cooling fan relay No. 1 power supply circuit (switch side).
7Radiator cooling fan relay No. 1, No. 2 and No. 3 check Check radiator cooling fan relay No. 1, No. 2 and No. 3. See RADIATOR COOLING FAN RELAY INSPECTION . Is it in good condition?Go to Step 8.Replace faulty radiator cooling fan relay.
8Main fan motor drive circuit check Turin OFF ignition switch and disconnect main fan motor connector. Check for proper connection to main fan motor at each terminal. If OK, check that main fan motor drive circuit (B1) is in the following conditions. Wiring harness resistance of main fan motor drive circuit is less than 3 ohms or less. Insulation resistance between main fan drive circuit and vehicle body ground is infinity. Circuit voltage of main fan motor drive circuit is 0 - 1 V with ignition switch in ON position. Are they in good condition?Go to Step 9.Repair or replace main fan motor drive circuit.
9Radiator cooling fan relay No. 3 power supply circuit (switch side) check Check that radiator cooling fan relay No. 3 power supply circuit (switch side) (A3) is in the following conditions. Wiring harness resistance of radiator cooling fan relay No. 3 power supply circuit (switch side) is 3 ohms or less. Insulation resistance between radiator cooling fan relay No. 3 power supply circuit (switch side) and vehicle body ground is infinity. Circuit voltage of radiator cooling fan relay No. 3 power supply circuit (switch side) is 0 - 1 V with ignition switch in ON position. Is it in good condition?Go to Step 10.Repair or replace radiator cooling fan relay No. 3 power supply circuit (switch side).
10Sub fan motor drive circuit check Turn OFF ignition switch and disconnect sub fan motor connector. Check for proper connection to sub fan motor at each terminal. If OK, check that sub fan motor drive circuit (B2) is in the following conditions. Wiring harness resistance of sub fan motor drive circuit is 3 ohms or less. Insulation resistance between sub fan drive circuit and vehicle body ground is infinity. Circuit voltage of sub fan motor drive circuit is 0 - 1 V with ignition switch in ON position. Is it in good condition?Go to Step 11.Repair or replace sub fan motor drive circuit.
11Sub fan motor ground circuit check Measure resistance between sub fan motor ground circuit (C2) and vehicle body ground. Is resistance 3ohms or less?Go to Step 12.Repair or replace sub fan motor ground circuit.
12Main fan motor and sub fan motor check Check main fan motor and sub fan motor. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION . Is it in good condition?Substitute a known-good ECM and recheck.Replace main fan motor or sub fan motor. See RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION .

TROUBLESHOOTING CHART

Scheme 4

Scheme 4: Cooling System Components
Scheme 4: Cooling System Components

Radiator Cap Removal and Installation

WARNINGTo avoid getting burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can gush out under pressure if radiator cap is taken off too soon.

Removal

  1. Turn radiator cap counterclockwise until it stops. CAUTION: Do not push down radiator cap while turning it.
  2. Remove radiator cap according to the following procedure. Wait until pressure is relieved (hissing sound is gone). Push down radiator cap and continue to turn it counterclockwise. Remove radiator cap.

Scheme 5

Scheme 5: Installation
Scheme 5: Installation
  1. Install radiator cap (1) according to the following procedure. Put radiator cap (1) on water filler. Push down radiator cap and turn it clockwise until it fully stops. CAUTION: Push radiator cap until its gasket (2) contacts water filler port (3).
  2. Check for coolant leaks. See «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Coolant Level Check

WARNINGTo avoid getting burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can gush out under pressure if radiator cap is taken off too soon.

To check level, lift hood and look at translucent reservoir.

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

When engine is cool, check coolant level in reservoir (1).

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 rust inhibitors or other additives that claim to improve system. They may be harmful to proper operation of system, and are unnecessary expense.

Scheme 6

Scheme 6
Scheme 6

Engine Cooling System Inspection

WARNINGTo avoid getting burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can gush out under pressure if cap is taken off too soon.

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Check cooling system for leakage or damage.
  2. Remove radiator cap. See «RADIATOR CAP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cap-removal-and-installation) .
  3. Check coolant for proper level and freeze protection.
  4. Check coolant leaks from cooling system according to the following procedure. Attach pressure tester (1) to water filler, and then apply specified pressure to cooling system. Cooling system holding pressure 110 kPa (1.1 kgf/cm2, 15.9 psi) Check that cooling system holds the pressure. If cooling system does not hold applied pressure, Check cooling system for coolant leaks.
  5. Check radiator cap according to the following procedure. Attach pressure tester (1) to radiator cap (2), and then apply specified pressure. Radiator cap holding pressure 108 kPa (1.1 kgf/cm2, 15.6 psi) Check that radiator cap holds applied pressure. If the pressure at which radiator cap releases air is higher or lower than holding pressure, replace radiator cap.
  6. Detach pressure tester and rinse off spilled coolant.
  7. Install radiator cap on water filler. See «RADIATOR CAP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cap-removal-and-installation) .

Cooling System Draining

WARNINGTo avoid getting 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 9

Scheme 9
Scheme 9
  1. Remove radiator cap. See «RADIATOR CAP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cap-removal-and-installation) .
  2. Drain coolant from radiator drain plug (1).
  3. After draining coolant, be sure to tighten drain plug (1) securely.

Cooling System Flushing

WARNINGTo avoid getting burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can gush out under pressure if cap is taken off too soon.

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

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Remove radiator cap. See «RADIATOR CAP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cap-removal-and-installation) .
  2. With radiator cap removed, run engine until upper radiator hose is hot. NOTE: Determine that thermostat is open and coolant is circulating in the cooling system.
  3. Stop engine and drain coolant from radiator drain plug (1).
  4. Tighten radiator drain plug. Fill system with water and run engine until upper radiator hose becomes hot again.
  5. Repeat Steps 3) and 4) several times until drained liquid is nearly colorless.
  6. Tighten radiator drain plug (1) tightly.
  7. Remove reservoir cap (2) and reservoir (1).
  8. Empty reservoir of fluid and scrub its inside using soap and water. Flush it well with clean water and drain, Reinstall reservoir.

Cooling System Refilling

WARNINGTo avoid getting burned, do not remove radiator cap while engine and radiator are still hot. Scalding fluid and steam can gush out under pressure if cap is taken off too soon.

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13
  1. Fill reservoir (1) with coolant up to "FULL" level mark (3).
  2. Install reservoir cap (2) on reservoir (1).
  3. Fill radiator with coolant up to bottom of radiator filler neck (1) and install radiator cap. See «RADIATOR CAP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cap-removal-and-installation) . Coolant specification Freezing temperature: -36 °C (-33 °F) Antifreeze/anti-corrosion coolant concentration: 50% Coolant capacity Engine, radiator and heater (5 M/T model): 6.6 liters (13.95/11.61 US/Imp pt.) Engine, radiator and heater (4 A/T model): 6.5 liters (13.74/11.44 US/Imp pt.) Reservoir: 0.7 liters (1.48/1.23 US/Imp pt.) Total (5 M/T model): 7.3 liters (15.43/12.85 US/Imp pt.) Total (4 A/T model): 7.2 liters (15.22/12.67 US/Imp pt.)
  4. Run engine at idle speed.
  5. Run engine until radiator fan motor is operated.
  6. Stop engine and wait until engine comes cooled down to avoid getting burned.
  7. Add coolant to radiator up to bottom of radiator filler neck, and install radiator cap. See «RADIATOR CAP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cap-removal-and-installation) .
  8. Repeat Step 4) through 7).
  9. Confirm that coolant level in reservoir is at "FULL" level mark. If coolant is insufficient, add coolant.
  10. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Cooling Water Pipes or Hoses Removal and Installation

  1. Drain coolant, see «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
  2. To remove cooling water pipes or hoses, loosen clamp on each hose and pull hose end to disconnect it.

Installation

Reverse removal procedure for installation noting the following.

  1. Tighten each clamp securely with its fastener in proper direction, see «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
  2. Refill cooling system, see «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
  3. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Scheme 14

Scheme 14: Removal
Scheme 14: Removal

Scheme 15

Scheme 15
Scheme 15
  1. Drain coolant, see «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
  2. Disconnect radiator outlet hose (1) from thermostat cap (2).
  3. Remove thermostat cap (2) from water pump (3).
  4. Remove thermostat (1) from water pump (2).

Reverse removal procedure for installation noting the following.

Scheme 16

Scheme 16: Installation
Scheme 16: Installation
  1. When installing thermostat (1) on water pump case, be sure to position it so that air bleed valve (2) is aligned with match mark (3).
  2. Use new gasket when installing thermostat.
  3. Refill cooling system, see «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
  4. Verify that there is no coolant leakage at each connection, see «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Thermostat Inspection

Scheme 17

Scheme 17: Thermostat Inspection
Scheme 17: Thermostat Inspection

Scheme 18

Scheme 18
Scheme 18
  1. Check that air bleed valve (1) of thermostat is clean.
  2. Check that valve seat (2) is free from foreign matters which would prevent valve from seating tight.
  3. Check that wax pellet moves as follows: Immerse thermostat (1) in water, and heat water gradually. Check that valve starts opening at specific temperature. Temperature at which valve begins to open 80 - 84 °C (176 - 183 °F) Temperature at which valve become fully open 95 °C (203 °F) Thermostat valve lift More than 8 mm (0.3 in) at 95 °C (203 °F) If thermostat does not open as specified above, or sticks in any position, replace it. Such a unit, if reused, will bring about overcooling or overheating tendency.

Scheme 19

Scheme 19: Radiator Cooling Fan Operation
Scheme 19: Radiator Cooling Fan Operation
  1. Connect scan tool to DLC (1) with ignition switch OFF. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT)
  2. Turn ignition switch to ON position and clear DTC, see «DTC CLEARANCE»(/suzuki/grand-vitara/ii-2008-2012/remont/anti-locktraction-control/#antilock-brake-system-abs__dtc-clearance) .
  3. Select the "Radiator Fan" function in "Active Test".
  4. Check radiator cooling fan operation at low mid and high modes. If any abnormality is found, check cooling fan control system referring to «RADIATOR COOLING FAN CONTROL SYSTEM CHECK»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) . Radiator cooling fan operation RADIATOR COOLING FAN OPERATION REFERENCE Main fan motor Sub fan motor OFF OFF OFF Low mode Low speed Low speed Mid mode High speed OFF High mode High speed High speed

Scheme 20

Scheme 20: Radiator Cooling Fan Motor
Scheme 20: Radiator Cooling Fan Motor
  1. Disconnect main fan motor connector (connector color: black) (1) and sub fan motor connector (connector color: gray) (2).
  2. Connect fan motor connector and battery as shown in figure.
  3. Check that radiator cooling fan motors rotate smoothly and properly. If any abnormality is found, replace corresponding radiator cooling fan motor

Scheme 21

Scheme 21: Radiator Cooling Fan Relay Inspection
Scheme 21: Radiator Cooling Fan Relay Inspection
  1. Disconnect negative (-) cable from battery.
  2. Remove radiator cooling fan relays No. 1 (1), No. 2 (2) and No. 3 (3) from relay box.
  3. Check each of radiator cooling fan relays No. 1 and No. 2 (2) as follows. Check that there is no continuity between relay terminals "C" and "D". If there is continuity, replace relay. Connect battery positive (+) terminal to relay terminal "B". Connect battery negative (-) terminal to relay terminal "A". Check continuity between terminals "C" and "D". If there is no continuity, replace relay.
  4. Check radiator cooling fan relay No. 3 as follows. Check that there is no continuity between terminals "C" and "D". If there is continuity, replace relay. Check continuity between terminals "C" and "E". If there is no continuity, replace relay. Connect battery positive (+) terminal to relay terminal "B". Connect battery negative (-) terminal to terminal "A" of relay. Check continuity between terminals "C" and "D". If there is no continuity, replace relay.

Scheme 22

Scheme 22
Scheme 22

Radiator Cooling Fan Assembly Removal and Installation

Scheme 23

Scheme 23: Removal
Scheme 23: Removal

Scheme 24

Scheme 24
Scheme 24
  1. Disconnect negative (-) cable from battery.
  2. Disconnect main fan motor connector (connector color: black) (1) and sub fan motor connector (connector color: gray) (2).
  3. Remove air cleaner assembly and air cleaner outlet hose. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
  4. Detach P/S fluid reservoir (1) with reservoir bracket and hose connected. NOTE: No need to drain P/S fluid.
  5. Disconnect ground terminal (2).
  6. Remove reservoir (3) from radiator.
  7. Remove cooling fan assembly.

Reverse removal procedure for installation noting the following.

  1. Refill cooling system. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
  2. After installation, verify there is no coolant leakage at each connection, see «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Radiator Cooling Fan Disassembly and Reassembly

Scheme 25

Scheme 25: Disassembly
Scheme 25: Disassembly
  1. Remove fan (1) from cooling fan motor (2).
  2. Remove fan motor (2) from cooling fan shroud (3).

Reassembly

Reverse disassembly procedure for reassembly noting the following.

Scheme 26

Scheme 26: Reassembly
Scheme 26: Reassembly
  1. Tighten fan nuts and radiator cooling fan motor bolts to specified torque. Tightening torque Fan nut (a): 6 N.m (0.61 kg-m, 4.5 lbf-ft) Radiator cooling fan motor bolt (b): 4 N.m (0.41 kg-m, 3.0 lbf-ft)

Inspection

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

Cleaning

Clean front area of radiator cores.

Scheme 27

Scheme 27: Cleaning
Scheme 27: Cleaning

Radiator Removal and Installation

Scheme 28

Scheme 28: Removal
Scheme 28: Removal
  1. Disconnect negative (-) cable from battery.
  2. For 4 A/T model, drain A/T fluid, see «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
  3. Drain coolant, see «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
  4. Remove cooling fan assembly. " «RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__radiator-cooling-fan-assembly-removal-and) "
  5. For 4 A/T model, remove A/T fluid cooler hoses.
  6. Remove radiator inlet hose and outlet hose from radiator.
  7. Remove front grill, see «FRONT BUMPER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exterior-body-panels/#body-structure) .
  8. Remove condenser upper brackets (1) and lower brackets (2) from radiator.
  9. Remove radiator from vehicle.

Reverse removal procedures for installation noting the following.

  1. Refill cooling system referring to «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
  2. After installation, verify that there is no coolant leakage at each connection.
  3. Refill A/T fluid (A/T model), see «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .

Scheme 29

Scheme 29: Removal
Scheme 29: Removal
  1. Disconnect negative (-) cable from battery.
  2. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
  3. Remove accessory drive belt, see «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
  4. Remove exhaust manifold cover, see «EXHAUST SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-system-components) .
  5. Disconnect radiator outlet hose from water pump.
  6. Remove water inlet pipe (2) from water pump (1).
  7. Remove water pump (1) from cylinder block.

Reverse removal procedure for installation noting the following.

Scheme 30

Scheme 30: Installation
Scheme 30: Installation
  1. Use new gasket and O-ring.
  2. Tighten water pump bolts to specified torque. Tightening torque Water pump bolt (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
  3. Refill cooling system. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
  4. Check for coolant leaks, see «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Water Pump Inspection

CAUTIONDo not disassemble water pump. If pump has any part requiring repair, replace pump as assembly.

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

Scheme 31

Scheme 31
Scheme 31

Tightening Torque Specifications

Fastening partTightening torque
N.mKgf-mLbf-ft
Fan nut60.614.5
Radiator cooling fan motor bolt40.413.0
Water pump bolt252.518.5

TIGHTENING TORQUE SPECIFICATIONS

Note. The specified tightening torque is described in the following. COOLING SYSTEM COMPONENTS

Reference

For the tightening torque of fastener not specified in this section, refer to FASTENER INFORMATION .

Special Tool

SPECIAL TOOL SPECIFICATION SUZUKI scan tool (SUZUKI-SDT) - This kit includes following items. SUZUKI-SDT DLC3 cable USB cable AC/DC power supply Voltage meter probe Storage case

Scheme 32

Scheme 32: Special Tool
Scheme 32: Special Tool

See also:
• ACCESSORY DRIVE BELT INSPECTION
• BRAKES SYMPTOM DIAGNOSIS
• CLUTCH (HYDRAULIC TYPE) SYMPTOM DIAGNOSIS
• BATTERY INSPECTION
• GENERATOR TEST
• ECT (ENGINE COOLANT TEMPERATURE) SENSOR INSPECTION
• ECM (ENGINE CONTROL MODULE) REMOVAL AND INSTALLATION
• INSPECTION OF ECM AND ITS CIRCUITS
• DTC CLEARANCE
• AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION
• A/T FLUID CHANGE
• FRONT BUMPER COMPONENTS
• EXHAUST SYSTEM COMPONENTS
• FASTENER INFORMATION
• COOLANT LEVEL CHECK
• THERMOSTAT INSPECTION
• WATER PUMP INSPECTION
• RADIATOR ON-VEHICLE INSPECTION AND CLEANING
• ENGINE COOLING SYSTEM INSPECTION
• RADIATOR REMOVAL AND INSTALLATION
• COOLING FAN DESCRIPTION
• RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION
• RADIATOR CAP REMOVAL AND INSTALLATION
• COOLING SYSTEM DRAINING
• COOLING SYSTEM REFILLING
• COOLANT DESCRIPTION
• COOLING SYSTEM FLUSHING

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