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Engine Cooling System (n32a) Suzuki Grand Vitara II рестайлинг

Cooling System (mechanical) 32 illustrations ~2378 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 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 consists of the radiator, coolant reservoir, water pump, cooling fan and thermostat. The radiator is of tube-and-fin type.

Coolant Description

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. Ethylene glycol base antifreeze must be used when replenishing the system because of loss of coolant or providing added protection against freezing at temperature lower than -36 °C (-33 °F).
CAUTIONEthanol 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.

Anti freeze concentration table

Freeze protection temperature°C36
°F33
Concentration%50
QuantityLtr.8.7
US pt.18.39
Imp pt.15.31

ANTI FREEZE CONCENTRATION REFERENCE CHART

Coolant capacity

Engine, radiator and heater: 8.7 liters (18.39/15.31 US/Imp pt.)

Reservoir: 0.8 liters (1.69/1.41 us/Imp pt.)

Total: 9.5 liters (20.08/16.72 US/Imp pt.)

Scheme 33

Scheme 33: Coolant Circulation
Scheme 33: Coolant Circulation

Engine Cooling Symptom Diagnosis

ConditionPossible CauseAction
Engine overheats (Radiator fan operates)Loose or broken accessory drive beltAdjust or replace accessory drive belt. See ACCESSORY DRIVE BELT TENSION INSPECTION .
Not enough coolantCheck coolant level and add as necessary. See COOLANT LEVEL CHECK .
Faulty thermostatReplace thermostat assembly. See THERMOSTAT ASSEMBLY INSPECTION .
Faulty water pumpReplace water pump. See WATER PUMP INSPECTION .
Dirty or bent radiator finsClean or repair. RADIATOR ON-VEHICLE INSPECTION AND CLEANING .
Coolant leakage on cooling systemRepair cooling system. See ENGINE COOLING SYSTEM INSPECTION AND CLEANING .
Clogged radiatorCheck and replace radiator as necessary. See RADIATOR REMOVAL AND INSTALLATION .
Faulty radiator capCheck radiator cap. See ENGINE COOLING SYSTEM INSPECTION AND CLEANING .
Dragging brakesAdjust brake. See BRAKES SYMPTOM DIAGNOSIS .
Poorly charged batteryCheck and replace battery as necessary. See BATTERY INSPECTION .
Poor electricity generation by generatorCheck and repair generator as necessary. See GENERATOR SYMPTOM DIAGNOSIS .
ECT sensor faultyCheck and replace ECT sensor as necessary. See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION .
Radiator cooling fan motor faultyCheck and replace radiator cooling fan motor as necessary. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION .
ECM faultyCheck and replace ECM as necessary. See INSPECTION OF ECM AND ITS CIRCUITS .
Wiring or grounding faultyRepair as necessary .
Too much additional electrical equipmentDismount necessary pieces of equipment .
Engine overheats (Radiator fan does not operate)Fuse blownCheck and replace fuse .
Radiator cooling fan relay faultyCheck and replace radiator cooling fan relay as necessary. See RADIATOR COOLING FAN RELAY INSPECTION .
ECT sensor faultyCheck and replace ECT sensor as necessary. See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION .
Radiator cooling fan motor faultyCheck and replace radiator cooling fan motor as necessary. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION .
Wiring or grounding faultyRepair as necessary .
ECM faultyCheck and replace ECM as necessary. See INSPECTION OF ECM AND ITS CIRCUITS .

POSSIBLE CAUSE REFERENCE

Scheme 34

Scheme 34: Wiring Diagram
Scheme 34: Wiring Diagram

Troubleshooting

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

Note. Radiator cooling fan low speed control takes place as follows: If engine coolant temperature becomes 102 °C or higher with engine at idle, radiator fan relay No. 1 turns on and then radiator fan motor No. 1 and No. 2 run at low speed. When the coolant temperature becomes 99 °C or lower, both fan motors stop operating. Radiator cooling fan mid and high speed control takes place as follows: If engine coolant temperature becomes 106.5 °C or higher with engine at idle, radiator fan relay No. 3 turns on and then radiator fan motor No. 1 runs at high speed. With delay of 0.3 second after start of radiator fan motor No. 1, radiator fan relay No. 2 turns on and then radiator fan motor No. 2 runs at high speed. When engine coolant temperature drops to 103.5 °C or lower, high speed control is switched to low speed control. Before performed troubleshooting, be sure to read PRECAUTIONS OF ECM CIRCUIT INSPECTION . When measuring circuit voltage, resistance and/or pulse signal at ECM connector, connect special tool between ECM and ECM connectors. See INSPECTION OF ECM AND ITS CIRCUITS .

StepActionYESNO
1DTC check With ignition switch OFF, connect SUZUKI scan tool to DLC. With ignition switch ON, check DTC. Is DTC detected?Go to troubleshooting for applicable DTC and recheck.Go to Step 2.
2Radiator cooling fan low speed control circuit check Check radiator cooling fan when it starts operating at low speed. 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 speed control circuit check Check radiator cooling fan when it starts operating at mid and high speed. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION . Is it in good condition?Radiator cooling fan control circuits are in good condition.Go to Step 4.
4Radiator cooling fan relay No. 2 power supply circuit (contact side) check With ignition switch OFF, disconnect radiator cooling fan relay No. 2 from fuse box. Check radiator cooling fan relay No. 2 for proper terminal connections. If terminal connections are OK, turn ignition switch to ON position. Check that voltage between radiator cooling fan relay No. 2 power supply circuit (contact side) (C1) and vehicle body ground is battery voltage. Is voltage OK?Go to Step 5.Repair or replace defective wire harness.
5Radiator cooling fan relay No. 3 ground circuit check Check radiator cooling fan relay No. 3 for proper terminal connections. If connections are OK, check that wiring harness resistance between radiator cooling fan relay No. 3 ground circuit (B2) and vehicle body ground is less than 3 ohms. Is resistance OK?Go to Step 6.Repair or replace defective wire harness.
6Radiator cooling fan relay No. 1 power supply circuit (contact side) check Disconnect radiator cooling fan relay No. 1 from fuse box. Check radiator cooling fan relay No. 1 for proper terminal connections. If connections are OK, check that voltage between radiator cooling fan relay No. 1 power supply circuit (contact side) (A1) and vehicle body ground is battery voltage. Is voltage OK?Go to Step 7.Repair or replace defective wire harness.
7Radiator cooling fan relay No. 1, No. 2 and No. 3 check With ignition switch OFF, check radiator cooling fan relays No. 1, No. 2 and No. 3. See RADIATOR COOLING FAN RELAY INSPECTION . Are they in good condition?Go to Step 8.Replace radiator cooling fan relays No. 1, No. 2 and No. 3.
8Radiator cooling fan motor No. 1 drive circuit check Disconnect radiator cooling fan motor No. 1 connector. Check radiator cooling fan motor No. 1 for proper terminal connections. If connections are OK, check that radiator cooling fan motor No. 1 drive circuit (A2) is as follows. Wiring harness resistance of radiator cooling fan motor No. 1 drive circuit is less than 3 ohms. Insulation resistance is infinity between radiator cooling fan motor No. 1 drive circuit and vehicle body ground. Circuit voltage of radiator cooling fan motor No. 1 drive circuit is 0 - 1 V with ignition switch turned ON. Is it in good condition?Go to Step 9.Repair or replace defective wire harness.
9Radiator cooling fan relay No. 3 power supply circuit (contact side) check With ignition switch OFF, check that radiator cooling fan relay No. 3 power supply circuit (contact side) (B1) is as follows. Wiring harness resistance of radiator cooling fan relay No. 3 power supply circuit (contact side) is less than 3 ohms. Insulation resistance is infinity between radiator cooling fan relay No. 3 power supply circuit (contact side) and vehicle body ground. Circuit voltage of radiator cooling fan relay No. 3 power supply circuit (contact side) is 0 - 1 V with ignition switch turned ON. Is it in good condition?Go to Step 10.Repair or replace defective wire harness.
10Radiator cooling fan relay No. 2 drive circuit (contact side) check With ignition switch OFF, disconnect radiator cooling fan motor No. 2 connector. Check radiator cooling fan motor No. 2 for proper terminal connections. If connections are OK, check that radiator cooling fan relay No. 2 drive circuit (contact side) (C2) is as follows. Wiring harness resistance of radiator cooling fan relay No. 2 drive circuit (contact side) is less than 3 ohms. Insulation resistance is infinity between radiator cooling fan relay No. 2 drive circuit (contact side) and vehicle body ground. Circuit voltage of radiator cooling fan relay No. 2 drive circuit (contact side) is 0 - 1 V with ignition switch turned ON. Is it in good condition?Go to Step 11.Repair or replace defective wire harness.
11Radiator cooling fan motor No. 2 ground circuit check Check that wiring harness resistance between radiator cooling fan motor No. 2 ground circuit (C3) and vehicle body ground is less than 3 ohms. Is resistance OK?Go to Step 12.Repair or replace defective wire harness.
12Radiator cooling fan motor No. 1 and No. 2 check Check radiator cooling fan motors No. 1 and No. 2. See RADIATOR COOLING FAN ASSEMBLY ON-VEHICLE INSPECTION . Are they in good condition?Substitute a known-good ECM and recheck. See ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION .Replace radiator cooling fan motor No. 1 and/or No. 2. See RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION .

TROUBLESHOOTING CHART

Cooling System Components

Note. For water inlet pipe bolt tightening order, see THERMOSTAT ASSEMBLY REMOVAL AND INSTALLATION .

Scheme 35

Scheme 35: Cooling System Components
Scheme 35: Cooling System Components

Coolant Level Check

WARNINGTo avoid danger of being 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.

Lift hood and check coolant level in 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 cap (4).

If coolant level is below LOW mark (3), 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 36

Scheme 36
Scheme 36

Engine Cooling System Inspection and Cleaning

WARNINGTo avoid danger of being 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 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38
  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. Check cooling system as follows. Install pressure tester (1) to radiator filler neck and apply specified pressure to pressurize cooling system. Cooling system holding pressure 110 kPa (1.1 kgf/cm2, 15.6 psi) Check that cooling system holds applied pressure. If it does not hold the pressure, check that there is no coolant leakage in cooling system.
  5. Check radiator cap as follows. Install pressure tester (1) to radiator cap (2) and apply specified pressure is put on radiator cap. Radiator cap holding pressure 110 kPa (1.1 kgf/cm2, 15.6 psi) In case a pressure higher than specified value is applied to radiator cap, check if pressure is relieved. In case pressure is not relieved even if a pressure larger than specified value is applied to radiator cap, or in case pressure is relieved when a pressure lower than specified value is applied, replace radiator cap.
  6. Remove pressure tester and wipe off adherent coolant of the tester.
  7. Install radiator cap to radiator filler neck of radiator. CAUTION: After installing radiator cap to radiator, make sure that the line formed by lugs of cap is parallel to radiator top.

Cooling System Draining

WARNINGTo avoid danger of being 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 39

Scheme 39
Scheme 39
  1. Remove engine front under cover.
  2. Remove radiator cap.
  3. Drain coolant from radiator drain plug (1).
  4. After draining coolant, be sure to tighten drain plug (1) securely.

Cooling System Flushing

WARNINGTo avoid danger of being 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 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41
  1. Remove radiator cap when engine is cool as follows. Turn cap counterclockwise slowly until it comes to a stop. (Do not press down while turning it.) Wait until pressure is relieved (indicated by 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. 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. Close radiator drain plug (1) tightly.
  7. Remove reservoir cap (2) and reservoir (1).
  8. Empty reservoir of fluid and scrub and clean its inside reservoir with soap and water. Flush it well with clean water and remove water from inside, reinstall reservoir.

Scheme 42

Scheme 42: Cooling System Refilling
Scheme 42: Cooling System Refilling

Scheme 43

Scheme 43
Scheme 43
  1. Fill reservoir cap (2) with coolant up to "FULL" level mark (3).
  2. Install reservoir cap (2) on reservoir (1).
  3. Remove air ventilation plug (1) from water inlet pipe (2).
  4. Pour coolant through radiator filler neck until coolant flow out from air ventilation plug hole.
  5. Install air ventilation plug to water inlet pipe.
  6. Fill radiator with coolant up to bottom of radiator filler neck and install radiator cap.
  7. Run engine at idle speed.
  8. Stop engine when radiator fan motor is operated.
  9. Wait until engine comes cooled down to avoid danger of being burned.
  10. Add coolant to radiator up to bottom of radiator filler neck, and install radiator cap.
  11. Repeat Step 7) through 10).
  12. Confirm that coolant level in reservoir is at "FULL" level mark of reservoir cap. If coolant is insufficient, add coolant.

Cooling Water Pipes or Hoses Removal and Installation

Removal

  1. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-draining) .
  2. To remove a hoses, loosen clamp on it and pull the hose end off 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-n32a__cooling-system-components) .
  2. Refill cooling system referring to «COOLING SYSTEM FLUSHING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-flushing) .

Scheme 44

Scheme 44: Removal
Scheme 44: Removal

Scheme 45

Scheme 45
Scheme 45
  1. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-draining) .
  2. Remove intake upper manifold. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__intake-manifold-removal-and-installation) .
  3. Remove wiring harness (1) of HO2S-1 (bank 1) from water inlet pipe.
  4. Remove water inlet pipe (2).
  5. Remove heater inlet hose (3), heater outlet hose (4), water inlet hose (5) and water outlet hose (6) from thermostat assembly.
  6. Remove thermostat assembly (1) from cylinder block.

Reverse removal procedure for installation noting the following.

  1. Use new gasket when installing thermostat assembly.
  2. Tighten water inlet pipe bolts in numerical order ("1" - "3") as shown figure.
  3. Refill cooling system referring to «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
  4. Verify that there is no coolant leakage at each connection.

Scheme 46

Scheme 46: Thermostat Assembly Inspection
Scheme 46: Thermostat Assembly Inspection

Scheme 47

Scheme 47
Scheme 47
  1. Check to make sure that air bleed valve (1) of thermostat assembly is clean.
  2. Check to make sure that valve seat (2) is free from foreign matters which would prevent valve from seating tight.
  3. Check thermostatic movement pellet as follows. Immerse thermostat assembly (1) in water, and heat water gradually. Check that wax pellet starts opening at specified temperature. Temperature at which valve begins to open (at lift 0.35 mm (0.014 in)): 80 - 84 °C (176.0 - 183.2 °F) Temperature at which valve become fully open: 95 °C (203 °F) Valve lift: More than 8 mm (0.3 in) at 95 °C (203 °F)
  4. If valve starts opening at a temperature substantially below or above specified temperature, replace thermostat assembly. See «THERMOSTAT ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .

Scheme 48

Scheme 48: Radiator Cooling Fan Assembly On-Vehicle Inspection
Scheme 48: Radiator Cooling Fan Assembly On-Vehicle Inspection

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50

Scheme 51

Scheme 51
Scheme 51
  1. Operate radiator cooling fan motor as follows. Connect scan tool to DLC (1) with ignition switch OFF. Turn ignition switch ON, clear DTC and select "RADIATOR FAN" under "ACTIVE TEST" mode on scan tool. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT) Reference: fan motor operation condition High speed operation [A]: Starts at coolant temperature of 106.5 °C (223.7 °F) Mid speed operation [B]: Starts at coolant temperature of 106.5 °C (223.7 °F) Low speed operation [C]: Starts at coolant temperature of 102 °C (215.6 °F) OFF [D]: Stops at coolant temperature of 99 °C (210.2 °F)
  2. Check radiator cooling fan motors No. 1 (1) and No. 2 (2) as follows. Connect battery to each fan motor connector as shown in figure. Check that each radiator cooling fan rotates smoothly. If any abnormality is found, replace fan motors.

Scheme 52

Scheme 52: Radiator Cooling Fan Relay Inspection
Scheme 52: Radiator Cooling Fan Relay Inspection
  1. Disconnect negative (-) cable at battery.
  2. Remove radiator cooling fan relay No. 1 (1), No. 2 (2) and/or No. 3 (3) from relay box.
  3. Check radiator cooling fan relay No. 1 and No. 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. 3 as follows. Check that there is no continuity between terminals "C" and "E". If there is continuity, replace relay. Check that there is continuity between terminals "C" and "D". If there is no 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 "E". If there is no continuity, replace relay.

Radiator Cooling Fan Assembly Removal and Installation

Scheme 53

Scheme 53: Removal
Scheme 53: Removal

Scheme 54

Scheme 54
Scheme 54
  1. Disconnect negative cable from battery.
  2. Disconnect radiator cooling fan motor connectors (1).
  3. With hose connected, detach P/S reservoir tank (1) from its bracket.
  4. Disconnect ground cable (2).
  5. Remove reservoir tank (3) from radiator.
  6. Remove air cleaner suction pipe. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
  7. Remove radiator cooling fan assembly from radiator.

Reverse removal procedure for installation.

Radiator Cooling Fan Disassembly and Reassembly

Scheme 55

Scheme 55: Disassembly
Scheme 55: Disassembly
  1. Remove fans (1) from radiator cooling fan motors No. 1 and No. 2 (2).
  2. Remove radiator cooling fan motors No. 1 and No. 2 from cooling fan shroud (3).

Reassembly

Reverse disassembly procedures for reassembly.

Inspection

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

Cleaning

Clean front area of radiator cores.

Scheme 56

Scheme 56: Cleaning
Scheme 56: Cleaning

Radiator Removal and Installation

  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-n32a__cooling-system-draining) .
  3. Drain A/T fluid (5 A/T model). See «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
  4. Remove radiator inlet hose and outlet hose from radiator. See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-components) .
  5. Remove oil hoses No. 3 and No. 4 from radiator (5 A/T model). See «OIL COOLER HOSE AND PIPE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
  6. Remove radiator cooling fan assembly. See «RADIATOR COOLING FAN ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__radiator-cooling-fan-assembly-removal-and) .
  7. Remove front bumper. See «FRONT BUMPER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exterior-body-panels/#body-structure) .
  8. Remove condenser bracket bolt from condenser.
  9. Remove radiator bracket. See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-components) .
  10. 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-n32a) .
  2. After installation, check each connection for coolant leakage each connection.
  3. Refill A/T with A/T fluid (5 A/T model). See «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .

Scheme 57

Scheme 57: Removal
Scheme 57: Removal

Scheme 58

Scheme 58
Scheme 58

Scheme 59

Scheme 59
Scheme 59
  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-n32a__cooling-system-draining) .
  3. Remove reservoir (1).
  4. Remove accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
  5. Remove water pump pulley (1). Special Tool (A): Water pump pulley holding tool (EN-46104)
  6. Remove water pump assembly (1) and gasket (2) from cylinder block.

Scheme 60

Scheme 60: Installation
Scheme 60: Installation

Scheme 61

Scheme 61
Scheme 61
  1. Clean mating surfaces of water pump assembly and timing chain cover.
  2. Install new gasket (2) to timing chain cover.
  3. Install water pump assembly (1) to timing chain cover and tighten bolts to specified torque. Tightening torque Water pump bolt (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft)
  4. Install water pump pulley (1) and tighten bolts to specified torque. Special Tool (A): Water pump pulley holding tool (EN-46104) Tightening torque Water pump pulley bolt (a): 12 N.m (1.2 kg-m, 9.0 lbf-ft)
  5. Install accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
  6. Install reservoir (1).
  7. Refill cooling system referring to «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
  8. Connect negative cable to battery.
  9. Check each part for leakage.

Water Pump Inspection

CAUTIONDo not disassemble water pump. If pump has any part requiring repair, replace pump 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 62

Scheme 62
Scheme 62

Tightening Torque Specifications

Fastening partTightening torque
N.mKgf-mLbf-ft
Water pump bolt101.07.5
Water pump pulley bolt121.29.0

TIGHTENING TORQUE SPECIFICATIONS

Reference

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

Special Tool

SPECIAL TOOL REFERENCE 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 Water pump pulley holding tool - EN-46104: This tool is not applied with SUZUKI part number

Scheme 63

Scheme 63: Special Tool
Scheme 63: Special Tool

Scheme 64

Scheme 64
Scheme 64

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