Engine Cooling System: Removal & Installation Suzuki Verona I

Thermostat Removal

Scheme 3

Scheme 4

1. Drain the coolant. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .
2. Loosen the hose clamp on the coolant hose at the thermostat housing.
3. Disconnect the coolant hose from the thermostat housing.
4. Remove the mounting bolts that hold the thermostat housing to the cylinder head.
5. Remove the thermostat housing from the head.
6. Remove the O-ring seal from the head.
7. Check the valve seat for foreign matter that could prevent the valve from seating properly.
8. Check the thermostat for proper operation. Refer to «Thermostat Test»(ref-257290-S18933427862007070900000) .
9. Clean the thermostat housing and the cylinder head mating surfaces.

Scheme 5

1. Coat the sealing surface of a new O-ring seal with Lubriplater®.
2. Install a new O-ring seal into the recess in the cylinder head.
3. Secure the thermostat housing to the cylinder head with the mounting bolts. Tighten: Tighten the thermostat housing mounting bolts to 10 N.m (89 lb-in.).
4. Connect the coolant hose to the thermostat housing.
5. Secure the coolant hose to the thermostat housing with a hose clamp.
6. Refill the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .

Scheme 6

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Scheme 8

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Scheme 10

1. Drain the engine cooling system to a level below the thermostat housing. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .
2. Remove the accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT REMOVAL»(ref-257310-S08211357142007070900000) .
3. Loosen the hose clamp on the coolant hose at the thermostat housing and the water pump.
4. Disconnect the coolant hose from the thermostat housing and the water pump.
5. Remove the power steering pump mounting bolts.
6. Remove the generator. Refer to «GENERATOR REMOVAL»(ref-257294-S05060234262007070900000) .
7. Remove the compressor. Refer to «COMPRESSOR REMOVAL»(ref-257313-S25609243372007070900000) .
8. Remove the bracket bolts.
9. Remove the auto tensioner mounting bolt.
10. Remove the auto tensioner.
11. Remove the water pump mounting bolts.
12. Remove the water pump.
13. Remove the water pump gasket.
14. Inspect the water pump body for cracks and leaks.
15. Clean the mating surfaces of the water pump and the engine block.

Scheme 11

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Scheme 13

1. Install a new gasket to the water pump.
2. Secure the water pump to the engine block with the mounting bolts. Tighten: Tighten the water pump mounting bolts to 23 N.m (17 lb-ft).
3. Install a auto tensioner with the mounting bolt. Tighten: Tighten the auto tensioner bolt to 45 N.m (33 lb-ft).
4. Install the bracket.
5. Install the bracket bolts. Tighten: Tighten the bracket retaining bolts to 45 N.m (33 lb-ft).
6. Install the power steering pump.
7. Install the power steering pump retaining bolts. Tighten: Tighten the power steering pump retaining bolts to 25 N.m (18 lb-ft).
8. Install the generator. Refer to «GENERATOR REMOVAL»(ref-257294-S05060234262007070900000) .
9. Install the compressor. Refer to «COMPRESSOR INSTALLATION»(ref-257313-S14739247242007070900000) .
10. Install the serpentine accessory drive belt. Refer to «SERPENTINE ACCESSORY DRIVE BELT INSTALLATION»(ref-257310-S33453024392007070900000) .
11. Refill the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .

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Scheme 17

1. Disconnect the negative battery cable.
2. Remove the air cleaner inlet hose bolts.
3. Remove the air cleaner inlet hose.
4. Drain the coolant. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .
5. Disconnect the upper radiator hose.
6. Disconnect the cooling fan electrical connector.
7. Remove the fan shroud assembly upward and remove the fan shroud assembly from the vehicle.

Electric Cooling Fan Installation

1. Install the fan shroud assembly to the radiator.
2. Secure the shroud to the top of the radiator with the mounting bolts. Tighten: Tighten the fan assembly mounting bolts to 4 N.m (35 lb-in.).
3. Connect the cooling fan electrical connector.
4. Connect the upper radiator hose.
5. Install the air cleaner inlet hose.
6. Install the air cleaner inlet hose bolts. Tighten: Tighten the air cleaner inlet hose bolts to 6 N.m (53 lb-in.).
7. Connect the negative battery cable.

Surge Tank Removal

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Scheme 19

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

Surge Tank Installation

1. Install the surge tank to the support mount.
2. Secure the surge tank with the attaching bolt. Tighten: Tighten the surge tank attaching bolt to 8 N.m (71 lb-in.).
3. Connect the return hose and the throttle body hose to the top of the surge tank.
4. Connect the feed hose to the bottom of the surge tank.
5. Secure the return hose, the throttle body hose, and the feed hose to the surge tank with the hose clamps.
6. Fill the surge tank with the coolant to the center ridge, or to the MAX mark.

Scheme 20

Scheme 21

1. Disconnect the negative battery cable.
2. Drain the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .
3. Remove the main and the auxiliary cooling fans. Refer to «Electric Cooling Fan Removal»(ref-257290-S28050833512007070900000) .
4. Remove the upper radiator retaining bolt.
5. Remove the upper radiator retaining bracket.
6. Remove the upper radiator hose clamp.
7. Disconnect the upper radiator hose from the radiator.
8. Remove the hose clamp from the surge tank hose at the radiator.
9. Disconnect the surge tank hose from the radiator.
10. Remove the lower radiator hose clamp.
11. Disconnect the lower radiator hose from the radiator.
12. Disconnect the transaxle cooler pipes from the lower radiator tank, if equipped.
13. Remove the bolt and the transaxle pipe support clamp from the radiator.
14. Remove the radiator from the vehicle. NOTE: The radiator still contains a substantial amount of coolant. Drain the remainder of the coolant from the radiator into a drain pan.

Radiator Installation

1. Set the radiator into place in the vehicle with the radiator bottom posts in the rubber shock bumpers.
2. Connect the transaxle cooler pipes to the lower radiator tank, if equipped.
3. Install the transaxle pipe and support clamp to the radiator with a bolt.
4. Connect the surge tank hose to the radiator.
5. Secure the surge tank hose with a hose clamp.
6. Connect the upper radiator hose and the lower radiator hose to the radiator.
7. Secure each hose with a hose clamp.
8. Position the radiator retainers in place.
9. Install the upper radiator retainer bracket.
10. Install the upper radiator retaining bolt.
11. Install the main and the auxiliary cooling fans. Refer to «Electric Cooling Fan Installation»(ref-257290-S01841638972007070900000) .
12. Refill the engine cooling system. Refer to «Draining and Refilling the Cooling System»(ref-257290-S30388178292007070900000) .
13. Connect the negative battery cable. Tighten: Tighten the radiator retaining bolt to 14 N.m (10 lb-ft).