Engine Cooling System: Other Suzuki Vitara I

Cooling System Check

Cooling system should be serviced as follows.

Scheme 26

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

Checking Coolant Level

1. To check level, lift hood and look at "see-through" coolant reservoir.
2. It is not necessary to remove radiator cap to check coolant level.
3. When engine is cool, check coolant level in reservoir.
4. A normal coolant level should be between "FULL" and "LOW" marks on reservoir.
5. If coolant level is below "LOW" mark, remove reservoir cap and add proper coolant to reservoir to bring coolant level up to "FULL" mark.
6. 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.

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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 30

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. See «COOLANT DESCRIPTION»(ref-179488-S16566227272005070800000) and «COOLING SYSTEM FLUSH & REFILL»(ref-179488-S04241370222005070800000) .

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1. Drain coolant and tighten drain plug.
2. Remove thermostat cap (1).
3. Remove thermostat.

Scheme 32

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 water pump.
3. Fill cooling system. See «COOLANT DESCRIPTION»(ref-179488-S16566227272005070800000) and «COOLING SYSTEM FLUSH & REFILL»(ref-179488-S04241370222005070800000) .
4. Connect negative cable at battery.
5. After installation, check each part for leakage.

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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. See «THERMOSTAT DESCRIPTION»(ref-179488-S11982926802005070800000) . 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.

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1. Disconnect negative cable at battery.
2. Drain coolant.
3. Remove radiator outlet hose from thermostat cap (2).
4. Remove heater outlet pipe bolt (1).
5. Remove generator belt by loosening tensioner pulley. See «GENERATOR BELT»(ref-163058-S19376368422004061700000) .
6. Remove water pump assembly (1) by removing its 4 bolts (2). NOTE: Do not lose dowel pin when removing water pump assembly (1).

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1. Install new O-ring (1) to water pump (2). NOTE: Do not forget to install dowel pins on water pump side before mounting water pump to engine block.
2. Install water pump (1) by using new bolts (2) to cylinder block and tighten to specified torque. NOTE: Use NEW bolts (total of 4) to install water pump to engine block. Failure to do so may result water leakage. Tightening torque, Water pump bolt (a): 27 N.m (2.7 kg-m, 19.5 lb-ft)
3. Install heater outlet pipe bolt (1).
4. Install generator belt. See «GENERATOR BELT»(ref-163058-S19376368422004061700000) .
5. Install radiator outlet hose to thermostat cap (2).
6. Refill cooling system with proper coolant. See «COOLANT DESCRIPTION»(ref-179488-S16566227272005070800000) and «COOLING SYSTEM FLUSH & REFILL»(ref-179488-S04241370222005070800000) .
7. Connect negative cable at battery.

Cleaning

Clean frontal area of radiator cores.

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