Suzuki Grand Vitara JB416 / JB420. Manual - part 123

1F-8 Engine Cooling System: 

Cooling Water Pipes or Hoses Removal and 
Installation

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Removal

1) Drain coolant referring to “Cooling System Draining”.
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.
• Tighten each clamp securely.
• Refill cooling system referring to Step 7) to 17) of 

“Cooling System Flush and Refill”.

Thermostat Removal and Installation (For M16 
Engine Model)

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Removal

1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold 

Removal and Installation: For M16A Engine with 
VVT in Section 1D”.

3) Disconnect water inlet hose (1) and heater outlet 

No.2 hose (2) from each pipe.

4) Remove thermostat case (3) with thermostat cap (4).
5) Remove thermostat cap (4) from thermostat case 

(3).

6) Remove thermostat from thermostat case (3).

Installation
Reverse removal procedure for installation noting the 
following points.
• When positioning thermostat (1) on thermostat case 

(2), by aligning air bleed valve (3) of thermostat with 
mark (4) of thermostat case.

• Use new O-rings when installing.
• Refill cooling system referring to Step 7) to 17) of 

“Cooling System Flush and Refill”.

• Verify that there is no coolant leakage at each 

connection.

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Engine Cooling System:  1F-9

Thermostat Removal and Installation (For J20 
Engine Model)

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Removal

1) Drain coolant referring to “Cooling System Draining”.
2) Disconnect radiator outlet hose from thermostat cap 

(1).

3) Remove thermostat cap (1) from water pump (2).
4) Remove thermostat from water pump (2).

Installation
Reverse removal procedure for installation noting the 
following points.
• When positioning thermostat (1) on water pump case, 

be sure to position it so that air bleed valve (2) comes 
at match mark (3) and into the recession of water 
pump case.

• Use new O-ring when installing.
• Refill cooling system referring to Step 7) to 17) of 

“Cooling System Flush and Refill”.

• Verify that there is no coolant leakage at each 

connection.

Thermostat Inspection

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• Make sure that air bleed valve (1) of thermostat is 

clean.
Should this valve be clogged, engine would tend to 
overheat.

• Check to make sure that valve seat (2) is free from 

foreign matters which would prevent valve from 
seating tight.

• Check thermostat seal (3) for breakage, deterioration 

or any other damage.

• Check thermostatic movement of wax pellet as 

follows:
a. Immerse thermostat (1) in water, and heat water 

gradually.

b. 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 overcooling or overheating 
tendency.

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2. Thermometer

3. Heater

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1F-10 Engine Cooling System: 

Radiator Cooling Fan Motor On-Vehicle 
Inspection

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1) Check main and/or sub fan operation of radiator 

cooling fan as follows.
a) Connect battery to main fan motor coupler 

(coupler color: black) or sub fan motor coupler 
(coupler color: gray) as shown in figure.

b) 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: 7.4 – 10.9 A
Sub fan operation: 6.7 – 9.7 A

Radiator Cooling Fan Relay Inspection

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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.
a) Check that there is no continuity between 

terminals “C” and “D”. If there is continuity, 
replace relay.

b) Connect battery positive (+) terminal to terminal 

“B” of relay.

c) Connect battery negative (–) terminal to terminal 

“A” of relay.

d) 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.

a) Check that there is no continuity between 

terminals “G” or “H” and “F”. If there is continuity, 
replace relay.

b) Check continuity between terminals “I” and “H”. If 

there is no continuity, replace relay.

c) Connect battery positive (+) terminal to terminal 

“F” of relay.

d) Connect battery negative (–) terminal to terminal 

“E” of relay.

e) Check continuity between terminals “G” and “H”. 

If there is no continuity, replace relay.

1. Main fan motor
2. Sub fan motor

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Engine Cooling System:  1F-11

Radiator Cooling Fan Assembly Removal and 
Installation

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Removal

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.

Installation
Reverse removal procedure for installation noting the 
following.
• Refill cooling system referring to Step 7) to 17) of 

“Cooling System Flush and Refill”.

• After installation, verify there is no coolant leakage at 

each connection.

Radiator On-Vehicle Inspection and Cleaning

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

Cleaning
Clean frontal area of radiator cores.

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“D”

“B”

“A”

“C”

“A”

“B”

“D”

“C”

“H”

“F”

“E”

“G”

“I”

“F”

“E”

“H”

“I”

“G”

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