Content .. 57 58 59 60 ..

Suzuki Grand Vitara JB419. Manual - part 59

Engine Cooling System: 1F-4

Repair Instructions

Cooling System Components

S5JB0B1606001

I5JB0B160013-01

1. Radiator

13. Radiator inlet hose No.2

25. Turbocharger inlet hose

2. Degassing tank cap

14. Radiator outlet hose No.1

26. Heater outlet hose No.1

3. Degassing tank

15. Radiator outlet pipe No.1

27. Heater outlet hose No.2

4. Thermostat assembly

: Do not disassemble.

16. Radiator outlet hose No.2

28. Heater inlet hose

5. ECT sensor

17. Radiator outlet pipe No.2

29. Thermostat outlet hose and pipe

6. Additional heater

18. Heat exchanger inlet hose

30. Ventilation hose (radiator to degassing tank)

7. Turbocharger electric water pump

19. Heat exchanger outlet hose

31. Ventilation hose (radiator inlet pipe to degassing tank)

8. Fan shroud guide

20. Additional heater inlet hose No.1

32. 3-way joint

9. Drain plug

21. Additional heater inlet hose No.2

33. Radiator cooling fan

10. Air ventilation plug

22. Additional heater outlet hose

34. Radiator cooling fan motor

11. Radiator inlet hose No.1

23. Turbocharger electric water pump inlet hose

12. Radiator inlet pipe

24. Turbocharger electric water pump outlet hose

1F-5 Engine Cooling System:

Coolant Level Check

S5JB0B1606002

WARNING

To help avoid danger of being burned, do not
remove degassing tank cap while engine and
radiator are still hot. Scalding fluid and steam
can be blown out under pressure if
degassing tank cap is taken off too soon.

To check level, lift hood and look at “see-through”
degassing tank.
It is not necessary to remove degassing tank cap to
check coolant level.
When engine is cool, check coolant level in degassing
tank (1).
A normal coolant level should be between “MAXI” mark
(2) and “MINI” mark (3) on degassing tank (1).
If coolant level is below “MINI” mark (3), remove
degassing tank cap (4) and add proper coolant to
degassing tank to bring coolant level up to “MAXI” mark
(2).

NOTE
If proper 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, and
are unnecessary expense.

Engine Cooling System Inspection and
Cleaning

S5JB0B1606003

WARNING

To help avoid danger of being burned, do not
remove degassing tank 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.

1) Check cooling system for leakage or damage.
2) Wash degassing tank cap and filler neck with clean

water by removing degassing tank cap when engine
is cold.

3) Check coolant for proper level and freeze protection.

4) Using a pressure tester (1), check system and

degassing tank cap (2) for proper pressure holding
capacity.
If replacement of cap is required, use a proper cap
for this vehicle.

Cooling system and degassing tank cap holding
pressure (for inspection)
Approx. 140 kPa (1.4 kg/cm

, 19.9 psi)

5) Tighten hose clamps and inspect all hoses. Replace

hoses whenever cracked, swollen or otherwise
deteriorated.

6) Clean frontal area of radiator core.

Cooling System Draining

S5JB0B1606004

WARNING

To help avoid danger of being burned, do not
remove degassing tank 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.

1) Remove degassing tank cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug

(1) securely.

I5JB0B160002-01

I5JB0B160003-02

I5JB0A161006-01

Engine Cooling System: 1F-6

Cooling System Refilling

S5JB0B1606005

WARNING

To help avoid danger of being burned, do not
remove degassing tank 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.

NOTE
For detail of coolant specification, refer to
“Coolant Description”.

1) Close radiator drain plug.
2) Remove air ventilation plug (2) from thermostat

assembly (3).

3) Fill degassing tank with coolant until coolant flow out

from air ventilation plug, and then tighten air
ventilation plug.

4) Fill degassing tank with coolant up to “MAXI” level

mark (4).

5) Install degassing tank cap (1).
6) Run engine as follows in order to bleed air remained

in engine and radiator.
a) Run engine at 1500 r/min until upper radiator

hose is hot.

b) Race engine at 3500 r/min 4 times.
c) Run engine at 2000 r/min for 20 minutes.
d) Race engine at 3500 r/min 4 times.

NOTE
If coolant level comes lower than “MINI” level
mark (5) during this step, perform the
following procedures.
1. Stop engine and wait until engine is

cooled.

2. Fill degassing tank with coolant up to

“MAXI” level mark.

3. Repeat Step 6) again.

7) Stop engine and wait until engine is cooled.
8) Fill degassing tank with coolant up to “MAXI” level

mark.

Cooling System Flushing

S5JB0B1606018

WARNING

To help avoid danger of being burned, do not
remove degassing tank 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.

1) Drain coolant referring to “Cooling System Draining”.
2) Close radiator drain plug.
3) Remove air ventilation plug (2) from thermostat

assembly (3).

4) Fill degassing tank with water until water flow out

from air ventilation plug, and then tighten air
ventilation plug.

5) Fill degassing tank with coolant up to “MAXI” level

mark (4).

I5JB0B160004-02

1F-7 Engine Cooling System:

6) Install degassing tank cap (1).

7) Run engine until upper radiator hose is hot.
8) Stop engine.
9) Wait until engine is cooled, and drain water from

cooling system.

10) Repeat Step 2) to 9) several times until drained liquid

is nearly colorless.

11) Fill cooling system with coolant referring to “Cooling

System Refilling”.

Cooling Water Pipe or Hose Removal and
Installation

S5JB0B1606006

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 referring to “Cooling

System Components”.

• Refill cooling system referring to “Cooling System

Refilling”.

Thermostat Assembly Removal and Installation

S5JB0B1606019

CAUTION

Never disassemble thermostat assembly.
Disassembly will spoil its original function. If
faulty condition is found, replace it with new
one.

Removal

1) Remove engine assembly referring to “Engine

Assembly Removal and Installation in Section 1D”.

2) Disconnect water hoses (1) from thermostat

assembly (3).