Suzuki Grand Vitara JB416 / JB420. Service manual — part 122

1F-4 Engine Cooling System:

Repair Instructions

Cooling System Components

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Engine Cooling System: 1F-5

[B]

8

(a)

21

25

24

15

7

11

6

16

5

33

3

16

14

31

34

29

30

29

32

32

1

4

36

35

37

38

26

2

39

22

23

10

10

9

9

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[A]: M16 engine model

14. Thermostat

29. To cylinder head

[B]: J20 engine model

15. Thermostat cap

30. To water pump

1. Radiator

16. Radiator inlet No.2 hose

31. To heater core

2. Reservoir

17. Water filler neck

32. To throttle body

3. Radiator cap

18. Water inlet hose

33. Water bypass No.2 hose

4. Drain plug

19. Radiator outlet pipe

34. Water bypass No.1 hose

5. Radiator outlet hose

20. Heater outlet No.2 hose

35. Main fan motor

6. Radiator inlet No.1 hose

21. Heater pipe

36. Sub fan motor

7. Water outlet cap

22. Reservoir hose

37. Sub fan

8. ECT sensor

23. Water filler neck bracket

38. Main fan

9. Gasket

24. Heater inlet hose

39. Reservoir cap

10. O-ring

25. Heater outlet No.1 hose

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

11. Water outlet pipe

26. Fan shroud

: Do not reuse.

12. Thermostat case water outlet pipe

27. To water filler neck

13. Thermostat case

28. To timing chain cover

1F-6 Engine Cooling System:

Coolant Level Check

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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 radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between “FULL” mark
(2) and “LOW” mark (3) on reservoir (1).
If coolant level is below “LOW” mark (3), remove
reservoir cap (4) and 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 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

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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.

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 (1), check system and

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

NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kg/cm

2

, 15.6 psi)

5) Tighten hose clamps and inspect all hoses. Replace

hoses whenever cracked, swollen or otherwise
deteriorated.

6) Clean frontal area of radiator core.

4

1

4

1

2

3

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Engine Cooling System: 1F-7

Cooling System Draining

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

(1) securely.

Cooling System Flush and Refill

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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.

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

1) Remove radiator cap as follows when engine is cool.

a) Turn cap counterclockwise slowly until it reaches

a “stop” (Do not press down while turning it).

b) Wait until pressure is relieved (indicated by a

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. 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) Close radiator drain plug (1) tightly.

7) Remove reservoir (1) and remove cap (2) from

reservoir (1).

8) Pour out any fluid, scrub and clean inside of

reservoir with soap and water.
Flush it well with clean water and drain, Reinstall
reservoir.

9) Fill reservoir with coolant up to “FULL” level mark (3).

10) Install reservoir cap (2) on reservoir.

11) Fill radiator with coolant up to bottom of radiator filler

neck and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.

12) Run engine at idle speed.
13) Run engine until radiator fan motor is operated.
14) Stop engine and wait until engine comes cooled

down to help avoid danger of being burned.

15) Add coolant to radiator up to bottom of radiator filler

neck, and install radiator cap, making sure that the
ear of cap lines is parallel to radiator.

16) Repeat Step 12) through 15).
17) Confirm that reservoir coolant level is “FULL” level

mark (3). If coolant is insufficient, repeat Step 9) and
10).

1

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1

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2

1

2

1

3

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