Suzuki Grand Vitara JB419. Service manual — part 60

Engine Cooling System: 1F-8

Radiator Cooling Fan Motor On-Vehicle
Inspection

S5JB0B1606009

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

cooling fans 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: 10.9 – 14.4 A
Sub fan operation: 10.9 – 14.4 A

Radiator Cooling Fan Relay Inspection

S5JB0B1606010

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

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

there is 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 continuity, replace relay.

1. Main fan motor

3. Battery

2. Sub fan motor

4. Fan motor coupler

I5JB0A161012-02

I5JB0A161011-01

[A]: For radiator cooling fan relay No.1 and No.3
[B]: For radiator cooling fan relay No.2

1

2

3

“D”

“B”

“A”

“C”

“A”

“B”

“D”

“C”

“H”

“F”

“E”

“G”

“I”

“F”

“E”

“H”

“I”

“G”

[A]

[B]

I5JB0B160007-01

1F-9 Engine Cooling System:

Radiator Cooling Fan Assembly Removal and
Installation

S5JB0B1606011

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 degassing tank (1) from radiator.

6) Remove cooling fan assembly.

CAUTION

!

Be sure not to damage condenser inlet pipe.

Installation
Reverse removal procedure for installation noting the
following.
• Refill cooling system referring to “Cooling System

Refilling”.

• After installation, verify there is no coolant leakage at

each connection.

Radiator On-Vehicle Inspection and Cleaning

S5JB0B1606012

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

Cleaning
Clean frontal area of radiator cores.

Radiator Removal and Installation

S5JB0B1606013

Removal

1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining”.
3) Remove cooling fan assembly referring to “Radiator

Cooling Fan Assembly Removal and Installation”.

4) Remove radiator inlet and outlet hose from radiator.
5) Remove radiator from vehicle.

Installation
Reverse removal procedures, noting the following.
• Refill cooling system referring to “Cooling System

Refilling”.

• After installation, verify there is no coolant leakage

each connection.

Water Pump Removal and Installation

S5JB0B1606020

Removal

1) Drain coolant referring to “Cooling System Draining”.
2) Remove timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation in Section 1D”.

3) Remove water pump assembly (1).

1

I5JB0B160010-01

1

2

I5JB0B160012-01

I2RH01160014-01

I5JB0B160008-01

Engine Cooling System: 1F-10

Installation

1) Remove oil and dust from sealing surface of cylinder

block and water pump.

2) Apply sealant to three bolts (1).

“A”: Thread lock cement (Loctite
FRENETANCH

®)

3) Install water pump assembly (2) with new gasket.

Tightening torque
Water pump assembly bolt (a): 10 N·m (1.0 kgf-
m, 7.5 lb-ft)

4) Install timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation in Section 1D”.

5) Refill coolant referring to “Cooling System Refilling”.

Water Pump Inspection

S5JB0B1606017

CAUTION

!

Do not disassemble water pump.
If any repair is required on pump, replace it
as assembly.

Rotate water pump by hand to check for smooth
operation. If pump does not rotate smoothly or makes
abnormal noise, replace it.

Specifications

Tightening Torque Specifications

S5JB0B1607001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0B1608001

I5JB0B160009-01

I5JB0B160011-01

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Thermostat bolt

8

0.8

6.0

)

Water pump assembly bolt

10

1.0

7.5

)

Material

SUZUKI recommended product or Specification

Note

Thread lock cement

Loctite FRENETANCH

®

—

)

1G-1 Fuel System:

Engine

Fuel System

Precautions

Precautions on Fuel System Service

S5JB0B1700001

WARNING

!

• Before attempting service of any type on fuel system, the following should be always observed in

order to reduce the risk of fire and personal injury.
– Disconnect negative (–) cable at battery.
– Do not smoke, and place no smoking signs near work area.
– Be sure to have CO

2

fire extinguisher handy.

– Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot

heater).

– Wear safety glasses.
– To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then

reinstall it.

– As fuel feed line is still under high fuel pressure even after engine was stopped, loosening or

disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened
or disconnected. Before loosening or disconnecting fuel high presser line, make sure to relieve
fuel pressure referring to “Fuel Pressure Relief Procedure”.

– A small amount of fuel may be released after the fuel line is disconnected. In order to reduce the

chance of personal injury, cover the fitting to be disconnected with a lint-free cloth. Be sure to put
that cloth in an approved container when disconnection is completed.

– When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified

torque.

– The system can inject the diesel fuel into the engine at a pressure up to 160,000 kPa (1,600 kg/

cm

2

, 22,760 psi). Before carrying out any work, check that the injector rail is not under pressure

and that the fuel temperature is not too high.

– Do not place your hand near to a leak on the high pressure fuel circuit.
– Do not run engine with disconnecting fuel pipe and/or removing fuel system components.
– Do not expose removed fuel system parts to dust. Keep always clean.
– When servicing the fuel tank, it should be treated with respect, with no contact with sharp edges

or hot surfaces. In addition, the fuel tank should not be dropped since fuel tank, fuel pump and
other components can be damaged by the impact. If dropped, all components should be replaced
because there is a risk of damage.

– Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each

hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, mark sure that it has no twist or kink.

• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and
cause serious injuries or death and damage.