Suzuki Grand Vitara JB627. Service manual — part 103

1F-6 Engine Cooling System:

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 water outlet

cap 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 water outlet

cap 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).

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Engine Cooling System: 1F-7

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

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Removal

1) Drain coolant referring to “Cooling System Draining”.
2) Disconnect radiator outlet hose (3) from water inlet

pipe (1).

3) Remove thermostat cap (2) with water inlet pipe.
4) Remove thermostat from thermostat case.

Installation
Reverse removal procedure for installation noting the
following points.
• 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.

• 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 O-ring (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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4. Bypass valve

2. Thermometer

3. Heater

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1F-8 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: 10.9 – 14.4 A
Sub fan operation: 10.3 – 13.3 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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“D”

“B”

“A”

“C”

“A”

“B”

“D”

“C”

“H”

“F”

“E”

“G”

“I”

“F”

“E”

“H”

“I”

“G”

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Engine Cooling System: 1F-9

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.

Radiator Removal and Installation

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Removal

1) Disconnect negative (–) cable at battery.
2) For A/T, drain A/T fluid referring to “A/T Fluid Change

in Section 5A”.

3) Drain coolant.
4) Remove cooling fan assembly referring to “Radiator

Cooling Fan Assembly Removal and Installation”.

5) For A/T, remove A/T fluid cooler inlet and outlet

hoses.

6) Remove radiator outlet hose from radiator.
7) Remove condenser bolts from condenser brackets.
8) Remove radiator from vehicle.

Installation
Reverse removal procedures, 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

each connection.

• Refill A/T fluid referring to “A/T Fluid Change in

Section 5A”.

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