1987 SUZUKI GRAND VITARA radiator cap

6-4. IMPORTANT STEPS FOR
REINSTALLATION
Water Pump
1) Install new pump gasket to cylinder block.
2) Install water pump to cylinder block.
Tightening torque
for bolts & nuts
lo- 13 N-m
1 .O - 1.3 kg-m
7.5 - 9.0 lb-ft
After installing water pump, install rubber seal
between water pump and oil pump, and another
between water pump and cylinder head.
Fig, 6-201. Rubber seal
3) Install belt tensioner plate, tensioner,
tensioner spring, timing belt and timing belt
outside cover.
NOTE:
l Special care must be used when installing belt
tensioner and timing belt. Be sure to refer to
p. 3-48 of this manual.
l Torque each bolt and nut to specification.
4) Install crankshaft pulley, water pump
pulley, pump drive belt, cooling fan &
clutch and radiator shroud.
5) Adjust intake and exhaust valve lashes.
(For adjustment and related data, refer to
p. 3-53 of this manual).
6) Adjust water pump belt tension.
(Refer to P. 6-10).
7) Connect negative cable at battery.
8) Fill the cooling system.
Thermostat
1) When positioning the thermostat on the
intake manifold, be sure to bring its air brea-
ther valve (iJ to front side of the engine.
Fig. 6-21
2) Install new gasket and
intake manifold.
3) Fill the cooling system.
thermostat cap to
Cooling Fan, Fan clutch and Water Pump Belt
Once cooling fan, fan clutch or water pump belt
has been removed, make sure to tighten bolts
and nuts securely in reinstallation and adjust
pump belt tension to specification. (For specifi-
ed tension, refer to p. 6-10.)
6-9

Coolant
The coolant recovery system is standard. The
coolant in the radiator expands with heat, and
the overflow is collected in the reservoir tank.
When the system cools down, the coolant is
drawn back into the radiator.
The cooling system has been filled at the factory
with a quality coolant that is either 50/50
mixture of water and GOLDEN CRUISER
1200 or 30/70 mixture of water and GOLDEN
CRUISER 1200.
The 50/50 mixture coolant solution provides
freezing protection to -36°C (-33”F), the
30/70 mixture coolant solution provides freezing.
protection to -16°C (3” F).
GOLDEN CRUISER 1200 - “Anti-freeze and
Summer Coolant” - its effects
1) Its freezing temperature is much lower and
depends on the concentration of GOLDEN
CRUISER 1200. It is an anti-freeze coolant.
2) It does not corrode the metal surfaces of the
cooling circuit.It is an anti-corrosion
coolant.
3) It does not develop foam or bubbles. It is a
foam-inhibited coolant.
When changing the engine coolant, use mixture
of 50% water and 50% GOLDEN CRUISER
1200 for the market where ambient tempera-
ture falls lower than -16°C (3°F) in winter and
mixture of 70% water and 30% GOLDEN
CRUISER 1200 for the market where am-
bient temperature doesn’t fall lower than -16°C
(3” F).
ANTI-FREEZE PROPORTIONING CHART
Freezing
Temperature
GOLDEN
CRUISERConcentration
OC-16-36
OF3-33
%3050
Ratio of corn-Itr.1.4413.362.4012.40
pound tous pt.3.04l7.10 5.0715.07cooling waterImp. pt.2.5315.914.221422
Reservoir tank0.6 liters
(1.3/1.1 US/Imp pt.)I
Total4.8 liters
(10.1/8.4 US/Imp pt.)
NOTE:
l Alcohol or methanol base coolants or plain
water alone should not be used in cooling
system at any time, as damage to cooling
system could occur.
l Even in a market where no freezing tempe-
rature is anticipated, mixture of 70% water
and 30% GOLDEN CRUISER 1200
should be used for the purpose of corrosion
protection and lubrication.
Coolant Level
,To check level, lift hood and look at “see
through” water reservoir tank.
It is not necessary to remove radiator cap to
check coolant level.
WARNING:
To help avoid danger of being burned:
l do not remove reservoir tank cap while
coolant is “boiling”, and
l do not remove radiator cap while engine
and radiator are still hot
Scalding fluid and steam can be blown out
under pressure if either cap is taken off too
soon.
When engine is cool, check coolant level in reser-
voir tank. A normal coolant level should be
between “FULL” and “LOW’ marks on reser-
voir tank.
If coolant level is below “LOW” mark, remove
reservoir tank cap and add proper coolant to
tank to bring coolant level up to “FULL” mark.
Then, reinstall cap aligning the arrow marks on
the tank and cap.
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 unneces-
sary expense.
6-11

Fig. 6-25
1. Reservoir tank
2. Arrow mark
Cooling System Service
Cooling system should be serviced as follows.
1) Check cooling system for leaks 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, check system and
radiator cap for proper pressure holding
capacity 0.9 kg/cm2 (12.8 psi, 90 kPa). If
replacement of cap is required, use proper
cap specified for this vehicle.
5)Tighten hose clamps and inspect all hoses.
Replace hoses whenever cracked, swollen or
otherwise deteriorated.
6) Clean frontal area of radiator core.
NOTE:
After installing radiator cap 0 to radiator, make
sure that its ear @ is aligned with reservoir
tank hose @I as shown in Figure. If not, turn
cap more to align its ear with hose.
Fig. 6-26 Installation of radiator cap
Cooling System, Flush and Refill
1) Remove radiator cap when engine is cool:
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.d
I2) With radiator cap removed, run engine unti. .upper radiator hose is hot (this shows that
thermostat is open and coolant is flowing
through system).
3) Stop engine and open radiator drain plug @
to drain coolant.
Fig. 6-27 Radiator drain plug
6-12

4) Close 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) Drain system and then close radiator drain
plug tightly.
7) Disconnect hose from water reservoir tank.
Remove tank and pour out any fluid. Scrub
and clean inside of tank with soap and water.
Flush it well with clean water and drain.
Reinstall tank and hose.
8)Add proper mixture coolant (refer to page
6-11 of GOLDEN CRUISER 1200 and _,
water to radiator and tank.
Fill radiator to the base of radiator filler
neck and reservoir tank to “FULL” level
mark. Reinstall reservoir tank cap, aligning
the arrow marks on the tank and cap.
9) Run engine, with rediator cap removed, until
radiator upper hose is hot.
10) With engine idling, add coolant to radiator
until level reaches the bottom of filler neck.
Install radiator cap, making sure that the ear
of cap lines up with reservoir tank hose.
Cooling Fan Clutch
Inspect fluid coupling for oil leakage.
If necessary, replace fan clutch assembly. Do not
disassemble clutch assembly.
Fig. 6-28
6-13

7-4. REMOVAL AND INSTALLATION
Removal
[Heater and blower motor]
1. Disconnect battery negative cable.
2. Drain cooling system.
WARNING:
To help avoid the danger of being burned, do
not remove the drain plug and the radiator
cap while the engine and radiator are still hot.
Scalding fluid and steam can be blown out
under pressure if the plug and cap are taken
off too soon.
Fig 7-51. Drain plug2. Radiator
3. Disconnect heater inlet and outlet hoses
from heater unit pipes.
4. Remove instrument panel ass’y with speedo-
meter ass’y as follows.
1) Take off horn pad and remove steering
wheel using special tool @.
2) If equipped with radio and cigarette lighter,
disconnect radio and cigarette lighter lead
wires, and pull out radio case with radio
and cigarette lighter after loosening case
stay screw, and remove radio case bracket.
3) Pull out ashtray and loosen ashtray plate
screws.
4) Disconnect front food opening cable from
lock ass’y.
5) Loosen panel box stay screw and hood
opening cable lock nut on back side of
panel box cover.
6) Disconnect lead wires to control lever at
the coupler and heater control cables.
7) Pull out lever knobs and plate, and loosen
lever case screws.
8) Remove defroster and side ventilator hoses.
9) Disconnect lead wires to speedometer and
switches installed instrument panel at the
couplers.
10) Disconnect speedometer cable from speedo-
meter.
11) Release wire harness clamps installed to
instrument panel.
12) Loosen screws securing instrument panel.
13) Remove instrument panel.
NOTE:
l Before removing, recheck to ascertain all
hoses, wire harness, cables and screws are
disconnected from instrument paneL
l When removing heater lever case which is
fitted in steering column holder, be very
careful not to damage it
5. Remove steering column holder after loosen-
ing front door open stopper screws.
Fig. 7-7Fig. 7-6@ Special tool (Steering wheel
remover 09944-360 10)
7-5

3) Make sure to assemble stator terminal
insulator properly.
10-2. BATTERY
1. Stator terminal insulator
Fig. lo-20
4) Alternator V belt tension.
1. Crankshaft pulley
2. Water pump pulley
3. Alternator pulley
A :Belt deflection
Fig. 1021
Drive belt deflection
(Under 10 kg thumb
pressure)
6-9mm
(0.24 - 0.35 in)
NOTE:
Clamp brake pipe with pipe clamp on radiator
under cover after installing radiator under cover.
GENERAL DESCRIPTION
The battery has three major functions in the
electrical system. First, it is a source of electrical
energy for cranking the engine. Second it acts as
a voltage stabilizer for the electrical system. And
third, it can, for a limited time, provide energy
when the electrical load exceeds the output of
the generator.
Each new car shipped from the factory is
fitted with following battery.
IModel55BzR=l(NXIOO-S6 6))
1 Rated capacityt 137 kC (38 Ah)/5HR j
This battery is completely sealed, except for six
small vent holes in the top. These vent holes
allows the small amount of gas produced in the
battery to escape. This sealed battery has a
built-in temperature compensated indicator in
the top of the battery.
Fig. lo-22
CARE OF THE BATTERY
[Electrolyte freezing]
The freezing point of electrolyte depends on its
specific gravity. Since freezing may ruin a
battery, it should be protected against freezing
by keeping it in a fully charged condition.
10-10