1987 SUZUKI GRAND VITARA Service Repair Manual

Radiator Cap
A pressure-vent cap is used on the radiator. The
cap contains a pressure valve and vacuum valve.
The pressure valve is held against its seat by a
spring of pre-determined strength which protects
the cooling system by relieving the pressure if
the pressure in cooling system rises by 0.9
kg/cm2 (12.8 psi, 90 kPa). The vacuum valve is
held against its seat by a light spring which
permits opening of the valve to relieve vacuum
created in the system when it cools off and
which otherwise might cause the radiator to
collapse.
The cap has its face marked 0.9, which means
that its pressure valve opens at 0.9 kg/cm2
(12.8 psi, 90 kPa).
NOTE:
Do not remove radiator cap to check engine
coolant level; check coolant visually the see-
through water reservoir tank.
Coolant should be added only to reservoir tank
as necessary.
4
WARNING:
As long as there is pressure in the cooling
system, the temperature can be considerab-
ly higher than the boiling temperature of
the solution in the radiator without causing
the solution to boil. Removal of the
radiator cap whileengine is hot and pressure
is high will cause the solution to boil
instantaneously and possibly with explosive
force, spewing the solution over engine,
fenders and person removing cap. If the
solution contains flammable anti-freeze
such as alcohol (not recommended for use
at any time), there is also the possibility of
causing a serious fire.
2’
I6
. Pressure valve
Vacuum valve
3. To water reservoir tank4. Pressure relief5. Vacuum relief
6. From water reservoir tank
Fig. 6-2
Water Reservoir Tank
A “see-through” plastic reservoir tank is connect-
ed to the radiator by a hose. As the car is
driven, the coolant is heated and expands. The
portion of the coolant displaced by this ex-
pansion flows from the radiator into the reservoir
tank.
When the car is stopped and the coolant cools
and contracts, the displaced coolant is drawn
back into the radiator by vacuum.
Thus, the radiator is kept filled with coolant to
the desired level at all times, resulting in increas-
ed cooling efficiency.
Coolant level should be between “FULL” and
“LOW’ marks on the reservoir tank.
Coolant should be added only to the reservoir
tank as necessary.
Fig. 6-3 Water reservoir tank
6-3

Water Pump
The centrifugal type water pump is used in the
cooling system. The pump impeller is supported
by a totally sealed bearing. The water pump can
not be disassembled.
Fig. 6-4
Thermostat
A wax pellet type thermostat is used in the
coolant outlet passage to control the flow of
engine coolant, to provide fast engine warm up
and to regulate coolant temperatures.
A wax pellet element is hermetically contained
in a metal case, and expands when heated and
contracts when cooled.
When the pellet is heated and expands, the metal
case pushes down the valve to open it.
As the pellet is cooled, the contraction allows a
spring to close the valve.
Thus, the valve remains closed while the coolant
is cold, preventing circulation of coolant through
the radiator.
In the top portion of the thermostat, an air
bleed valve is provided; this valve is for venting
out the gas or air, if any, that is accumulated in
the circuit.
There are two types of thermostat, A and B, as
given below. Either one is used depending on
vehicle specifications. The temperature at which
the valve begins to open is stamped on each
thermostat. Be sure to note this stamped tempe-
rature for replacement.
IThermostat functional spec. f 1.5’C (2.7’F)I
IIThermostat “A” (Thermostat “B” 1
Temp. at which
valve begins to82°C (179’F)
open
BB’C (190°F)
Temp. at which
valve become
fully open
95% (203’F)1OO’C (212’F)
Valve liftMore thanMore than
8 mm at 95’C8 mm at 1OO’C
Fig. 6-5 Thermostat
1. Air bleed valve
At this point, coolant is allowed to circulate
only throughout the engine to warm it quickly
and evenly.
As the engine warms, the pellet expands and the
thermostat valve opens, permitting coolant to
flow through the radiator.
6-4

6-2. .REMOVAL
WARNING:
l Check to make sure that cooling water
temperature is cold before removing any
part of cooling system components.
l Also be sure to disconnect 0 cord from
battery 0 terminal before removing any
part.
1. Coolant Draining
1) Remove radiator cap.
2) Loosen drain
its waterside.
-on radiator to enPtY
-
Illi
Fig. 6-6
2.Cooling Water Pipes or Hoses
1) Drain cooling system.
2)To remove these pipes or hoses, loosen
screw on each pipe or hose clip and pull
hose end off.
3. Water Pump Drive Belt
1) Loosen water pump drive belt tension.
2) Remove belt.
4.Cooling Fan, Fan Clutch and Water Pump
Pulley
1) Remove radiator shroud securing bolts
(4 PCS) and cooling fan securing nuts (or
bolts, 4 pcs).
Fig. 6-8
2)Then remove radiator shroud and cooling
fan and/or fan clutch and water pump
pulley at the same time.
5. Radiator
1) Drain cooling system.
2) Loosen water pump drive belt tension.
3) Remove radiator shroud and cooling fan &
clutch at the same time.. ”
4) Disconnect water hoses from radiator.
5) Remove radiator.
FI& 6-9
Fig. 6-7
6-5

6. Thermostat
1) Drain cooling system.
2) Disconnect thermostat cap from intake
manifold.
Fig. 6-10
3) Remove thermostat.
1. Crankshaft pulley2. Crankshaft pulley bolt
3.Crank timing belt pulley bolt
Fig. 6- 12
5) Remove timing belt outside cover.
I
Fig. 6- 11Fig. 6- 13
7. Water Pump
1) Drain cooling system.
Refer to 1. Coolant draining on previous
page.
2) Remove the radiator shroud and cooling
fan & clutch at the same time.
Refer to item 4 on previous page.
3) Loosen water pump drive belt tension.
Then remove water pump pulley and pump
drive belt.
4) Remove crankshaft pulley by removing
4 pulley bolts. Crankshaft timing belt
pulley bolt at the center is needs not to be
loosened.
6-6

6) Loosen tensioner bolt and stud, and remove
belt from crank timing belt pulley and
camshaft pulley after pushing up tensioner
plate fully with finger as shown in Figure.
24 1
1.Timing belt
2.Tensioner plate3.Tensioner bolt4.Tensioner stud
Fig.6-14
8) Remove water pump assembly.
7) Remove timing belt tensioner, plate and
spring.
1. Water pump
Fig. 6- 15
6-3. INSPECTION OF COMPONENTS
Thermostat
1) Make sure that air bleed valve of thermostat
is clear. Should this valve be clogged, engine
would tend to overheat.
Fig. 6- 16
1. Air bleed valve
2) Check valve seat for some foreign matters
3) Check thermostatic movement of wax pellet
being stuck which prevent valve from
seating tight.
as follows:
Immerse thermostat in water, and heat
water gradually.
Check that valve starts to open at specifi-
cation temp.
If valve starts to open at a temperature
substantially below or above, thermostat
unit should be replaced with a new one.
Such a unit, if reused, will bring about
overcooling or overheating tendency.
1. Thermostat
2. Thermometer
Fig. 6- 173. Heater
6-7

Radiator
If the water side of the radiator is found exces-
sively rusted or covered with scales, clean it
by flushing with the radiator cleaner compound.
This flushing should be carried out at regular
intervals for scale or rust formation advances
with time even where a recommended type of
coolant is used. Periodical flushing will prove
more economical.
Inspect the radiator cores and straighten the
flattened or bent fins, if any. Clean the cores,
removing road grimes and trashes.
Excessive rust or scale formation on the wet side
of the radiator lowers the cooling efficiency.
Flattened or bent fins obstruct the flow of air
through the core to impede heat dissipation.
I
Radiator flushingTwo years
interval(recommended)I
Water Pump
NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it
as assembly.
l Rotate water pump by hand to check for
smooth operation.
If pump does not rotate smoothly or makes
an abnormal noise, replace it.
Fig. 6- 19
Fig. 6-18
Water Temperature Gauge
For gauge inspection, refer to SECTION 21
BODY ELECTRICAL EQUIPMENT of this
manual.
6-8

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

Radiator6-5. MAINTENANCE SERVICE
1) Tighten bolts securely for proper installa-
tion. Also, fix joints of 2 hoses with clamps.
Fig. 6-22
2) Install radiator shroud and cooling fan &
clutch at the same time.
3) Tighten shroud bolts and fan clutch nuts.
4) Adjust water pump belt tension.
5) Fill specified amount of coolant.
Water Pump Belt
1) Inspect belt for cracks, cuts, deformation,
wear and cleanliness. If it is necessary to
replace belt, refer to ~6-5 for procedure.
2) Check belt for tension. Belt is in proper
tension when it deflects 6 to 9 mm (0.24 -
0.35 in.) under thumb pressure (about 10 kg
or 22 lb.).
Belt tension
specification
6 - 9 mm (0:24 - 0.35 in.)
as deflectionI
Water pump pulley
Crankshaft pulley
Fig. 623
3) If belt is too tight or too loose, adjust it to
proper tension by displacing alternator
position.
Fig. 6-
4) Tighten alternator adjusting bolt and pivot
bolt.
WARNING:
All adjustments described above are to be
performed with ENGINE NOT RUNNING.
6-10