1987 SUZUKI GRAND VITARA engine coolant

SECTION 6
ENGINE COOLING SYSTEM
CONTENTS
6-l. GENERAL DESCRIPTION .. . . . . . . . . . . . . . . . . . . . ..m..*.........6-2
6-2. REMOVAL...............................................6-5
6.3. INSPECTION OF COMPONENTS..............................6-7
THERMOSTAT...........................................6-7
RADIATOR..............................................6-8
WATER PUMP............................................6-8
6-4.IMPORTANT STEPS FOR REINSTALLATION....................6-9
WATER PUMP..............................................6-9
THERMOSTAT.............................................6-9
COOLING FAN AND WATER PUMP BELT.......................6-9
RADIATOR................................................6-10
6-5. MAINTENANCE SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6-10
WATER PUMP BELT.........................................6-10
COOLANT..............................................6-11
COOLANT LEVEL........................................6-11
COOLING SYSTEM SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
COOLING SYSTEM, FLUSH AND REFILL . . . . . . . . . . . . . . . . . . . . . . 6-12
6-1
6

6-l. GENERAL DESCRIPTION
The cooling system consists of the radiator cap,
radiator, water reservoir tank, hoses, water
pump, cooling fan & clutch, thermostat. The
radiator is of tube-and-fin type.
Cooling System Circulation
During engine warm-up (thermostat closed),
the water pump discharges coolant into the
water jacket chamber adjacent to No. 1 cylinder.
Coolant then flows through the cylinder block
and the cylinder head. Coolant then returns to
the water pump through intake manifold, heater
inlet hose, heater unit, heater outlet hose, and
water intake pipe.
During normal temperatures (thermostat open),
coolant takes the same basic route but is now
allowed to flow past the thermostat, the inlet
hose and the radiator, and then back to the
water pump through the outlet hose and the
water intake pipe.
1.Radiator inlet hose
2.Radiator outlet hose
3.Water intake pipe
4.Thermostat
6.Water pump
6.Water pump drive belt
7.Intake manifold
8.Carburetor
9.Heater inlet hose10.Heater outlet hose11.Bypass hose
2\
Fig. 6- 1 Cooling system
6-2

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

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

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