2005 SUZUKI JIMNY water pump

Downloaded from www.Manualslib.com manuals search engine 6B-4 ENGINE COOLING
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.
Thermostat
A wax pellet type thermostat is used in the cooling system.
The temperature at which the valve begins to open is stamped on
thermostat.
In the top portion of the thermostat, an air bleed valve (1) is pro-
vided; this valve is for venting out the gas or air, if any, that is
accumulated in the circuit.
Cooling Fan Clutch
Fluid is enclosed in the cooling fan clutch (2) and at its center
front, there is a bimetal (3) whose thermal reaction and the engine
speed control the cooling fan speed.
Coolant (Water) Temperature Gauge
A water temp. gauge is located at intake manifold.
This gauge activates a temp. meter in the instrument cluster.
When installing, wind sealing tape on gauge thread and tighten it.
NOTE:
Do not disassemble clutch assembly.
WARNING:
Keep hands, tools, and clothing away from engine cool-
ing fan (1) to help prevent personal injury.

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Diagnosis
Condition Possible Cause Correction
Engine overheats
Loose or broken water pump belt
Not enough coolant
Faulty thermostat
Faulty water pump
Dirty or bent radiator fins
Coolant leakage on cooling system
Defective cooling fan clutch
Plugged radiator
Faulty radiator cap
Maladjusted ignition timing
Dragging brakes
Slipping clutchAdjust or replace.
Check coolant level and add as
necessary.
Replace.
Replace.
Clean or remedy.
Repair.
Check and replace as necessary.
Check and replace radiator as
necessary.
Replace.
Check system related parts.
Adjust brake.
Adjust or replace.

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-9
9) Run engine, with radiator 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 hose.
Water Pump Belt Tension
1) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If it is necessary to replace belt, refer to “Water Pump
Belt and Cooling Fan” in this section.
2) Check belt for tension. Belt is in proper tension when it
deflects 4.5 to 5.5 mm (0.18 – 0.22 in.) under thumb pres-
sure (about 10 kg or 22 lb.).
Water pump belt tension
“a” : 4.5 – 5.5 mm (0.18 – 0.22 in.) as deflection / 10 kg (22
lbs)
3) If belt is too tight or too loose, adjust it to proper tension by
displacing generator position.
4) Tighten generator adjusting bolt and pivot bolts as specified
torque.
Tightening torque
Generator adjusting bolt (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Generator pivot bolts (b) : 50 N·m (5.0 kg-m, 36.0 lb-ft)
5) Connect negative cable at battery terminal.WARNING:
Disconnect negative cable at battery before checking and
adjusting belt tension.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-13
Water Pump Belt and Cooling Fan
REMOVAL
1) Remove radiator shroud securing bolts (1).
2) Remove radiator by referring to “Radiator” in this section.
3) Loosen water pump drive belt tension.
4) Remove cooling fan by removing securing nuts.
Remove power steering and/or compressor drive belt before
removing water pump belt.
5) Remove pump belt.
INSTALLATION
Once cooling fan 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 specified tension, refer to
“Water Pump Belt Tension” in this section.
WATER PUMP BELT TENSION INSPECTION
1) Check belt tension. It should be within specification. Refer to
“Water Pump Belt Tension” in this section.
2) If tension is out of specification, adjust it.
For its adjustment, refer to “Water Pump Belt Tension” in this
section.
After adjustment, be sure to tighten bolts.
COOLING FAN CLUTCH INSPECTION
Inspect fluid coupling for oil leakage.
If necessary, replace fan clutch assembly. Do not disassemble
clutch assembly.

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-15
Water Pump
COMPONENTS
REMOVAL
1) Drain cooling system.
Refer to Step 6) of “Cooling System Flush and Refill” in this
section.
2) Remove the radiator shroud.
3) Remove radiator referring to “Radiator” in this section.
4) Loosen water pump drive belt tension.
Then remove water pump pulley (2) with fan clutch (3) and
pump drive belt.
5) Remove water pump assembly (1).
1. Water pump 4. Radiator cooling fan 7. Radiator cooling fan mounting bolt
2. Water pump pulley 5. Water pump mounting bolts Tightening Torque
3. Radiator cooling fan clutch 6. Water pump pulley and fan clutch mounting nuts
1. Drain plug

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INSPECTION
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes an abnormal
noise, replace it.
INSTALLATION
1) Apply sealant to water pump (1).
“A” : Sealant 99000-31150
Sealant quantity for mating surface of water pump
Width “a” : 3mm (0.12 in.)
Height “b” : 2mm (0.08 in.)
2) Install water pump (1) to cylinder block.
Tightening torque
Water pump bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Install water pump pulley (2) with fan clutch (3).
Tightening torque
Water pump pulley nuts (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Fan clutch bolts (c) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install water pump drive belt, cooling fan and radiator
shroud.
5) Adjust water pump belt tension.
Refer to “Water Pump Belt Tension” in this section.
6) Connect negative cable at battery.
7) Fill the cooling system.NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-17
Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Ethylene glycol base
coolant (Anti-freeze /
Anti-corrosion coolant)–Additive to engine cooling system for improving
cooling efficiency and for protection against
rusting.
SealantSUZUKI BOND NO.1207C
(99000 – 31150)To apply to water pump mating surface.
Fastening partTightening torque
Nm kg-m lb-ft
Water pump bolt 23 2.3 17.0
Thermostat cap bolt 11 1.1 8.0
Thermostat case bolt 25 2.5 18.0
Fun clutch bolt 11 1.1 8.0

Downloaded from www.Manualslib.com manuals search engine 6C-6 ENGINE FUEL
12) Remove fuel tank (1) from vehicle. Remove fuel tank protec-
tor (3) and inlet valve (2) as necessary.
FUEL TANK PURGING PROCEDURE
The following procedure is used for purging the fuel tank.
1) After removing fuel tank, remove all hoses and fuel pump
assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Move tank to flushing area.
4) Fill tank with warm water or tap water, and agitate vigorously
and drain. Repeat this washing until inside of tank is clean.
Replace tank if its inside is rusty.
5) Completely flush out remaining water after washing.
CAUTION:
This purging procedure will not remove all fuel vapor. Do
not attempt any repair on tank where heat or flame is
required, as an explosion resulting in personal injury
could occur.