2008 SUZUKI SWIFT engine coolant

Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-20
15) Install A/C compressor to its bracket (if equipped) referring to “Compressor Assembly Removal and
Installation in Section 7B” or “Compressor Assembly
Removal and Installa tion in Section 7B”.
16) Adjust A/C compressor belt tension (if equipped) referring to “Compressor Drive Belt Inspection and
Adjustment in Section 7B” or “Compressor Drive Belt
Inspection and Adjustment in Section 7B”.
17) Check to ensure that a ll removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
18) Refill cooling system with coolant referring to “Cooling System Flush and Refill in Section 1F”. 19) Refill engine with engine oil
referring to “Engine Oil
and Filter Change in Section 0B”.
20) Refill transaxle with transa xle oil referring to“Manual
Transaxle Oil Change in Section 5B” or “A/T Fluid
Change in Section 5A”.
21) Install battery and tray.
22) Connect positive and negative cable at battery.
23) Install engine hood and connect windshield washer hose.
24) Verify that there is no fu el leakage, coolant leakage,
oil leakage and exhaust gas leakage at each
connection.
Timing Chain Cover ComponentsS7RS0B1406012
I6RS0C140015-02
1. Crankshaft pulley bolt 13. Oil gallery pipe No.2 bolt
2. Crankshaft pulley 14. Oil gallery pipe No.3
3. Oil seal : Apply engine oil to oil seal lip. 15. Oil gallery pipe No.3 bolt
4. Timing chain cover : Apply sealant 99000-31140 to the mating surface of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface of timing chain cover referring to the
figure of Step 4) of “Installation” under “Timing Chain Cover Removal and Installation”. 16. O-ring
: Apply engine oil.
5. Pin 17. Oil control valve
6. Cap bolt 18. Oil control valve mounting nut
7. Timing chain cover mounting bolts 19. Cap
8. Timing chain cover mounting nut : 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Oil gallery pipe No.1 :25 N⋅m (2.5 kgf-m, 18.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 1E-4 Engine Lubrication System:
Heat Exchanger On-Vehicle InspectionS7RS0B1506002
• Check heat exchanger for deformation wear or damage.
• Check heat exchanger for coolant leakage and oil leakage.
If any malcondition is found, replace O-ring, stand bolt
gasket and/or heat exchanger.
Heat Exchanger Removal and InstallationS7RS0B1506003
Removal
1) Drain engine oil by removing drain plug.
2) Drain coolant referring to “Cooling System Draining in Section 1F”.
3) Remove exhaust manifold referring to “Exhaust Manifold Removal and Inst allation in Section 1K”.
4) Remove heat exchanger inlet No. 1 hose and outlet No. 1 hose.
5) Remove heat exchanger, O-ring and gasket by removing heat exchanger stand bolt. Installation
Reverse removal procedure for installation noting the
followings.
• Use new stand bolt gasket.
• Apply engine oil to new O-ring and install it to heat
exchanger.
• Install heat exchanger (1) while matching the projection of heat exchanger (2) in rib of the cylinder
block (3) as shown in figure.
• Install heat exchanger stand bolt (4) to specified torque.
Tightening torque
Heat exchanger stand bolt (a): 22 N·m (2.2 kgf-m,
16.0 lb-ft)
• Refill cooling system with co olant referring to “Cooling
System Flush and Refill in Section 1F”.
• Refill engine with engine oil referring to “Engine Oil and Filter Change in Section 0B”.
• Upon completion of installation, check for engine coolant and oil leaks.
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Downloaded from www.Manualslib.com manuals search engine 1F-1 Engine Cooling System:
Engine
Engine Cooling System
General Description
Cooling System DescriptionS7RS0B1601001
The cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan and
thermostat. The radiator is of tube-and-fin type.
Coolant DescriptionS7RS0B1601002
WARNING!
• Do not remove radiator cap to check engine coolant level; check coolant visually at the see-through coolant reservoir. Coolant should be added only to reservoir as necessary.
• As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal
of the radiator cap while engine 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.
• Check to make sure that engine coolant temperature is cold before removing any part of cooling system.
• Also be sure to disconnect negative cable from battery terminal before removing any part.

The coolant recovery system is standard. The coolant in the radiator expands with heat, and the coolant is overflowed
to the reservoir.
When the system cools down, the coolant is drawn back into the radiator.
The cooling system has be en filled with a quality coolant that is a 50/50 mixture of water and ethylene glycol
antifreeze.
This 50/50 mixture coolant solution provides freezing protection to –36 °C (–33 °F).
• Maintain cooling system freeze protection at –36 °C (–33 °F) to ensure protection against corrosion and loss of
coolant from boiling. This should be done even if freezing temperatures are not expected.
• Add ethylene glycol base coolant when coolant has to be added because of coolant loss or to provide added protection against freezing at temperature lower than –36 °C (–33 °F).
NOTE
• Alcohol or methanol base coolant or plain water alone should not be used in cooling system at any
time as damage to cooling system could occur.
• Coolant must be mixed with deminerated water or distilled water.

Anti-freeze proportioning table
For M/T model For A/T model
Freezing temperature °
C –36 –36
° F –33 –33
Anti-freeze / Anti-corrosion coolant concentration % 50 50
Ratio of compound to cooling water ltr. 3.10/3.10 3.05/3.05
US pt. 6.55/6.55 6.44/6.44
Imp pt. 5.46/5.46 5.37/5.37

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-2
Coolant capacity
For M/T model:• Engine, radiator and heater: 5.5 liters (11.62/9.68 US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 US/lmp pt.)
• Total: 6.2 liters (13.10/10.91 US/lmp pt.)
For A/T model: • Engine, radiator and heater: 5.4 liters (11.41/9.50 US/lmp pt.)
• Reservoir: 0.7 liters (1.48/1.23 US/lmp pt.)
• Total: 6.1 liters (12.89/10.74 US/lmp pt.)
Schematic and Routing Diagram
Coolant CirculationS7RS0B1602001
While the engine is warmed up (thermosta t closed), coolant circulates as follows.
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1. Radiator inlet hose
6. Water pump11. Heater core
2. Radiator outlet hose 7. Throttle body12. Radiator
3. Throttle body inlet hose 8. Engine13. Heat exchanger
4. Throttle body outlet hose 9. Heater core inlet hose
5. Thermostat 10. Heater core outlet hose

Downloaded from www.Manualslib.com manuals search engine 1F-3 Engine Cooling System:
When coolant is warmed up to normal temperature and the thermostat opens, coolant passes through the radiator
core to be cooled as follows.
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10 3 7
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6
5
2 12 1
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1. Radiator inlet hose
6. Water pump11. Heater core
2. Radiator outlet hose 7. Throttle body12. Radiator
3. Throttle body inlet hose 8. Engine13. Heat exchanger
4. Throttle body outlet hose 9. Heater core inlet hose
5. Thermostat 10. Heater core outlet hose

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-4
Diagnostic Information and Procedures
Engine Cooling Symptom DiagnosisS7RS0B1604001
ConditionPossible cause Correction / Reference Item
Engine overheats
(Radiator fan operates) Loose or broken water pump belt
Adjust or replace.
Not enough coolant Check coolant level and add as necessary.
Faulty thermostat Replace.
Faulty water pump Replace.
Dirty or bent radiator fins Clean or remedy.
Coolant leakage on cooling system Repair.
Clogged radiator Check and replace radiator as necessary.
Faulty radiator cap Replace.
Improper ignition timing Adjust.
Dragging brakes Adjust brake.
Slipping clutch Adjust or replace.
Poor charge battery Check and replace as necessary.
Poor generation generator Check and repair.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan relay No.2 and/or
No.3 faulty Check and replace as necessary.
Radiator fan motor faulty Check and replace as necessary.
ECM faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
Equipped with too much electric load
part(s) Dismount.
Engine overheats
(Radiator fan does not
operate) Fuse blown
Check 30 A fuse of relay/fuse box and check
for short circuit to ground.
Radiator cooling fan relay No.1 faulty Check and replace as necessary.
ECT sensor faulty Check and replace as necessary.
Radiator cooling fan motor faulty Check and replace as necessary.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check and replace as necessary.

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-6
Coolant Level CheckS7RS0B1606002
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 radiator
cap is taken off too soon.

To check level, lift hood and look at “see-through”
coolant reservoir.
It is not necessary to remove radiator cap to check
coolant level.
When engine is cool, check coolant level in reservoir (1).
A normal coolant level should be between FULL mark
(2) and LOW mark (3) on reservoir (1).
If coolant level is below LOW mark (3), remove reservoir
cap (4) and add proper coolant to reservoir to bring
coolant level up to FULL mark (2).
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 unnecessary expense.

Engine Cooling System Inspection and
Cleaning
S7RS0B1606003
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.

1) Check cooling system for leakage or damage.
2) Wash radiator cap and fille r 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 (1), check system and radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap
for this vehicle.
NOTE
After installing radiator cap to radiator, make
sure that the ear of cap lines is parallel to
radiator.

Cooling system and radiator cap holding
pressure (for inspection)
110 kPa (1.1 kg/cm2, 15.6 psi)
5) Tighten hose clamps and inspect all hoses. Replace hoses whenever cracked, swollen or otherwise
deteriorated.
6) Clean frontal area of radiator core.
Cooling System DrainingS7RS0B1606004
1) Remove radiator cap.
2) Drain coolant from radiator drain plug (1).
3) After draining coolant, be sure to tighten drain plug (1) securely.
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