1998-2003 Suzuki Alto 4 Door Engine Cooling User Manual
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Engine Cooling for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

6B
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
CONTENTS
GENERAL DESCRIPTION 6B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Circulation 6B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS 6B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 6B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant 6B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Level 6B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Service 6B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Flush and Refill 6B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Belt Tension 6B- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Draining 6B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Water Pipes or Hoses 6B- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 6B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Belt 6B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 6B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS 6B-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6B-2 ENGINE COOLING
GENERAL DESCRIPTION
The cooling system mainly consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan
and thermostat. The radiator is of tube-and-fin type.
COOLING SYSTEM CIRCULATION
1) While the engine is warmed up (thermostat closed), coolant circulates as follows.
Water pump Cylinder block Cylinder head
Thermostat closed
Throttle body
Heater unit
Water inlet pipe
Intake manifold
(F8D engine)
(F8B engine)
2) When coolant is warmed up to normal operating temperature and the thermostat opens, coolant passes through
the radiator core to be cooled as well as the above flow circuit.
1. Radiator inlet hose
2. Radiator outlet hose
3. Intake manifold
4. Thermostat
5. Water pump
6. Throttle body
7. Cylinder block
8. Cylinder head
9. Heater inlet hose (if equipped)
10. Heater outlet hose (if equipped)
11. Radiator
12. Reservoir
13. Radiator cap
14. Cooling fan
15. Heater unit
F8B engine F8D engine
ENGINE COOLING 6B-3
DIAGNOSIS
Symptom
Possible Cause Remedy
Engine overheats D Loose or broken water pump belt
D Not enough coolant
D Faulty thermostat
D Faulty water pump
D Dirty or bent radiator fins
D Coolant leakage on cooling system
D Defective cooling fan motor
D Faulty fan motor control circuit
D Plugged radiator
D Faulty radiator cap
D Improper ignition timing
D Dragging brakes
D Slipping clutch
Adjust or replace.
Check coolant level and add as necessary.
Replace.
Replace.
Clean or remedy.
Repair.
Check and replace as necessary.
Refer to SECTION 6E1.
Check and replace radiator as necessary.
Replace.
Adjust.
Adjust brake.
Adjust or replace.
6B-4 ENGINE COOLING
MAINTENANCE
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 a 50/50 mixture of water and
ethylene glycol antifreeze (70/30; in a market where
no freezing temperature is anticipated).
This 50/50 mixture coolant solution provides freezing
protection to –365C (–335F).
D Maintain cooling system freeze protection at
–365C (–335F) to ensure protection against corro-
sion and loss of coolant from boiling. This should be
done even if freezing temperatures are not ex-
pected.
D 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 –365C (–335F).
NOTE:
D Alcohol or methanol base coolant or plain
water alone should not be used in cooling
system at any time as damage to cooling sys-
tem could occur.
D Even in a market where no freezing tempera-
ture is anticipated, mixture of 70% water and
30% ethylene glycol antifreeze (Antifreeze/
Anticorrosion coolant) should be used for
the purpose of corrosion protection and lu-
brication.
ANTI-FREEZE PROPORTIONING CHART
R
-
Freezing tem
p
erature
5C –16 –36
O
PO
R
Freezing
temperature
5F 3 –33
E
ZE PR
O
C
HART
Anti-freeze/Anti-corrosion
coolant concentration
% 30 50
F
RE
E
N
G C
ltr. 1.05/2.45 1.75/1.75
N
TI-
F
ONI
N
Ratio of compound to cooling water US pt. 2.22/5.18 3.70/3.70
A
N
TI
O
lmp pt. 1.85/4.31 3.08/3.08
N
T
T
Y
Engine radiator and heater
3.0 liters
(6.34/5.28 US/Imp. pt.)
C
OOLA
N
C
APACI
T
Reservoir tank
0.5 liters
(1.06/0.88 US/lmp. pt.)
C
C
Total
3.5 liters
(7.40/6.16 US/Imp. pt.)
COOLANT LEVEL
Coolant Level
To check level, lift hood and look at “see-through” coolant reservoir
tank.
It is not necessary to remove radiator cap to check coolant level.
When engine is cool, check coolant level in reservoir tank (1).
A normal coolant level should be between FULL and LOW marks
on reservoir tank.
If coolant level is below LOW mark (2), remove reservoir tank cap
and add proper coolant to tank to bring coolant level up to FULL
mark (3). Then, reinstall cap (4).
NOTE:
If proper quality antifreeze is used, there is no need to add ex-
tra inhibitors or additives that claim to improve system.
They may be harmful to proper operation of system, and are
unnecessary expense.
WARNING:
To help avoid danger of being burned:
D do not remove reservoir tank cap while coolant is boil-
ing, and
D do not remove radiator cap while engine and radiator
are still hot.
Scalding fluid and steam can be blown out under pres-
sure if either cap is taken off too soon.
COOLING SYSTEM SERVICE
Cooling system should be serviced as follows.
1) Check cooling system for leakage 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.
WARNING:
To help avoid danger of being burned, do not remove ra-
diator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.
ENGINE COOLING 6B-5
4) Using a pressure tester (1), check system and radiator cap (2)
for proper pressure holding capacity about 90 kPa (0.9 kg/cm
2
,
12.8 psi). 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.
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 FLUSH AND REFILL
1) Remove radiator cap when engine is cool:
Turn cap counterclockwise slowly until it reaches a “stop”.
(Do not press down while turning it.)
Wait until pressure is relieved (indicated by a hissing sound)
then press down on cap and continue to turn it counterclock-
wise.
2) With radiator cap removed, run engine until upper radiator
hose is hot (this shows that thermostat is open and coolant is
flowing through system).
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.
3) Stop engine and drain coolant.
4) Close drain plug. Add water until system is filled and run en-
gine 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 (1) tightly (for
F8D engine).
F8D engine
6B-6 ENGINE COOLING
7) Remove reservoir tank (1) and remove cap (2) from reservoir
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.
8) Add 50/50 mixture of good quality ethylene glycol antifreeze
and water to radiator and tank.
Fill radiator to the base of radiator filler neck and reservoir tank
to FULL level mark (3). Reinstall reservoir tank cap.
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 is parallel to radiator.
WATER PUMP BELT TENSION
1) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If it is necessary to replace belt, refer to page 6B-10 for proce-
dure.
WARNING:
D Disconnect negative cable at battery before checking
and adjusting belt tension.
D See WARNING described in COOLING SYSTEM SER-
VICE.
2) Check belt (1) for tension. Belt is in proper tension when it de-
flects 6 – 7 mm (0.24 – 0.27 in.) under thumb pressure (about
10 kg or 22 Ib.).
Belt tension “a”: 6 – 7 mm (0.24 – 0.27 in.) as deflection
NOTE:
When replacing belt with a new one, adjust belt tension to
5 – 6 mm (0.20 – 0.24 in.).
3) If belt is too tight or too loose, adjust it to proper tension by dis-
placing generator position.
4) Tighten belt adjusting bolt (2) and generator pivot bolts (3).
5) Connect negative cable at battery terminal.
ENGINE COOLING 6B-7
ON-VEHICLE SERVICE
WARNING:
D Check to make sure that engine coolant temperature
is cold before removing any part of cooling system.
D Also be sure to disconnect negative cord from battery
terminal before removing any part.
COOLING SYSTEM DRAINING
1) Remove radiator cap.
2) Loosen drain plug (1) on radiator (F8D engine) or disconnect ra-
diator outlet hose (F8B engine) to drain coolant.
3) After draining coolant, be sure to tighten drain plug securely.
4) Fill cooling system. (Refer to Item COOLANT of MAINTE-
NANCE.)
COOLING WATER PIPES OR HOSES
: Tightening Torque
: Do not reuse
without heater
HEATER (if equipped)
F8D engine
REMOVAL
1) Drain cooling system.
2) To remove these pipes or hoses, loosen clamp on each hose
and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, noting
the following.
D Tighten each clamp securely.
D Refill cooling system with proper coolant, referring to description
on COOLANT of MAINTENANCE.
6B-8 ENGINE COOLING
THERMOSTAT
REMOVAL
1) Drain coolant and tighten drain plug.
2) Remove air cleaner case together with air inlet hose.
3) Remove thermostat cap (1) with air cleaner case bracket.
4) Remove thermostat (2) and gasket.
F8B engine
F8D engine
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clean.
Should this valve be clogged, engine would tend to overheat.
2) Check to make sure that valve seat is free from foreign matters
which would prevent valve from seating tight.
4) Check thermostatic movement of wax pellet as follows:
(1) Immerse thermostat in water, and heat water gradually.
(2) Check that valve starts to open at specific temperature.
(3) If valve starts to open at a temperature substantially below
or above specific temperature, thermostat unit should be re-
placed with a new one. Such a unit, if reused, will bring about
overcooling or overheating tendency.
1. Thermostat
2. Thermometer
3. Heater
ENGINE COOLING 6B-9
Thermostat functional spec. "1.55C (2.75F)
Temp. at which valve begins
to open
825C (1795F)
Temp. at which valve be-
come fully open
955C (2035F)
Valve lift More than 8 mm at 955C
INSTALLATION
1) When positioning thermostat (1) on thermostat case (2), be
sure to position it so that air bleed valve (3) aligns with arrow
mark on case as shown in figure (F8D engine).
2) Install new gasket.
F8D engine
3) Install thermostat cap to thermostat case.
4) Connect cooling water hose.
5) Fill cooling system (refer to page 6B-6, 6B-7).
6) Install air cleaner case.
7) Connect negative cable at battery.
8) After installation, check each part for leakage.
WATER PUMP BELT
REMOVAL
1) Disconnect negative cable at battery.
2) Loosen drive belt adjusting bolt (1) and generator pivot bolts (2).
3) Slacken belt by displacing generator and then remove it.
INSTALLATION
1) Install belt to water pump pulley, crankshaft pulley and genera-
tor pulley.
2) Tighten water pump belt adjusting bolt and pivot bolts.
3) Connect negative cable at battery.
WATER PUMP BELT TENSION INSPECTION AND AD-
JUSTMENT
For this inspection or adjustment, refer to WATER PUMP BELT
TENSION.
6B-10 ENGINE COOLING
RADIATOR
REMOVAL
1) Disconnect cables at battery and remove battery and its tray.
2) Drain cooling system by loosening drain plug or disconnecting
radiator outlet hose.
F8D engine
3) Disconnect coupler of cooling fan motor.
4) Remove radiator bolts.
5) Disconnect radiator inlet and outlet hoses and reservoir tank
hose from radiator.
6) Remove radiator from vehicle.
INSPECTION
Check radiator for leakage or damage. Straighten bent fins, if any.
CLEANING
Clean frontal area of radiator cores.
INSTALLATION
Reverse removal procedures.
NOTE:
D Refill cooling system with proper coolant referring to
COOLANT item of MAINTENANCE.
D Refer to the figure at REMOVAL for tightening torque.
D After installation, check each joint for leakage.
ENGINE COOLING 6B-11
WATER PUMP
REMOVAL
F8B engine
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Remove A/C compressor drive belt (if equipped) and water
pump drive belt. Remove water pump pulley.
4) Remove crankshaft pulley (1).
Remove timing belt and tensioner according to procedure de-
scribed in TIMING BELT AND TENSIONER of SECTION 6A.
5) Remove timing belt tensioner and crankshaft timing belt pulley
by using special tool.
Special Tool
(A): 09930-40113
6) Remove crankshaft timing belt pulley and timing belt inside cov-
er.
7) Remove generator adjusting arm.
8) Remove water pump, gasket and rubber seal.
F8D engine
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Remove water pump belt, A/C compressor drive belt (if
equipped) and water pump pulley.
4) Remove crankshaft pulley and timing belt outside cover.
5) Remove timing belt and tensioner according to procedure de-
scribed in item TIMING BELT AND TENSIONER of SECTION
6A1.
6) Remove water pump (1), gasket (2) and rubber seal.
6B-12 ENGINE COOLING
INSPECTION
NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes abnormal noise, re-
place it.
INSTALLATION
F8B engine
1) Install new gasket to cylinder block.
2) Install water pump to cylinder block.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
3) Install timing belt inside cover.
4) Install crankshaft timing belt guide, pulley and camshaft timing
belt pulley.
Tightening Torque
(a): 55 N·m (5.5 kg-m, 40.0 lb-ft)
5) Remove cylinder head cover and loosen all valve adjusting
screws of intake and exhaust rocker arms fully.
6) Install belt tensioner, tensioner spring and timing belt and ad-
just timing belt tension according to procedure described in
TIMING BELT AND TENSIONER of SECTION 6A.
7) Install timing belt outside cover, crankshaft pulley, water pump
pulley and drive belts Refer to SECTION 6A.
8) Adjust all valve lashes refer to SECTION 6A.
9) Adjust water pump drive belt tension and A/C compressor
drive belt tension (if equipped).
10) Connect negative cable at battery.
11) Fill cooling system.
ENGINE COOLING 6B-13
F8D engine
1) Install new pump gasket (1) to cylinder block.
2) Install water pump (1) to cylinder block.
Tightening Torque
(a): 11 N·m (1.1 kg-m, 8.0 lb-ft)
3) After installing water pump, install rubber seal (2).
4) Install belt tensioner and timing belt and adjust timing belt ac-
cording to procedure described in item TIMING BELT AND
TENSIONER of SECTION 6A1.
5) Adjust drive belt tension.
6) Fill cooling system.
7) After installation, check each part for leakage.
6B-14 ENGINE COOLING
REQUIRED SERVICE MATERIAL
MATERIALS
USE
Ethylene glycol base coolant
(Anti-freeze/Anti-corrosion coolant)
Additive to engine cooling system for improving cooling
efficiency and for protection against rusting.

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