Get Engine Cooling -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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.

Engine Cooling -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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