section 7b SUZUKI JIMNY 2005 3.G Service Workshop Manual

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-11
Coolant Draining
1) Remove radiator cap (1).
2) Loosen drain plug on radiator to drain coolant.
3) After draining coolant, be sure to tighten drain plug securely.
4) Fill cooling system. Refer to “Coolant” in this section.
Cooling Water Pipes or Hoses
REMOVAL
1) Drain cooling system.
2) To remove water pipes or hoses, loosen screw on each pipe
or hose clip and pull hose end off.
INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
Tighten each clamp bolt securely.
Refill cooling system with proper coolant, referring to
description on “Coolant” and “Cooling System Flush and
Refill” in this section.
Thermostat
REMOVAL
1) Drain cooling system and tighten drain plug.
2) Remove intake manifold, referring to “Throttle Body and
Intake Manifold” in Section 6A1.
3) Disconnect thermostat cap (1) from thermostat case (2).
4) Remove thermostat (3).

Downloaded from www.Manualslib.com manuals search engine 6B-12 ENGINE COOLING
INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clear.
Should this valve be clogged, engine would tend to overheat.
2) Check valve seat for some foreign matters being stuck which
prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
a) Immerse thermostat (1) in water, and heat water gradually.
b) Check that valve starts to open at specification temp.
c) If valve starts to open at a temperature substantially below
or above, thermostat unit should be replaced with a new
one.
Such a unit, if re-used, will bring about overcooling or over-
heating tendency.
Thermostat functional specification
INSTALLATION
1) When positioning the thermostat (2) on the thermostat case
(1), be sure to align its air breather valve (3) with mark (4).
2) Install thermostat cap (5) to thermostat case with align air
bleed valve and mark.
Then, tighten mounting bolts to specified torque.
Tightening torque
Thermostat cap bolts
(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Thermostat case bolts
(b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
3) Install intake manifold by referring to “Throttle Body and
Intake Manifold” in Section 6A1.
4) Fill the cooling system.
Temp. at which valve begins
to open80 – 84 °C (176 – 183 °F)
Temp. at which valve
becomes fully open93 – 97 °C (199 – 207 °F)
Valve liftMore than 8 mm at 95 °C
(203 °F)
2. Thermometer
3. Heater

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 6B-14 ENGINE COOLING
Radiator
REMOVAL
1) Drain cooling system.
2) Remove radiator shroud.
3) Disconnect water hoses from radiator.
4) With automatic transmission (A/T) vehicle, disconnect addi-
tional two fluid hoses from radiator.
Place some container under radiator to receive A/T fluid
which will flow out when hose is disconnected.
5) Install radiator protection board to between radiator and
cooling fan.
6) Remove radiator after removing two bolts (1).
INSPECTION
If the water side of the radiator is found excessively rusted or cov-
ered with scales, clean it by flushing with the radiator cleaner
compound.
This flushing should be carried out at regular intervals for scale or
rust formation advances with time even where a recommended
type of coolant is used. Periodical flushing will prove more eco-
nomical.
Inspect the radiator cores and straighten the flattened or bent
fins, if any. Clean the cores, removing road grimes and trashes.
Excessive rust or scale formation on the wet side of the radiator
lowers the cooling efficiency.
Flattened or bent fins obstruct the flow of air through the core to
impede heat dissipation.
Radiator flushing interval recommended
Two years
INSTALLATION
Reverse removal procedures.
NOTE:
Refill cooling system with proper coolant referring to
“Coolant” and “Cooling System Flush and Refill” in
this section.
With automatic transmission vehicle, fill A/T fluid up to
specified level. For procedure to check A/T fluid and its
level, refer to “Changing Fluid” in Section 7B.
After installation, check each joint for leakage.

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

Downloaded from www.Manualslib.com manuals search engine 6B-16 ENGINE COOLING
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 FUEL 6C-1
6F1
7A
7A1
7A
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
6G
6C
6K
9
10
10A
10B
SECTION 6C
ENGINE FUEL
CONTENTS
General Description ....................................... 6C-2
Fuel System ................................................. 6C-2
Fuel Tank ..................................................... 6C-2
Fuel Pump Assembly ................................... 6C-3
Fuel Filler Cap .............................................. 6C-3
On-Vehicle Service......................................... 6C-4Fuel Lines .................................................... 6C-4
Fuel Filler Cap.............................................. 6C-4
Fuel Tank ..................................................... 6C-4
Fuel Pump Assembly ................................... 6C-7
Tightening Torque Specification ................ 6C-10
Special Tool .................................................. 6C-10

CAUTION:
For vehicles with a catalytic converter, be sure to use unleaded fuel only. Use of leaded and/or low
lead fuel can result in engine damage and reduce the effectiveness of the emission control system.

Downloaded from www.Manualslib.com manuals search engine 6C-2 ENGINE FUEL
General Description
Fuel System
The main components of the fuel system are fuel tank, fuel pump assembly with fuel filter and fuel level gauge
and fuel cut valve, fuel feed line, fuel return line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to “Fuel Delivery System” and “Emission Control System” in
Section 6E.
Fuel Tank
The fuel tank is located under the rear section of the vehicle. The
fuel pump assembly is installed in fuel tank. Whenever servicing
the fuel pump assembly, the fuel tank must be removed from the
vehicle.
1. Fuel tank 4. Fuel filler cap 7. Fuel vapor line 10. Fuel filler hose clamp
2. Fuel pump assembly 5. Fuel feed line 8. Fuel filler neck Tightening torque
3. Breather hose 6. Fuel return line 9. Fuel tank mounting bolt

Downloaded from www.Manualslib.com manuals search engine ENGINE FUEL 6C-3
Fuel Pump Assembly
The fuel pump assembly (1) consists of fuel pump (6), fuel filter
(2), fuel level gauge (5) and fuel cut valve (4).
FUEL PUMP
For structure and operation of the fuel pump, refer to “Fuel Deliv-
ery System” in Section 6E.
FUEL CUT VALVE
The fuel cut valve consists of a float and a spring. It allows only
the fuel vapor to flow into the canister and prevents the fuel from
flowing into the canister.
Fuel Filler Cap
The fuel tank filler neck has a vacuum cap.
A ratchet tightening device on the threaded fuel filler cap reduces
the chances of incorrect installation, which would prevent sealing
fuel vapors.
After the gasket (2) on fuel filler cap and the filler neck flange con-
tact, the ratchet produces a loud clicking noise, indicating the seal
has been set.
This cap has a vacuum relief valve (1) inside.
The vacuum relief valve opens to relieve the vacuum created in
the fuel tank.
3. Suction filter