coolant SUZUKI JIMNY 2005 3.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-71
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying oil to rod bolts and tighten cap nuts (3) gradu-
ally as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat Step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice.
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
8) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
9) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection. NOTE:
Before installing bearing cap, make sure to check con-
necting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod” in this sec-
tion.

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Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove A/C compressor and/or P/S pump belt (if
equipped).
5) Remove generator belt.
6) Drain engine oil.
7) Drain coolant.
8) Disconnect radiator inlet and outlet hoses from each pipe.
9) Disconnect A/T fluid hoses (2) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
10) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
11) Remove radiator with cooling fan referring to Section 6B.
Then remove water pump pulley.
12) With hose connected, detach P/S pump from its bracket (if
equipped) referring to “Power Steering Pump” in Section
3B1.
13) If vehicle equipped with A/C compressor, work of right hand
steering vehicle differs from its of left hand steering vehicle.
Each work is as follows. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of engine
assembly.

Downloaded from www.Manualslib.com manuals search engine 6A1-78 ENGINE MECHANICAL (M13 ENGINE)
Install seal ring and exhaust pipe to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Reverse disconnected hoses, cables and electric wires for
connection.
7) Install air cleaner outlet hoses.
8) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
9) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
10) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
11) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
12) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
13) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) Connect negative cable at battery.
15) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-1
6B
SECTION 6B
ENGINE COOLING
CONTENTS
General Description ........................................6B-2
Cooling System Circulation ........................... 6B-2
Radiator Cap ................................................. 6B-3
Coolant Reservoir ......................................... 6B-3
Water Pump .................................................. 6B-4
Thermostat .................................................... 6B-4
Cooling Fan Clutch ........................................ 6B-4
Coolant (Water) Temperature Gauge............ 6B-4
Diagnosis .........................................................6B-5
Maintenance ....................................................6B-6
Coolant .......................................................... 6B-6
Coolant Level ................................................ 6B-7
Cooling System Service ................................ 6B-7Cooling System Flush and Refill ................... 6B-8
Water Pump Belt Tension ............................. 6B-9
On-Vehicle Service ....................................... 6B-10
Cooling System Component ....................... 6B-10
Coolant Draining ......................................... 6B-11
Cooling Water Pipes or Hoses .................... 6B-11
Thermostat .................................................. 6B-11
Water Pump Belt and Cooling Fan ............. 6B-13
Radiator ...................................................... 6B-14
Water Pump ................................................ 6B-15
Required Service Material ............................ 6B-17
Tightening Torque Specification ................. 6B-17

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-3
Radiator Cap
A pressure-vent cap is used on the radiator. The cap contains a
pressure valve (1) and ventilation valve (2).
The cap has its face marked 1.1, which means that its pressure
valve opens at 1.1 kg/cm
2 (15.6 psi, 110 kPa).
Coolant Reservoir
A “see-through” plastic reservoir (1) is connected to the radiator
by a hose.
Coolant level should be between “FULL” level mark (2) and
“LOW” level mark (3) on the reservoir.
Coolant should be added only to the reservoir as necessary.NOTE:
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.
WARNING:
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 caus-
ing 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 or causing a serious
fire.
[A]: At air bleed 3. From reservoir
[B]: At valves closed 4. To reservoir
[C]: At pressure relief 5. Pressure in radiator
[D]: At vacuum relief
NOTE:
When installing reservoir cap, set arrow marks (4) on the
reservoir and cap as the figure.

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.

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-5
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 6B-6 ENGINE COOLING
Maintenance
Coolant
The coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col-
lected in the reservoir.
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 either 50/50 mixture of water and
anti-freeze / anti-corrosion coolant (ethylene glycol antifreeze).
The 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).
Anti-freeze proportioning table
Coolant capacity Freezing temperature°C– 16– 36
°F3– 33
Anti-freeze / Anti-corrosion
coolant concentration%30 50
Ratio of compound
to cooling waterItr. 1.35/3.15 2.25/2.25
US pt. 2.85/6.65 4.75/4.75
Imp pt. 2.37/5.53 3.95/3.95
Engine radiator and heater 5.2 liters (11.0/9.2 US/lmp. pt.)
Reservoir 0.7 liters (1.5/1.2 US/lmp. pt.)
Total 5.9 liters (12.5/10.5 US/lmp. pt.)
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.
Even in a market where no freezing temperature is anticipated, mixture of 70% water and 30% ethyl-
ene glycol antifreeze (Antifreeze / Anticorrosion coolant) should be used for the purpose of corro-
sion protection and lubrication.

Downloaded from www.Manualslib.com manuals search engine ENGINE COOLING 6B-7
Coolant Level
To check level, look at “see-through” 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” (2) and “LOW”
(3) marks on reservoir (1).
If coolant level is below “LOW” mark, remove reservoir cap and
add proper coolant to reservoir to bring coolant level up to “FULL”
mark. Then, reinstall cap.
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 remov-
ing radiator cap when engine is cold.
3) Check coolant for proper level and freeze protection.
4) Using a pressure tester, check system and radiator cap for
proper pressure holding capacity 1.1 kg/cm
2 (15.6 psi, 110
kPa). If replacement of cap is required, use proper cap spec-
ified for this vehicle. WARNING:
To help avoid danger of being burned:
Do not remove reservoir cap while coolant is “boiling”,
and
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.
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.
When installing reservoir cap, set arrow marks (4) on
the reservoir and cap as the figure.
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 pres-
sure if cap is taken off too soon.

Downloaded from www.Manualslib.com manuals search engine 6B-8 ENGINE COOLING
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 slowly to the left 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 to the left.
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).
3) Stop engine and open radiator drain plug (1) to drain cool-
ant.
4) Close drain plug. Add water until system is filled and run
engine 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 tightly.
7) Disconnect hose from water reservoir (1). Remove reservoir
and pour out any fluid. Scrub and clean inside of reservoir
with soap and water. Flush it well with clean water and drain.
Reinstall reservoir and hose.
8) Add 50/50 mixture of good quality ethylene glycol antifreeze
and water to radiator and reservoir.
Fill radiator to the base of radiator filler neck and reservoir to
“FULL” level mark (2). Reinstall reservoir cap setting the
arrow marks (4) on the reservoir and cap as the figure. NOTE:
After installing radiator cap (1) to radiator, make sure that
its ear (2) is aligned with reservoir hose (3) as shown in
figure.
If not, turn cap more to align its ear with hose.
WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot. Scald-
ing fluid and steam can be blown out under pressure if
cap is taken off too soon.
3. LOW level mark