Engine cooling replace SUZUKI SWIFT 2005 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine Engine Cooling System: 1F-8
Thermostat Removal and InstallationS7RS0B1606007
Removal1) Drain coolant referring to “Cooling System Draining”.
2) Remove intake manifold referring to “Intake Manifold Removal and Installa tion in Section 1D”.
3) Remove generator referring to “Generator Dismounting and Remounting in Section 1J”.
4) Disconnect water hose (1) and heater hose (2) from each pipe.
5) Remove thermostat case (3) with thermostat cap (4)
and water inlet pipe (5).
6) Remove water inlet pipe with thermostat cap from thermostat case.
7) Remove thermostat from thermostat case (3).
Installation
Reverse removal procedure for installation noting the
following points.
• Install thermostat cap (1) to thermostat case (2) by aligning match mark (3) of thermostat case with air
bleed valve (4) of the thermostat (5).
• Use new O-rings when installing.
• Adjust water pump belt tension referring to “Water Pump / Generator Drive Belt Tension Inspection and
Adjustment in Section 1J”.
• Adjust A/C compressor belt tension referring to “Compressor Drive Belt Inspection and Adjustment in
Section 7B” or “Compressor Drive Belt Inspection and
Adjustment in Section 7B”. • Refill cooling system referrin
g to Step 7) to 22) of
“Cooling System Flush and Refill”.
• Verify that there is no coolant leakage at each connection.
Thermostat InspectionS7RS0B1606008
• Make sure that air bleed valve (1) of thermostat is clean.
• Check to make sure that va lve seat (2) is free from
foreign matters which would prevent valve from
seating tight.
• Check thermostat seal (3) for breakage, deterioration or any other damage.
• 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 specific temperature.
Temperature at which valve begins to open
80 – 84 °C (176 – 183 °F)
Temperature at which valve become fully open
95 – 97 °C (203 °F)
Va l v e l i ft
More than 8 mm at 95 °C (203 ° F)
If valve starts to open at a temperature substantially
below or above specific temperature, thermostat unit
should be replaced with a new one. Such a unit, if
reused, will bring about ov ercooling or overheating
tendency.
I3RM0A160007-01
4
5 3
1 2
I7RS0B160006-01
2. Thermometer
3. Heater
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I2RH01160012-01

Downloaded from www.Manualslib.com manuals search engine 1F-9 Engine Cooling System:
Radiator Cooling Fan Motor On-Vehicle
Inspection
S7RS0B1606009
1) Check low speed operation of radiator cooling fan as follows.
a) Connect battery to fan motor coupler as shown in figure.
b) Check that radiator cooling fan rotates smoothly. If any abnormality is found, replace fan motor.
2) Check high speed operation of radiator cooling fan as follows.
a) Connect battery to fan motor coupler as shown in figure.
b) Check that radiator cooling fan rotates smoothly and its rotational speed is faster than low speed
operation.
If any abnormality is found, replace fan motor.
Reference: Fan motor sp ecified current at 12
V
Low speed operation: 14.0 A maximum
High speed operation: 18.0 A maximum
Radiator Cooling Fan Relay InspectionS7RS0B1606010
1) Disconnect negative (–) cable at battery.
2) Remove radiator cooling fa n relay No.1 (1), No.2 (2)
and/or No.3 (3) from relay box.
3) Check that there is no continuity between terminal “C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “B”
of relay.
5) Connect battery negative (–) terminal “A” of relay.
6) Check continuity between terminal “C” and “D”. If there is no continuity when relay is connected to the
battery, replace relay.
[A]: Low speed operation
[B]: High speed operation
[A] [B]
I7RS0B160007-01
“D”
“B” “A”
“C”
1
2
3
I4RS0B160004-01

Downloaded from www.Manualslib.com manuals search engine 1F-11 Engine Cooling System:
Water Pump Removal and InstallationS7RS0B1606014
Removal1) Disconnect negative cable at battery.
2) Drain coolant.
3) Remove water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Removal and
Installation in Section 1J”.
4) Remove water pump assembly (1).
Installation 1) Apply sealant to mating surface of water pump (1) as shown in the figure.
“A”: Water tight sealant 99000–31250 (SUZUKI
Bond No.1207F)
Sealant quantity (to mating surface of water
pump)
Width “a”: 3 mm (0.12 in.)
Height “b”: 2 mm (0.08 in.) 2) Install water pump assemb
ly (1) to cylinder block
and tighten bolts and nut to specified torque.
Tightening torque
Water pump bolt and nut (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)
3) Install water pump pulley.
4) Install water pump / generator drive belt referring to “Water Pump / Generator Drive Belt Tension
Inspection and Adjustment in Section 1J”.
5) Install A/C compressor belt (if equipped) referring to “Compressor Drive Belt Inspection and Adjustment
in Section 7B” or “Compressor Drive Belt Inspection
and Adjustment in Section 7B”.
6) Refill cooling system referri ng to Step 7) to 22) of
“Cooling System Flush and Refill”.
7) Connect negative cable at battery.
8) Check each part for leakage.
Water Pump InspectionS7RS0B1606015
CAUTION!
Do not disassemble water pump.
If any repair is requir ed 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, replace it.
I2RH0B160016-01
I3RM0A160016-01
I2RH0B160018-01
I2RH0B160019-01

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-2
Lower than recommended pressure can cause:
• Tire squeal on turns
• Hard Steering
• Rapid and uneven wear on the edges of the tread
• Tire rim bruises and rupture
• Tire cord breakage
• High tire temperature
• Reduced handling
• High fuel consumption
Replacement Tires
When replacement is necessary, the original equipment
type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load
range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride,
handling, speedometer / odometer calibration, vehicle
ground clearance and tire or snow chain clearance to the
body and chassis.
It is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to
equalize braking traction.
WARNING!
Do not mix different types of tires on the
same vehicle such as radial, bias and bias-
belted tires except in emergencies, because
handling may be seriously affected and may
result in loss of control.

The metric term for tire infl ation pressure is the kilo
pascal (kPa). Tire pressures is usually printed in both
kPa and kgf/cm
2 on the “Tire Placard”.
Metric tire gauges are available from tool suppliers.
The chart, shown the table, converts commonly used
inflation pressures from kPa to kgf/cm
2 and psi.
Wheels DescriptionS7RS0B2401002
Wheel Maintenance
Wheel repairs that use welding, heating, or peening are
not approved. All damaged wheels should be replaced.
Replacement Wheels
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, air leak through welds,
have elongated bolt holes, if lug wheel bolts won’t stay
tight, or if they are heavily rusted. Wheels with greater
runout than shown in the following may cause
objectional vibrations.
Replacement wheels must be equivalent to the original
equipment wheels in load capacity, diameter, rim with
offset and mounting configuration. A wheel of improper
size or type may affect wheel and bearing life, brake
cooling, speedometer / odometer calibration, vehicle
ground clearance and tire clearance to body and
chassis.
How to Measure Wheel Runout
To measure the wheel runout, it is necessary to use an
accurate dial indicator. The tire may be on or off the
wheel. The wheel should be installed to the wheel
balancer of the like for proper measurement.
Take measurements of both lateral runout “a” and radial
runout “b” at both inside an d outside of the rim flange.
With the dial indicator set in place securely, turn the
wheel one full revolution slowly and record every reading
of the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Lateral runout limit “a”
: 0.3 mm (0.012 in.)
Radial runout limit “b”
: 0.3 mm (0.012 in.)
kPa kgf/cm2psi
Conversion: 1 psi =
6.895 kPa 1 kgf/cm
2 =
98.066 kPa 160 1.6 23
180 1.8 26
200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
300 3.0 44
I4RS0A240001-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-7
Diagnostic Information and Procedures
A/C System Symptom DiagnosisS7RS0B7214001
ConditionPossible cause Correction / Reference Item
No cool air comes out (A/
C system does not
operate) No refrigerant
Perform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blown Check related fuses, and then check for short
circuit to ground.
A/C switch faulty Check A/C switch referring to “A/C Switch
Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Evaporator thermistor (Evaporator
temperature sensor) faulty Check evaporator thermistor (evaporator
temperature sensor) referring to “Evaporator
Thermistor (Evaporator Temperature Sensor)
Inspection”.
A/C refrigerant pressure sensor faulty Check A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check ECM referring to “A/C System
Inspection at ECM”.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Compressor relay faulty Check compressor relay referring to
“Compressor Relay Inspection”.
BCM faulty Check BCM referring to “Inspection of BCM
and its Circuits in Section 10B”.
No cool air comes out
(radiator cooling fan
motor does not operate) Fuse blown
Check related fuses, and then check for short
circuit to ground.
Wiring or grounding faulty Repair as necessary.
Radiator cooling fan motor relay faulty Check radiator cooling fan motor relay
referring to “Radiator Cooling Fan Relay
Inspection in Section 1F”.
Radiator cooling fan motor faulty Check radiator cooling fan motor referring to
“Radiator Cooling Fan Removal and
Installation in Section 1F”.
ECM and/or its circuit faulty Check ECM and/or its circuit referring to “A/C
System Inspection at ECM”.
No cool air comes out
(blower motor does not
operate) Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection in Section 7A”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection in Section
7A”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.

Downloaded from www.Manualslib.com manuals search engine 7B-8 Air Conditioning System: Manual Type
Cool air does not come
out or insufficient cooling
(A/C system normal
operation)Insufficient or excessive charge of
refrigerant
Check the amount of refrigerant and system
for leaks.
Condenser clogged Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
A/C evaporator clogged or frosted Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Evaporator thermistor (Evaporator
temperature sensor) faulty Check evaporator thermistor (Evaporator
temperature sensor) referring to “Evaporator
Thermistor (Evaporator Temperature Sensor)
Inspection”.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Desiccant clogged Replace receiver/dryer.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor faulty Check compressor.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Air leaking from HVAC unit or air duct Repair as necessary.
Heater and ventilation system faulty Check HVAC unit.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
system circuit and compressor.
Cool air does not come
out only intermittently Wiring connection faulty
Repair as necessary.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Excessive moisture in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Excessive amount of refrigerant Check the amount of refrigerant.
Cool air comes out only
when driving vehicle at
high speed Condenser clogged
Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
Insufficient charge of refrigerant Check the amount of refrigerant and system
for leaks.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air does not come
out only when driving
vehicle at high speed Excessive amount of refrigerant
Check the amount of refrigerant.
A/C evaporator frosted Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 7B-10 Air Conditioning System: Manual Type
Abnormal Noise from Tension Pulley
Abnormal Noise from A/C Evaporator
Abnormal Noise from Blower Motor
A/C System Performance InspectionS7RS0B7214003
1) Confirm that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95
° F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• Air filter in HVAC unit is not clogged with dirt and
dust.
• Battery voltage is about 12 V.
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly
closed.
3) Connect high pressure charging hose (3) to high pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
4) Bleed the air in charging hoses (3) and (4) by loosening their nuts respectively utilizing the
refrigerant pressure. When a hissing sound is heard,
immediately tighten nut.
CAUTION!
Do not connect high and low pressure
charging hoses in reverse.

Condition Possible cause Correction / Reference Item
Clattering noise is heard
from pulley Worn or damaged bearing
Replace tension pulley.
Pulley cranks upon
contact Cracked or loose bracket
Replace or retighten bracket.
ConditionPossible cause Correction / Reference Item
Whistling sound is heard
from A/C evaporator Depending on the combination of the
interior / exterior temperatures, engine
rpm and refrigerant pressure, the
refrigerant flowing out of the expansion
valve may, under certain conditions,
make a whistling sound At times, slightly decrea
sing refrigerant volume
may stop this noise.
Inspect expansion valve and replace if faulty.
Condition Possible cause Correction / Reference Item
Blower motor emits a
chirping sound in
proportion to its speed of
rotation Worn or damaged motor brushes or
commutator
Replace blower motor.
Fluttering noise or large
droning noise is heard
from blower motor Leaves or other debris introduced from
fresh air inlet to blower motor
Remove debris and make sure that the screen
at fresh air inlet is intact.
53
2
1
4 6
I4RS0A720006-01

Downloaded from www.Manualslib.com manuals search engine 7B-12 Air Conditioning System: Manual Type
High pressure gauge
Low pressure gaugeCondition Possible cause Correction
Pressure is higher than
acceptable range
(“A” area) Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high pressure side Clean or replace.
Radiator cooling fan malfunction
(Insufficient cooling of condenser)
Check radiator cooling fan.
Dirty or bent condenser fins
(Insufficient cooling of condenser) Clean or repair.
Compressor malfunction (Insuffi cient oil etc.) Check compressor.
Engine overheat Check engine cooling system
referring to “Engin
e Cooling Symptom
Diagnosis in Section 1F”.
Pressure is lower than
acceptable range
(“B” area) Insufficient refrigerant
(Insufficient charge or leakage)
Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction
(valve opens too wide) Check expansion valve.
Compressor malfunction
(Insufficient compression) Check compressor.
Condition Possible cause Correction
Pressure is higher than
acceptable range
(“C” area) Expansion valve malfunction
(valve opens too wide)
Check expansion valve.
Compressor malfunction
(Insufficient compression) Check compressor.
Pressure is lower than
acceptable range
(“D” area) Insufficient refrigerant
(Insufficient charge or leakage)
Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction
(valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-13
11) Check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature
near air inlet of HVAC unit is 30 °C (86 °F) and the one at air outlet of center ventilation louver is 17 °C (62.6 °F),
their crossing point is within acceptable range as shown in the graph. In this case, cooling performance is
satisfactory and proper.
12) If crossing point is out of acceptable range, diagnose trouble referring to the following table.
Thermometer at center duct
NOTE
If ambient temperature is approximately 30 °C (86 °F), it is possible to diagnose A/C system in detail
referring to the following table.

[A]: Temp at air outlet of center ventilation louver [C]: Humidity
[B]: Temp near air inlet of HVAC unit [D]: Acceptable range
ConditionPossible cause Correction
Crossing point is higher
than acceptable range
(“E” area) Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins
Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in
cooling (heater) unit Repair or replace.
Compressor malfunct ion Check compressor.
Crossing point is lower
than acceptable range
(“F” area) Insufficient air volume from center duct
(Heater blower malfunction)
Check blower motor and fan.
Compressor malfunct ion Check compressor.
8 9
10 11 12 13 14
15 16 17 18 19
20
21
22
23
24
25 26
27
28
46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4
66.2 68.0
69.8
71.6
73.4
75.2
77.0
78.8 80.6
82.4
25 30 35
77 86 95
F C
C
F
“E”
“F”30 70 %
[A]
[B][C]
[D]
I7RS0A721007-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-15
A/C System Inspection at ECMS7RS0B7214004
Voltage Check
When checking voltage at ECM connector terminals related to A/C system, refer to “DTC P2101: Throttle Actuator
Control Motor Circuit Range / Performance in Section 1A”.
0.40 – 0.45
(4.0 – 4.5)
(57 – 64)
2.0 – 2.5
(20 – 25)
(285 – 355) High pressure reading on
both low and high
pressure sides.
Overcharged A/C
system.
Adjust refrigerant to
specified amount.
Faulty condenser
cooling operation. Clean condenser.
Faulty radiator cooling
fan operation. Inspect and repair
radiator cooling fan.
High pressure reading on
both low and high
pressure sides.
Low pressure side tubing
is not cold when touched. Presence of air in A/C
system
(Improperly
evacuated).Replace receiver/
dryer.
Inspect quantity of
compressor oil and
presence of
contaminants in oil.
Evacuate system and
recharge with fresh
refrigerant.
0.45 – 0.55
(4.5 – 5.5)
(64 – 78) High pressure reading on
both low and high
pressure sides.
Large amount of frost or
dew on the low pressure
side tubing.Faulty expansion
valve.
Refrigerant flow is not
regulated properly.
Replace expansion
valve.
Condition
Possible cause Correction
Manifold gauge MPa (kg/cm
2) (psi)
Detail
Lo Hi