Suzuki Grand Vitara JB627. Manual - part 102

1F-2 Engine Cooling System: 

Schematic and Routing Diagram

Coolant Circulation

S6JB0B1602001

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[A]

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[B]

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[A]: When thermostat is close

3. Throttle body inlet hose

7. Throttle body

11. Heater core

[B]: When thermostat is open

4. Throttle body outlet hose

8. Engine

12. Radiator

1. Radiator inlet hose

5. Thermostat

9. Heater core inlet hose

13. Forward

2. Radiator outlet hose

6. Water pump

10. Heater core outlet hose

Engine Cooling System:  1F-3

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis

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Condition

Possible cause

Correction / Reference Item

Engine overheats 
(Radiator fan operates)

Loose or broken water pump belt

Adjust or replace.

Not enough coolant

Check coolant level and add as necessary.

Faulty thermostat

Replace.

Faulty water pump

Replace.

Dirty or bent radiator fins

Clean or remedy.

Coolant leakage on cooling system

Repair.

Clogged radiator

Check and replace radiator as necessary.

Faulty radiator cap

Replace.

Improper ignition timing

Refer to “Ignition System Symptom Diagnosis 
in Section 1H”.

Dragging brakes

Adjust brake.

Slipping clutch

Adjust or replace.

Poor charge battery

Check and replace as necessary.

Poor generation generator

Check and repair.

ECT sensor faulty

Check and replace as necessary.

Radiator cooling fan relay No.2 and/or 
No.3 faulty

Check and replace as necessary.

Radiator fan motor faulty

Check and replace as necessary.

ECM faulty

Check and replace as necessary.

Wiring or grounding faulty

Repair as necessary.

Equipped with too much electric load 
part(s)

Dismount.

Engine overheats 
(Radiator fan does not 
operate)

Fuse blown

Check radiator fan fuse of relay/fuse box and 
check for short circuit to ground.

Radiator cooling fan relay No.1 faulty

Check and replace as necessary.

ECT sensor faulty

Check and replace as necessary.

Radiator cooling fan motor faulty

Check and replace as necessary.

Wiring or grounding faulty

Repair as necessary.

ECM faulty

Check and replace as necessary.

1F-4 Engine Cooling System: 

Repair Instructions

Cooling System Components

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1. Radiator

9. Gasket

17. Left side cylinder head water hose

25. Main fan motor

2. Reservoir

10. O-ring

18. Heater outlet hose

26. Sub fan motor

3. Radiator cap

11. Water outlet pipe

19. Reservoir hose

27. Sub fan

4. Drain plug

12. Water inlet pipe

20. Heater inlet hose

28. Main fan

5. Radiator outlet hose

13. Thermostat case

21. Heater outlet pipe

29. Reservoir cap

6. Radiator inlet hose

14. Thermostat

22. Fan shroud

: 12 N

⋅m (1.2 kgf-m, 9.0 lb-ft)

7. Water outlet cap

15. Thermostat cap

23. To cylinder head

: Do not reuse.

8. ECT sensor

16. Right side cylinder head water hose

24. To heater core

Engine Cooling System:  1F-5

Coolant Level Check

S6JB0B1606002

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 radiator 
cap is taken off too soon.

 

To check level, lift hood and look at “see-through” 
coolant 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” mark 
(2) and “LOW” mark (3) on reservoir (1).
If coolant level is below “LOW” mark (3), remove 
reservoir cap (4) and add proper coolant to reservoir to 
bring coolant level up to “FULL” mark (2).

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, and 
are unnecessary expense.

 

Engine Cooling System Inspection and 
Cleaning

S6JB0B1606003

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.

 

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.
4) Using a pressure tester (1), check system and 

radiator cap (2) for proper pressure holding capacity.
If replacement of cap is required, use a proper cap 
for this vehicle.

NOTE
After installing radiator cap to water outlet 
cap, make sure that the ear of cap lines is 
parallel to radiator.

 

Cooling system and radiator cap holding 
pressure (for inspection)
110 kPa (1.1 kg/cm

2

, 15.6 psi)

5) Tighten hose clamps and inspect all hoses. Replace 

hoses whenever cracked, swollen or otherwise 
deteriorated.

6) Clean frontal area of radiator core.

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