Suzuki Aerio, Verona 2002-06

Removal & Installation

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  1. Disconnect negative cable at battery.
  2.  
  3. Remove condenser cooling fan (if equipped with A/C).
  4.  
  5. Disconnect connector of radiator cooling fan motor.
  6.  
  7. Remove radiator cooling fan motor (1) from radiator (2).

    Click image to see an enlarged view

    Fig. Removing and installing cooling fan

  8.  

To install:

Reverse removal procedure for installation.

5- & 6-Cylinder Engines



  1. Disconnect ground cable of battery.
  2.  
  3. Remove the skid plate:
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.



    Loosen the six bolts and remove
     
    Lift and slide skid plate forward
     



    Click image to see an enlarged view

    Fig. Skid plate removal

  4.  
  5. Remove the right charge air hose:

    Undo the clamp (1)
     
    Remove the two bolts holding charge air hose (2)
     
    Remove charge air hose from the charge air cooler
     
    Bend down the hose and pipe

    Click image to see an enlarged view

    Fig. Removing the right charge air hose-5- and 6-Cylinder Engines



    Click image to see an enlarged view

    Fig. Location of mounting bolts on radiator assembly

     

  6.  
  7. Undo the mounting bolts so that the radiator assembly is lowered approximately 3 / 4 inch (20mm).
    NOTE
    Do not remove the bolts completely.

  8.  
  9. Undo the radiator connector and tie straps.
  10.  
  11. Move aside the cable harness.

    Click image to see an enlarged view

    Fig. Location of tie straps, connector, and cable harness

  12.  
  13. Remove the bolts of the engine cooling fan mounting.
  14.  
  15. Detach the hose of the expansion tank from the clip on the engine cooling fan.
  16.  
  17. Pull the fan upward to release it from the lower mounting.
  18.  
  19. Remove fan through lower part of vehicle.
  20.  

To install:

  1. Installation is the reverse of the removal process.
    NOTE
    Make sure the hood cable is not pinched when the fan is installed.

  2.  
  3. Tighten the two M6 bolts of the engine cooling fan mounting to 88 inch lbs. (10 Nm).
  4.  
  5. Tighten the two M8 mounting bolts of the radiator assembly to 18 ft. lbs. (24 Nm).
  6.  
  7. Install the charge air hose to the charge air cooler and tighten the two M5 bolts (2) to 44 inch lbs. (5 Nm).
  8.  
  9. Install the skid plate and tighten the six M10 bolts to 37 ft. lbs. (50 Nm).
  10.  
  11. Connect the battery cable and tighten to 22 inch lbs. (3 Nm).
  12.  

 
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