Suzuki Aerio, Verona 2002-06

Removal & Installation

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CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Be sure the engine is cold before removing the radiator.
  2.  
  3. Disconnect or remove:
    NOTE
    Do not allow engine coolant to contact the accessory drive belt.



    Engine fan, refer to Engine Fan removal and installation.
     
    Evacuation hose from the expansion tank.
     
    Upper and lower radiator hoses.
     



    Disconnect and plug the oil cooler hoses from the automatic transaxle.
     
    Four bolts on sides of radiator.

    Click image to see an enlarged view

    Fig. Radiator and bolt location

     

  4.  
  5. Remove the two radiator mounting bolts.
  6.  
  7. Remove radiator from underneath vehicle.

    Click image to see an enlarged view

    Fig. Removing the Radiator

  8.  

To install:

  1. Lift radiator into position from underneath vehicle.
  2.  
  3. Install:
    NOTE
    Ensure that the radiator is positioned correctly in the locating pins on top of the unit and no hoses are trapped when installing the radiator.



    The two M8 mounting bolts and tighten to 18 ft. lbs. (24 Nm)
     



    Four M6 bolts on sides of radiator and tighten to 88 inch lbs. (10 Nm).
     
    Connect and oil cooler hoses from the automatic transaxle.
     
    Upper and lower radiator hoses.
     
    Evacuation hose into expansion tank
     
    Engine fan, refer to Engine Fan removal and installation.
     

  4.  
  5. Be sure to refill the cooling system using the proper grade and type of engine coolant.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Run engine and allow it to reach full operating temperature. Recheck the coolant level and transaxle fluid level. Fill as required.
  10.  


CAUTION
Be careful not to damage fins of radiator. If radiator fin is bent, straighten it by using flat head screwdriver or pair of pliers.

  1. Disconnect negative cable at battery.
  2.  
  3. Drain cooling system by loosening drain plug of radiator.
  4.  
  5. Disconnect connector of cooling fan motor.
  6.  
  7. Remove condenser cooling fan (if equipped with A/C).
  8.  
  9. Remove reservoir (1).
  10.  
  11. Disconnect radiator inlet (2) and outlet hoses from radiator.
  12.  
  13. Disconnect A/T fluid hoses from radiator, if equipped with A/T vehicle.
  14.  
  15. Remove radiator cooling fan assembly (3).
  16.  
  17. Remove radiator.

    Click image to see an enlarged view

    Fig. Removing and installing radiator

  18.  

To install:

  1. Reverse removal procedures, noting the following.
  2.  
  3. Refill cooling system with proper coolant.
  4.  
  5. After installation, check each joint for leakage.
  6.  
  7. Check automatic fluid level (for A/T vehicle).
  8.  

 
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