Suzuki Aerio, Verona 2002-06

Removal & Installation

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2.0L And 2.3L Engines





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Fig. Water pump and related components-2.0L and 2.3L engines

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container and tighten the drain plug.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not lose dowel pins when removing water pump.



    Condenser cooling fan (if equipped with A/C)
     
    Radiator outlet hose from thermostat cap
     
    Heater outlet pipe bolt
     
    Serpentine belt
     
    Compressor from its bracket with hoses still attached (if equipped with A/C)
     
    Water pump bolts and the water pump
     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Do not forget to install dowel pins on water pump side before mounting water pump to cylinder block.


    WARNING
    Use NEW bolts to install water pump to cylinder block. Failure to do so may result water leakage.



    New O-ring to water pump.
     



    Heater outlet pipe to water pump
     



    Water pump with new bolts to cylinder block and tighten to 18 ft. lbs. (25 Nm)
     
    Compressor to its bracket (if equipped with A/C)
     
    Heater outlet pipe bolt
     
    Radiator outlet hose to thermostat cap
     
    Serpentine belt
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and top off the coolant as necessary.
  8.  
  9. Check the cooling system for leaks.
  10.  

2.5L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system and tighten the drain plug.
  6.  
  7. Remove or disconnect the following:

    Serpentine belt
     
    Coolant hose from the thermostat housing and the water pump
     
    Power steering pump mounting bolts
     
    Alternator
     
    Compressor
     
    Bracket bolts
     
    Auto tensioner mounting bolt and auto tensioner
     
    Water pump mounting bolts and water pump
     
    Water pump gasket
     

  8.  
  9. Inspect the water pump body for cracks and leaks.
  10.  
  11. Clean the mating surfaces of the water pump and the engine block.
  12.  

To install:

  1. Clean the water pump mounting surface of old gasket material.
  2.  
  3. Install or connect the following:

    New water pump gasket to the water pump
     
    Water pump onto the engine block and tighten the mounting bolts to 17 ft. lbs. (23 Nm)
     
    Auto tensioner with the mounting bolt. Tighten the auto tensioner bolt to 33 ft. lbs. (45 Nm).
     
    Bracket and bracket bolts. Tighten the bracket retaining bolts to 33 ft. lbs. (45 Nm).
     
    Power steering pump and retaining bolts. Tighten the power steering pump retaining bolts to 18 ft. lbs. (25 Nm).
     
    Compressor
     
    Alternator
     
    Serpentine belt
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and top off the coolant as necessary.
  10.  
  11. Check the cooling system for leaks.
  12.  

5-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug cover
     
    Fuel line clips
     
    Expansion tank
     
    Accessory drive belts
     
    Crankshaft damper guard
     
    Front wheel
     
    Inner fender panel
     
    Front timing cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Timing belt
     
    Front timing cover
     
    Inner fender panel
     
    Front wheel
     
    Crankshaft damper guard
     
    Accessory drive belts
     
    Expansion tank
     
    Fuel line clips
     
    Spark plug cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Water pump and gasket



    Click image to see an enlarged view

    Fig. Water pump installation

  6.  

6-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Raise the car.
  6.  
  7. Remove the lower engine splash guard.
  8.  
  9. Open the engine nipple. Drain the coolant into a container. Close the nipple.
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the bolts holding the pump at the cylinder block.
  14.  
  15. Tap the pump wheel using the shaft of a hammer. Remove the pump.
  16.  

To install:

  1. Carefully clean the gasket face.
  2.  
  3. Install a new gasket and the coolant pump. Tighten crosswise. Tighten to 13 ft. lbs. (17 Nm).
  4.  
  5. Install the timing belt.
  6.  
  7. Remove the lock grip pliers from the lower coolant hose.
  8.  
  9. Install the lower engine splash guard.
  10.  
  11. Remove the lock grip pliers from the upper coolant hose.
  12.  
  13. Fill coolant and check the level.
  14.  
  15. Check the power steering fluid level.
  16.  

8-Cylinder Engine



  1. Remove the expansion tank cap.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove protective 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.

  6.  
  7. Remove the 6 bolts.
  8.  
  9. Lift and slide the protective plate forward.
  10.  
  11. Remove the protective plate.
  12.  
  13. Draining coolant
  14.  
  15. Open the cock on the lower left edge of the radiator.
  16.  
  17. Drain the coolant into a clean receptacle.
  18.  
  19. Close the cock.
  20.  
  21. Install the protective plate.
  22.  
  23. Loosen the 4 bolts of the coolant pump belt pulley a few turns.
  24.  
  25. Remove the belt.
  26.  
  27. Remove the 4 bolts of the belt pulley.
  28.  
  29. Remove the 7 bolts of the coolant pump and the coolant pump. Discard the gasket.

    Click image to see an enlarged view

    Fig. Protective plate-8-cylinder engines

  30.  

To install:

Click image to see an enlarged view

Fig. Water pump-8-cylinder engines

  1. Clean the gasket surface for the coolant pump.
  2.  
  3. Install a new gasket and the coolant pump. Tighten the M6 bolts to 88 inch lbs. (10 Nm).
  4.  
  5. Position the belt pulley but do not tighten the bolts.
  6.  
  7. Install the auxiliary belt.
  8.  
  9. Tighten the 4 M6 bolts of the belt pulley to 88 inch lbs. (10 Nm).
  10.  
  11. Fill with coolant.
  12.  
  13. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluid as necessary.
  14.  

 
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