Suzuki Esteem, Swift 1994-02

Removal & Installation

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Click image to see an enlarged view

Fig. Water pump location-1.3L engine

1.3L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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 push the center pin too far in, or it will fall off into the fender.



    Air cleaner assembly and the Mass Air Flow (MAF) sensor and outlet hose
     
    Air cleaner bracket
     
    Right side fender apron clips by pushing the center pin
     



    Power steering and air conditioning belt, if equipped
     
    Loosen the water pump pulley bolts
     
    Alternator drive belt
     
    Water pump pulley
     

  8.  
  9. To remove the crankshaft pulley perform the following:
    1. If equipped with a manual transaxle, insert a suitable flat bladed tool into the hole in the bell housing next to the exhaust pipe. This will lock the crankshaft in place.
    2.  
    3. If equipped with an automatic transaxle, hold a suitable flat bladed tool in line with the oil pan and insert into the teeth of the drive plate. This will lock the crankshaft in place.
    4.  
    5. Loosen the crankshaft pulley bolts.
    6.  
    7. Remove the crankshaft timing belt pulley bolt with a 17mm socket.
    8.  
    9. Remove the pulley from the crankshaft.
    10.  
    11. Install the crankshaft bolt.
    12.  
    13. Remove the flat bladed tool that was used to lock the crankshaft in place.
      NOTE
      To remove the crankshaft pulley with the engine assembly mounted on the body, it is necessary to remove the crankshaft timing belt pulley bolt. If the engine assembly is dismounted, the bolt does not need to be removed.

    14.  

  10.  
  11. Remove or disconnect the following:
    CAUTION
    After the timing belt is removed never turn the camshafts or the crankshaft. Interference may occur between the pistons and the valves causing component damage.



    Resonator and the timing belt outside cover
     
    Loosen the right engine mounting bolt
     
    Timing belt
     



    Timing belt inside cover
     
    Water pump belt adjusting arm
     

  12.  
  13. Carefully remove the rubber seal between the water and oil pumps, and remove the seal between the water pump and the cylinder head.
  14.  
  15. Remove or disconnect the following:

    Water pump bolts and the water pump
     

  16.  

To install:

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

    New water pump gasket on the cylinder block
     
    Water pump on the cylinder block and tighten the bolts to 84-108 inch lbs. (10-13 Nm)
     
    Rubber seal between the water pump and the oil pump
     
    Seal between the water pump and the cylinder head
     
    Water pump belt adjusting arm
     

  4.  
  5. Install the timing belt inside cover.
  6.  
  7. With the crankshaft locked in position, remove the crankshaft bolt and install the crankshaft pulley. Tighten the crankshaft pulley bolts to 10-13 ft. lbs. (14-18 Nm). Using a 17mm socket, tighten the crankshaft timing belt pulley bolt to 76-83 ft. lbs. (105-115 Nm).
  8.  
  9. Install or connect the following:

    Timing belt
     
    Water pump pulley and drive belt. Tighten the water pump pulley bolts to 84-96 inch lbs. (9-12 Nm).
     
    Remaining components in the reverse order of removal
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and top off the coolant as necessary.
  16.  
  17. Check the cooling system for leaks.
  18.  
  19. Check the ignition timing.
  20.  



Click image to see an enlarged view

Fig. Water pump location-1.3L engine

  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 push the center pin too far in, or it will fall off into the fender.



    Air cleaner assembly and the Mass Air Flow (MAF) sensor and outlet hose
     
    Air cleaner bracket
     
    Right side fender apron clips by pushing the center pin
     



    Power steering and air conditioning belt, if equipped
     
    Loosen the water pump pulley bolts
     
    Alternator drive belt
     
    Water pump pulley
     

  8.  
  9. To remove the crankshaft pulley perform the following:
    1. If equipped with a manual transaxle, insert a suitable flat bladed tool into the hole in the bell housing next to the exhaust pipe. This will lock the crankshaft in place.
    2.  
    3. If equipped with an automatic transaxle, hold a suitable flat bladed tool in line with the oil pan and insert into the teeth of the drive plate. This will lock the crankshaft in place.
    4.  
    5. Loosen the crankshaft pulley bolts.
    6.  
    7. Remove the crankshaft timing belt pulley bolt with a 17mm socket.
    8.  
    9. Remove the pulley from the crankshaft.
    10.  
    11. Install the crankshaft bolt.
    12.  
    13. Remove the flat bladed tool that was used to lock the crankshaft in place.
      NOTE
      To remove the crankshaft pulley with the engine assembly mounted on the body, it is necessary to remove the crankshaft timing belt pulley bolt. If the engine assembly is dismounted, the bolt does not need to be removed.

    14.  

  10.  
  11. Remove or disconnect the following:
    CAUTION
    After the timing belt is removed never turn the camshafts or the crankshaft. Interference may occur between the pistons and the valves causing component damage.



    Resonator and the timing belt outside cover
     
    Loosen the right engine mounting bolt
     
    Timing belt
     



    Timing belt inside cover
     
    Water pump belt adjusting arm
     

  12.  
  13. Carefully remove the rubber seal between the water and oil pumps, and remove the seal between the water pump and the cylinder head.
  14.  
  15. Remove or disconnect the following:

    Water pump bolts and the water pump
     

  16.  

To install:

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

    New water pump gasket on the cylinder block
     
    Water pump on the cylinder block and tighten the bolts to 84-108 inch lbs. (10-13 Nm)
     
    Rubber seal between the water pump and the oil pump
     
    Seal between the water pump and the cylinder head
     
    Water pump belt adjusting arm
     

  4.  
  5. Install the timing belt inside cover.
  6.  
  7. With the crankshaft locked in position, remove the crankshaft bolt and install the crankshaft pulley. Tighten the crankshaft pulley bolts to 10-13 ft. lbs. (14-18 Nm). Using a 17mm socket, tighten the crankshaft timing belt pulley bolt to 76-83 ft. lbs. (105-115 Nm).
  8.  
  9. Install or connect the following:

    Timing belt
     
    Water pump pulley and drive belt. Tighten the water pump pulley bolts to 84-96 inch lbs. (9-12 Nm).
     
    Remaining components in the reverse order of removal
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and top off the coolant as necessary.
  16.  
  17. Check the cooling system for leaks.
  18.  
  19. Check the ignition timing.
  20.  

1.6L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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:

    Timing belt
     
    Alternator adjusting arm
     
    Oil dipstick guide and dipstick
     
    Water pump bolts, gasket, water pump and rubber seal
     

  8.  

To install:

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

    New water pump gasket on the cylinder block
     
    Water pump on the cylinder block and tighten the bolts to 96 inch lbs. (11 Nm)
     
    Rubber seal between the water pump and the oil pump
     
    Seal between the water pump and the cylinder head
     
    Timing belt
     
    Alternator adjusting arm
     
    Oil dipstick guide and dipstick using a new O-ring
     

  4.  
  5. Adjust drive belt tension.
  6.  
  7. Fill the cooling system with engine coolant.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and top off the coolant as necessary.
  12.  
  13. Check the ignition timing.

    Click image to see an enlarged view

    Fig. Exploded view of the water pump mounting-1.6L engine

  14.  

  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:

    Timing belt
     
    Alternator adjusting arm
     
    Oil dipstick guide and dipstick
     
    Water pump bolts, gasket, water pump and rubber seal
     

  8.  

To install:

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

    New water pump gasket on the cylinder block
     
    Water pump on the cylinder block and tighten the bolts to 96 inch lbs. (11 Nm)
     
    Rubber seal between the water pump and the oil pump
     
    Seal between the water pump and the cylinder head
     
    Timing belt
     
    Alternator adjusting arm
     
    Oil dipstick guide and dipstick using a new O-ring
     

  4.  
  5. Adjust drive belt tension.
  6.  
  7. Fill the cooling system with engine coolant.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and top off the coolant as necessary.
  12.  
  13. Check the ignition timing.

    Click image to see an enlarged view

    Fig. Exploded view of the water pump mounting-1.6L engine

  14.  

1.8L Engine




WARNING
Check to make sure that engine coolant temperature is cold before removing any part of cooling system.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove radiator outlet hose from thermostat cap.

    Click image to see an enlarged view

    Fig. Heater outlet pipe bolt (1), thermostat cap (2) and exhaust manifold cover (3)-1.8L engine

  8.  
  9. Remove heater outlet pipe bolt.
  10.  
  11. Remove accessory drive belt.
  12.  
  13. Remove radiator (for vehicle with A/C only).
  14.  
  15. Remove A/C compressor from its bracket with hose still attached (if equipped).
  16.  
  17. Remove water pump assembly by removing its 4 bolts. Do not lose dowel pin when removing water pump.

    Click image to see an enlarged view

    Fig. Water pump (1) and O-ring (2) assembly-1.8L engine

  18.  

To install:

  1. Install new O-ring to water pump. Do not forget to install dowel pins on water pump side before mounting water pump to engine block.
  2.  
  3. Install heater outlet pipe to water pump, then install water pump by using new bolts to cylinder block and tighten to 18 ft. lbs. (25 Nm).
  4.  
  5. Install A/C compressor to its bracket.
  6.  
  7. Install radiator.
  8.  
  9. Install heater outlet pipe bolt.
  10.  
  11. Install accessory drive belt.
  12.  
  13. Install radiator outlet hose to thermostat cap.
  14.  
  15. Fill the cooling system with engine coolant.
  16.  
  17. Connect the negative battery cable.
  18.  

 
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