Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Coolant Temperature Sender

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TESTING



See Figures 1, 2, 3, 4 and 5

  1. Remove the coolant temperature sender from the engine.
  2.  
  3. Position the sender in a container of water on your stove, as shown in the accompanying illustration.
  4.  



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Fig. Fig. 1: To test the sender, position it in a container full of water and slowly heat it on your stove



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Fig. Fig. 2: As the temperature of the water increases, the resistance of the sender should decrease

Refer to the accompanying charts for the approximate resistance at varying temperatures.

  1. Using an ohmmeter, measure and note the sender terminal-to-sender metal housing resistance.
  2.  
  3. Slowly heat the water in the container and observe the sender resistance exhibited on the ohmmeter. The resistance of the sender should smoothly and steadily decrease as the water temperature increases.
  4.  
  5. If the sender resistance does not react as noted, replace the sender with a new one.
  6.  



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Fig. Fig. 3: The sender should create the resistances shown in this chart, depending on its temperature-1986-95 1.3L and 1.6L engines



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Fig. Fig. 4: If the sender's resistance values are not within the specified ranges at the temperature indicated, replace the sender with a new one-1996-98 1.6L engines



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Fig. Fig. 5: The sender used in 1.8L engines should exhibit the indicated values when tested

REMOVAL & INSTALLATION



See Figures 6 and 7

On 1.3L and 1.6L engines, the coolant temperature sender is mounted in the front of the intake manifold. On the 1.8L engine, the sender is mounted next to the water outlet cap.



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Fig. Fig. 6: On the 1.3L and 1.6L engines, the temperature sender is mounted in the front of the intake manifold



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Fig. Fig. 7: The temperature sender (ECT sensor) used on 1.8L engines is mounted next to the water outlet cap and pipe

  1. Disconnect the negative battery cable.
  2.  
  3. Label and detach the wire from the sender unit.
  4.  
  5. Drain the cooling system until the coolant level is below the sender.
  6.  
  7. Remove the sender with an open end wrench.
  8.  

To install:
  1. Clean the sender threads, then wrap Teflon® pipe sealing tape around the sender threads.
  2.  
  3. Install the sender by hand, then tighten the sender to 71 inch lbs. (8 Nm).
  4.  
  5. Reattach the sender wire.
  6.  
  7. Connect the negative battery cable, and refill the cooling system.
  8.  

 
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