Suzuki Vitara, Grand Vitara, XL7 2000-06

Removal & Installation

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1.6L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Cooling fan and shroud
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Oil dipstick tube
     
    Alternator bracket
     
    Timing belt tensioner
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 106 inch lbs. (12 Nm).
     
    Timing belt tensioner
     
    Alternator bracket
     
    Oil dipstick tube. Tighten the bolt to 97 inch lbs. (11 Nm).
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Front cover
     
    Cooling fan and shroud
     
    Accessory drive belts
     
    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. Exploded view of the water pump mounting-1.6L engines

  6.  

  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
     
    Accessory drive belts
     
    Cooling fan and shroud
     
    Front cover
     
    Timing belt
     
    Oil dipstick tube
     
    Alternator bracket
     
    Timing belt tensioner
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 106 inch lbs. (12 Nm).
     
    Timing belt tensioner
     
    Alternator bracket
     
    Oil dipstick tube. Tighten the bolt to 97 inch lbs. (11 Nm).
     
    Timing belt
     
    Front cover
     
    Cooling fan and shroud
     
    Accessory drive belts
     
    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. Exploded view of the water pump mounting-1.6L engines

  6.  

1.8L And 2.0L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator hose at the thermostat housing
     
    Heater outlet pipe bolt
     
    Alternator belt
     
    Water pump
     

  6.  

To install:


NOTE
Use new water pump bolts for assembly.

  1. Install or connect the following:

    Water pump with a new O-ring seal. Tighten the bolts to 19 ft. lbs. (27 Nm).
     
    Alternator belt
     
    Heater outlet pipe bolt
     
    Radiator hose at the thermostat housing
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.0L Engine



  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
     
    Radiator hose at the thermostat housing
     
    Heater outlet pipe bolt
     
    Alternator belt
     
    Water pump
     

  6.  

To install:


NOTE
Use new water pump bolts for assembly.

  1. Install or connect the following:

    Water pump with a new O-ring seal. Tighten the bolts to 19 ft. lbs. (27 Nm).
     
    Alternator belt
     
    Heater outlet pipe bolt
     
    Radiator hose at the thermostat housing
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.5L & 2.7L 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
     
    Accessory drive belts
     
    Front timing cover
     
    Water pump

    Click image to see an enlarged view

    Fig. Water pump

     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new O-ring seal. Tighten the bolts to 19 ft. lbs. (27 Nm).
     
    Front timing cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

2.5L Engine



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new O-ring seal. Tighten the bolts to 19 ft. lbs. (27 Nm).
     
    Front cover
     
    Accessory drive belts
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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