Cooling Water Pipes or Hoses Removal and Installation: Installation

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install removed parts in reverse order of removal procedure, noting the followings.

Install thermostat case (1) to cylinder block with new O-ring (4).
Install water outlet pipe (2) to thermostat case (1) with new O-rings (4).
Install water outlet cap (3) to cylinder heads with new gaskets.

Fig 1: Identifying Thermostat Case, Water Outlet Pipe, Water Outlet Cap & O-Rings
Courtesy of SUZUKI OF AMERICA CORP.
Connect heater hose (5) to water outlet cap (3).
Connect ECT sensor (4) coupler.

Fig 2: Connecting ECT Sensor Coupler
Courtesy of SUZUKI OF AMERICA CORP.
Install throttle body and intake manifold.
For H25 engine model, refer to INTAKE MANIFOLD .

For H27 engine model, refer to THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION .
Install radiator outlet pipe (3) to thermostat case with new O-ring.
Install radiator inlet hose (1) and outlet hose (2).

Fig 3: Installing Radiator Inlet & Outlet Hoses
Courtesy of SUZUKI OF AMERICA CORP.
Refill cooling system with proper coolant, referring to COOLANT DESCRIPTION and COOLING SYSTEM FLUSH AND REFILL .