09100-08203 Suzuki Bolt 8x85

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - De-ionized Water 1
Ensure that all adjustments and repairs that are carried out to the Diesel Exhaust Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Exhaust Fluid (DEF) for the system are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.
Turn turning the battery disconnect switch to the OFF position.
Illustration 1 g06375561
Illustration 2 g06149190
Ensure that the area around Diesel Exhaust Fluid (DEF) injector (4) is clean and free dirt and debris. If necessary, clean the area around the DEF injector. Clean the area around the DEF injector with Tooling (B) and a suitable tool.
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Coolant - Change" for the correct procedure.
Remove the Diesel Exhaust Fluid (DEF) line from connection (3) on DEF injector (4). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. Use Tooling (A) to cap connection (3) on DEF injector (4) and plug the DEF line.
Remove the coolant lines from connection (1) and connection (2) on DEF injector (4). Use Tooling (A) to cap the connections on the DEF injector and plug the coolant lines.
Ensure that no Diesel Exhaust Fluid (DEF) enters the harness assembly or the harness connection.
Disconnect the harness assembly from connection (8) on DEF injector (4). Use Tooling (A) to cap the harness assembly and the connection on the DEF injector.
Remove bolts (7) and washers (6) (not shown). Remove DEF injector (4) from mixer module (5).
Remove gasket seal (9) from DEF injector (4).Note: To remove the mixer module the DEF injector removal is not required. Removal of the DEF lines and the electrical connection is required. Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Illustration 3 g06375574
Illustration 4 g06375580
Illustration 5 g06382618
If necessary, follow Step 10a through Step 10h to remove mixer module (5).
Sufficiently loosen V-band clamp (10) and position V-band clamp (10) away from mixer module (5), to allow removal of mixer module (5).
Sufficiently loosen V-band clamp (12) and position V-band clamp (12) away from mixer module (5), to allow removal of mixer module (5) from Selective Catalyst Reduction (SCR) (11)
If the V-band clamp (10) and V-band clamp (12) remain tight on the flanges, apply releasing fluid on the V-band clamps to assist removal. Lightly tap the bolts on the V-band clamps with a soft faced hammer to assist removal. Do not use a prybar to remove V-band clamps.
Remove bolts (15) from mixer module support bracket (14).
Remove mixer module (5) from SCR (11) and combined DOC and DPF (13).
Remove seal (16) and sealing ring (17) from mixer tube (5).
Remove seal (19) and sealing ring (18) from mixer tube (5).
Remove V-band clamps and discard.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B - De-ionized Water 1
Ensure that the DEF injector and the mixer module are free from wear and damage. Replace any component that is worn or damaged.