09103-06189 Suzuki BOLT, NO.7 (6X110)

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relive pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Mark and identify hose assemblies for installation purposes. Cap and plug hose assemblies to avoid system contamination.1. Drain the coolant from the radiator to a level below the aftercooler. 2. Remove two bolts (2) and the washers that hold bracket (1) to elbow (7). Remove bracket (2) from elbow (7).3. Disconnect hose assemblies (3) and (6) from elbow (7). Remove two bolts (5) and the washers that hold plate assembly (4) to elbow (7). Remove plate assembly (4) from elbow (7). Repeat this procedure for the remaining hose assembly, located on the other side of elbow (7). 4. Remove two bolts (8) from elbow (7). Remove elbow (7) from air inlet cover (9). The weight of elbow (7) is 19 Kg (41 lb). 5. Remove two bolts (11) and the washers from air inlet cover (9). Remove two O-rings (10) from air inlet cover (9). 6. Remove six bolts (12) from air inlet cover (9). Remove air inlet cover (9) from aftercooler core assembly (13). The weight of air inlet cover (9) is 20 Kg (44 lb) 7. Disconnect exhaust sensor wiring harness (14) at the electrical connection. Loosen hose clamp (17). Remove bolts two (16) and the washers from tube assembly (15). Remove tube assembly (15) and the O-ring seals from aftercooler core assembly (13). 8. Loosen hose clamp (19), not shown, on hose (18). Disconnect hose (18) from aftercooler core assembly (13). 9. Remove two bolts (20), the washers, and ring retainers (21) from aftercooler core assembly (13). 10. Using two people, remove aftercooler core assembly (13) and the seal from the engine. The weight of aftercooler core assembly (13) is 35 Kg (77 lb). The following steps are for the installation of the aftercooler. Inspect all O-ring seals for wear or damage and replace as necessary. 11. Using two people, install aftercooler core assembly (13) and the seal on the engine. The weight of aftercooler core assembly (13) is 35 Kg (77 lb). 12. Put ring retainers (21) on aftercooler core assembly (13). Install two bolts (20) and washers. 13. Connect hose (18) on aftercooler core assembly (13). Tighten hose clamp (19), not shown, on hose (18). 14. Put tube assembly (15) and the O-ring seal in position on aftercooler core assembly (13). Install two bolts (16) and the washers that hold tube assembly (15) to aftercooler core assembly (13). Tighten hose clamp (17). Connect exhaust sensor wiring harness (14) at the electrical connection. 15. Put air inlet cover (9) in position on aftercooler core assembly (13). Install six bolts (12) to aftercooler core assembly (7). The weight of air inlet cover (9) is 20 Kg (44 lb). 16. Install two O-ring seals (10) on air inlet cover (9). Install two bolts (11) and the washers in air inlet cover (9). 17. Put elbow (1) in position on air inlet cover (9). Install two bolts (8). 18. Put bracket (1) in position on elbow (7). Install two bolts (2) and the washers to bracket (1). Connect hose assemblies (3) and (6) to elbow (7). Put plate assembly (4) in position on elbow (7). Install two bolts (5) and the washers that hold plate assembly (4) to elbow (7).19. Refill the cooling system. The capacity of the cooling system is 300 L (79 U.S. gal). Refer to the Operations & Maintenance Manual for correct procedure.End By:a. install turbocharger