09116-08110 Suzuki BOLT (8X65)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
Ensure that all adjustments and repairs that are carried out to the Diesel Emission 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 Emission 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. Note: If the DEF tank is to be drained, ensure that the Electronic Control Module (ECM) is powered off before commencing the draining procedure. Failure to ensure that the ECM is powered off will cause the DEF level gauge to read incorrectly during the draining procedure and will not be accurate until the tank has been refilled.
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Illustration 1 g03730127
Remove the Diesel Emission Fluid (DEF) line from connection (3) (not shown) from manifold Diesel Exhaust Fluid (DEF) heater (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Remove the diesel emission fluid line from connection (6) from manifold DEF heater (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to cap connection (6) and connection (3) (not shown).
Use Tooling (A) to plug the DEF lines.
Loosen the hose clamps on the hose assemblies. Disconnect the hose assemblies from connection (4) and connection (5) from manifold DEF heater (7).
Use Tooling (A) to cap connection (4) and connection (5).
Use Tooling (A) to plug the hose assemblies.
Disconnect the harness assembly from harness assembly (9).
Remove Torx screws (1) from ring (2). Remove the ring from manifold DEF heater (7).
Remove manifold DEF heater (7) from DEF tank (10).
Remove O-ring seal (8) from manifold DEF heater (7).
Illustration 2 g03730136
If necessary, follow Step 4.a through Step 5 in order to remove filter (12) from manifold DEF heater (7).
Remove Torx screw from filter (12).
Remove filter (12).
Illustration 3 g03730140
If necessary, follow Step 15.a through Step 15.d in order to disassemble DEF tank (10).
Ensure that the area around cap on the DEF tank is clean. Drain DEF tank (10). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Tank - Flush" the correct procedure.
Remove plug (16) from DEF tank (10). Remove O-ring seal (15) from the plug.
Remove filler cap (13) from DEF tank (10).
Use a suitable tool, in order to press locking tabs (17) and remove filter screen (14) from the neck of DEF tank (10). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 247-5377 Torque Wrench 1
B - T15 Torx 1/4" Hexagon Drive 1
C - T25 Torx 1/4" Hexagon Drive 1
Ensure that the manifold DEF heater, DEF tank, filter, and filter screen are free from wear, damage, clean, and free from restriction. Replace any component that is not free from wear, damage, and free from restriction.
If necessary, clean DEF filler screen. Refer to Operation and Maintenance Manual, "DEF Filler Screen - Clean" the correct procedure.
Illustration 4 g03730140
If necessary, follow Step 3.a through Step 3.c in order to assemble DEF tank (10).
Install a new O-ring seal (15) to plug (16). Install the plug to DEF tank (10). Tighten the plug to a torque of 6 N m (53 lb in).
Install filter screen (14) to the neck of DEF tank (10).Ensure that locking tabs (17) are correctly engaged into the neck of DEF tank.
Install filler cap (13) to DEF tank (10).
Illustration 5 g03730136
If necessary, follow Step 4.a through Step 4.b in order to install filter (12) to manifold DEF heater (7).
Install filter (12) to manifold DEF heater (7). Ensure that the filter is correctly positioned onto the manifold DEF heater.
Install Torx screw to filter (12)