09116-08160 Suzuki BOLT (8X70)

1. Drain the coolant from the system.2. Remove four bolts (1) from the aftercooler water line (2). Repeat Step 1 for the lower water line.3. Remove four nuts and washers (3) and remove the water pump (4) and its gasket.4. Disconnect the aftercooler water line (2) and remove the gasket. The following steps are for the installation of the auxiliary water pump.5. Put the auxiliary water pump (4) in position with four nuts and washers (3).6. Connect water line (2) and install water line (1).7. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Auxiliary Water Pump
Start By:a. remove auxiliary water pump 1. Remove screws (1) and cover assembly (2) from body assembly (3). 2. Remove plate (5) and gasket (4) from the cover assembly. 3. Remove seal (6) and impeller assembly (7) from the body assembly. Make a note of the direction of the impeller blades for correct assembly. 4. Remove seal (8) from the shaft. 5. Use tool (A) and remove ring (10) from the shaft.6. Remove cover (9) [part of the seal assembly] from the body assembly. 7. Remove spring (11) [part of the seal assembly] from the body assembly. 8. Remove carbon seal (12) [part of the seal assembly] from the body assembly. 9. Remove bolts (14) and remove housing (13) from the body assembly (3). 10. Remove cam (15) and ceramic seal (16) [part of the seal assembly] from the body assembly (3). 11. Remove plate (17) from the body assembly. 12. Remove seal (18) from the shaft. 13. Use tool (B) and remove ring (19) from the housing. 14. Use a press and remove shaft (20) and the bearings from the housing. 15. Use a press and tool (C) to remove bearings (21) from the shaft (20). 16. Remove seal (22) from housing (13).Assemble Auxiliary Water Pump
1. Use tool group (A) and install seal (1) in housing (2). Make sure the lip of the seal is toward the bearing bore as shown. Put 1P808 General Purpose Lubricant on the lip of the seal. 2. Use a press and tool (B) to install bearings (4) on shaft (3). 3. Put 1P808 General Purpose Lubricant on the bearings and in the bearing bore of housing (2).4. Use a press and install shaft (3) and the bearings in housing (2). 5. Use tool (C) and install ring (5) in the housing. 6. Inspect seal (6) for wear or damage and make a replacement if necessary.7. Put clean engine oil on seal (6) and install the seal on the shaft as shown. 8. Put plate (8) in position in the body assembly as shown. 9. Make an alignment of the dowel (10) in body assembly (7) with cam (9). Install cam (9) in body assembly. 10. Install housing (2) on body assembly (7) and install the bolts that hold the two together. Parts (11), (12), (13) and (14) come as a seal assembly only.11. Put clean engine oil on the rubber part only of ceramic seal (11).12. Put clean engine oil in the seal bore of the body assembly and install ceramic seal (11), polished surface toward the impeller. If the face of the seal is damaged (marked or scratched) a replacement must be made. 13. Install seal (12) in the body assembly with the polished carbon seal face of the seal toward the ceramic seal. 14. Install spring (13) and cover (14) in the body assembly. 15. Use tool (D) and install ring (15) on the shaft that holds the seal assembly in place. 16. Inspect seal (16) for wear or damaged and make a replacement if necessary.17. Put clean engine oil on seal (16) and install on the shaft. 18. Put a small amount of 1P808 General Purpose Lubricant in the impeller bore.19. Make sure all impeller blades are bent in the same direction and in the correct direction of rotation.20. Use tool (E) and install impeller assembly (17) in the body assembly. 21. Install seal (18) in the impeller assembly. 22. Install gasket (19) and plate (21) on cover assembly (20).23. Make an alignment of the dowel in cover assembly (20) and the dowel hole in the cam and install cover assembly (20) with the screws that hold it.End By:a. install auxiliary water pump