16091-94900 Suzuki BOLT

3. Remove elbow (1) and fan drive lubricant tube (2).4. Loosen the clamps on hose (7), and move the hose down from cover (5).5. Disconnect cab heater return hose (6) at the valve.6. Mark the location of coolant conditioner hoses (3) and (4), and disconnect them at the fittings. 7. Remove O-ring seal (13) from elbow (11).8. Remove elbow (11) and tube (9).9. Disconnect cab heater supply valve (10) at the fitting.10. Remove four bolts (12) that hold the water pump to the bonnet. Remove O-ring seal (8) from the water pump. 11. Remove four nuts (15) and one bolt that hold water pump (14) to the timing gear housing.12. Remove the water pump and O-ring seal. The following steps are for installation of the water pump.13. Be sure the mating surface of the water pump and timing gear housing is clean.14. Be sure the mating surface of the water pump and bonnet is clean.15. Install a new O-ring seal on water pump (14).16. Install a new gasket between the water pump and the bonnet while installing the water pump on the timing gear housing.17. Install the four nuts and one bolt that hold water pump (14) to the timing gear housing.18. Install four bolts (12) that hold the water pump to the bonnet.19. Connect cab heater supply valve (10) to the fitting.20. Put clean glycerine on the O-ring seals, and install elbow (11) and tube (9). Install a new O-ring seal (13) in the elbow.21. Connect the coolant condition hoses (3) and (4) to the fittings. Connect the hoses in their original location.22. Connect cab heater return hose (6) to the valve.23. Move hose (7) into position on cover (5), and tighten the hose clamps.24. Install elbow (1) with new gaskets, and install fan drive lubricant tube (2).25. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.Disassemble Water Pump
Start By: a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and the washer. 4. Remove impeller (4) from the water pump housing with tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and the bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove the lip-type seal from the gear side of the water pump. Remove the ring and seal from the impeller side of the water pump.13. Use 6V1541 Quick Cure Primer to clean shaft (10) and the seal counterbore in the pump housing.Assemble Water Pump
1. Install seal (1) with tooling (A) as shown. Put clean engine oil on the lip of the seal. 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install washer and bolt that hold gear (6) to shaft (2).
Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Put ceramic ring (10) in position in rubber seal (9). Use hand pressure and tool (B) to install the ceramic ring in the housing.
Avoid contaminating the seal faces with grease or oil. Also, avoid stretching the rubber seal during installation.
The carbon seal assembly must rotate with the water pump shaft after installation.6. Remove spring (12) from seal assembly (11). Use hand pressure and the tool (which is with the replacement ring) to install the seal (11) assembly. Push seal assembly on the shaft until the seal face makes light contact.7. Install spring (12) on the shaft. 8. Install impeller (14) and the washer and nut (13) that hold the impeller to the pump shaft. Make an air pressure test of the seal at 140 kPa (20 psi). 9. Put clean engine oil on the O-ring seals (15). Install the O-ring seals on adapter (16).10. Install adapter (16) in the pump housing with the notch in alignment with dowel (17).End By: a. install water pump