54166-90J11 Suzuki BOLT (12X231)

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     1U-9203     Lever Puller     1    
143-8695 Shackle     1    
143-8698 Spool     1    
208-5040 Bar     1    
6V-3145 Load Leveler     1    Start By:
Remove the engine compartment shield. Refer to Disassembly and Assembly, "Engine Compartment Shield - Remove".
Remove the hood and engine enclosure. Refer to Disassembly and Assembly, "Hood and Engine Enclosure - Remove".
Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand.Remove the cooling system pressure cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Care must be taken to ensure that fluids 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.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all lines, on all hoses, on all wires and on all tubes for installation purposes. Plug all lines, all hoses and all tubes. This will help to prevent fluid loss and this will help to keep contaminants from entering the system.
Drain the coolant from the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Illustration 1 g01081815
Remove side panels (1A) from both sides of the machine.
Illustration 2 g01081722
Disconnect harness assemblies (1) and (2). Remove clips (3) that hold harness assemblies (1) and (2) in position. Move harness assemblies (1) and (2) away from the engine and the torque converter.
Illustration 3 g01081724
Loosen clamp (4). Remove tube (5) .
Disconnect hose assemblies (6) and (7) .
Disconnect hose assemblies (8), (9), (10), and (11). Remove any clips that hold hose assemblies (8), (9), (10), and (11) to the engine.
Disconnect harness assemblies and cable assemblies from electrical starting motor (12). Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Illustration 4 g01081769
Loosen hose clamps (13) at both ends of tube (14). Remove tube (14) .
Loosen hose clamps (15) at both ends of tube (16). Remove U-bolt (17). Remove tube (16) .
Loosen hose clamps (20) and (21). Disconnect tubes (18) and (19).
Disconnect plate assembly 22, and move plate assembly 22 away from the engine.
Disconnect hose assemblies (23). Remove any clips that hold hose assemblies (23) to the engine.
Disconnect hose assembly (24) .
Loosen hose clamps (25) from both ends of tube (26). Remove tube (25) .
Illustration 5 g01081816
Remove clip (28) and tube (27) .Show/hi