11301-96302-02M Suzuki Cylinder Assembly

Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g03818123
Typical example
Illustration 2 g03818172
Typical example
Disconnect engine harness assembly (10) for exhaust gas recirculation valve (2).
Remove harness (10) from clip (9).
Remove bolts (3) and bolts (5) from tube assembly (1). Support the exhaust gas recirculation valve as the bolts (3) are removed.
Remove tube assembly (1) from exhaust cooler (NRS) (7) and exhaust gas recirculation valve (2).
Remove gasket (4) (not shown) and gasket (6) (not shown).
Remove exhaust gas recirculation valve (2) from the inlet manifold (12).
Remove gasket (13) (not shown).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5598 Anti-Seize Compound 1
Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.Dispose of all fluids according to local regulations and mandates.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Inspect inside the exhaust gas recirculation valve for deposits or debris. Use a suitable clean lint free cloth with a suitable engine cleaner to clean inside the exhaust gas recirculation valve.
Illustration 3 g03818123
Typical example
Illustration 4 g03818172
Typical example
Clean the gasket surface of exhaust gas recirculation valve (2).
Ensure that tube assembly (1) is clean and free from restriction, wear, and damage. If necessary, replace the tube assembly.
Position a new gasket (13) (not shown) onto exhaust gas recirculation valve (2). Ensure that the gasket is correctly orientated.
Position exhaust gas recirculation valve (2) onto inlet manifold (12).
Position a new gasket (3) (not shown) between tube assembly (1) and exhaust gas recirculation valve (2).
Position tube assembly (1) onto exhaust cooler (NRS) (7).
Apply Tooling (A) to the threads of bolts (3).
Loosely install bolts (3) to tube assembly (1).
Position a new gasket (6) (not shown) onto tube assembly (1).
Position tube assembly (1) onto exhaust cooler (NRS) (7).
Apply Tooling (A) to the threads nuts (5).
Loosely install nuts (5) to tube assembly (1).
Install harness assembly (10) into clip (11).
Tighten bolts (3) and nuts (5) to a torque of 25 N m (221 lb in). Ensure that tube assembly (1) is not strained as the bolts are tightened.
Connect engine harness assembly (8) to harne