11400-95896 Suzuki Gasket Set

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the cooling system to a level below the transmission oil cooler.
At operating temperature, the transmission oil tank is hot and under pressure. Hot oil can cause burns. Remove the breather filter cap only when the engine is stopped and the breather filter cap is cool enough to touch. Slowly loosen the breather filter cap to release any pressure in the transmission tank. Be cautious of hot transmission oil when any lines are disconnected in the transmission system.
2. Drain the transmission oil to a level below the transmission oil cooler. 3. Disconnect and plug two hoses (1) from the transmission oil cooler bypass body. 4. Remove bolt (2), the washers and spacer that secures tube (3) to the bracket.5. Place tube (3) away from the bonnet. 6. Remove two bolts (5) and the washers that secure bonnet (6) to bracket (4). 7. Remove six bolts (7) that secure bonnet (6) to the brake oil cooler. 8. Remove bolt (8), the washers, spacer and bracket from bonnet (6).9. Remove the remaining five bolts (9) that secure bonnet (6) to the engine.10. Remove bonnet (6) from the oil coolers.11. Remove two O-ring seals from bonnet (6) where engine oil cooler (10) connects.12. Remove the gasket that seals the bonnet to the engine.13. Remove two O-ring seals from the transmission oil cooler where bonnet (6) connects. 14. Remove four bolts (11) from cooler inlet bonnet (12).15. Use two people and remove transmission oil cooler (13) from cooler inlet bonnet (12). The weight of transmission oil cooler is approximately 26 kg (57 lb).16. Remove the gasket from the end of transmission oil cooler (13).
The following steps are for the installation of the transmission oil cooler.
Prior to installation, inspect all parts for damage or wear. If necessary, replace worn or damaged parts with new parts. 17. Place the gasket and transmission oil cooler (13) in position on cooler inlet bonnet (12).18. Install four bolts (11) fastening transmission oil cooler (13) to cooler inlet bonnet (12). 19. Install the two O-ring seals on engine oil cooler (10) that seals engine oil cooler (10) and bonnet (6).20. Install the two O-ring seals in bonnet (6) that seals bonnet (6) and the transmission oil cooler.21. Place the gasket in position between bonnet (6) and the engine.22. Install bonnet (6) on the oil coolers.23. Install five bolts (9). Install one bolt (8), the spacer, washer and bracket in bonnet (6). 24. Install six bolts (1) securing bonnet (6) to the brake oil cooler. 25. Install two bolts (9) and the washers that secure bonnet (10) to bracket (8). 26. Install bolt (6), the washers and nut securing tube (7) to the bracket. 27. Install two bolts and washers (5) that fasten bonnet (6) to bracket (4). 28. Install bolt (2), the washers and nut fastening tube (3) to the bracket. 29. Connect two hoses (1) on the transmission oil cooler bypass valve.30. Refill the transmission with the proper oil. Refer to the Operation & Maintenance Manual, SEBU6968 for the correct capacity and fluid.31. Refill the coolant system with the proper coolant. Refer to the Operation & Maintenance Manual, SEBU6968 for the correct capacity and fluid.End By:a. install crankcase guards