36610-99EB0 Suzuki HARNESS ASSY, WIRING

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     138-7575     Link Bracket     2    Note: Check all of the O-ring seals and the components for wear or for damage. Replace the components, if necessary. Replace all of the gaskets prior to assembly. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed. Clean all of the components with a cloth that is free of loose material (lint).
Illustration 1 g00711179
Lubricate the sealing surface of seal (17) with 5P-3975 Rubber Lubricant. Position seal (17) and radiator core assembly (15) on the radiator bottom tank assembly. Install two bolts (16) and the hard washers that hold radiator core assembly (15) in position. Do not tighten the bolts at this time.
Repeat Step 1 for each of the radiator core assemblies (15) that need to be installed.
Illustration 2 g00572201
Adjust gap (X) at the front of the radiator to a distance of 6.5 mm (0.25 inch). Adjust gap (Y) at the rear of the radiator to a distance of 2.0 1.5 mm (0.08 0.06 inch).
Verify that none of the radiator core assemblies are touching each other. Tighten bolts (16) that hold the radiator core assemblies to the radiator bottom tank assembly.
Illustration 3 g00652889
Lubricate the sealing surface of the 23 seals (not shown) with 5P-3975 Rubber Lubricant. Position the 23 seals on the top surfaces of the 23 radiator core assemblies.
Attach Tooling (A) to radiator top tank assembly (11). Position a suitable lifting device on Tooling (A). Secure the lifting device to a suitable hoist. Lift radiator top tank assembly (11) into position on the radiator core assemblies, as shown. The weight of the radiator top tank assembly is 95 kg (209 lb).
Install 20 bolts (12) and the hard washers that hold radiator top tank assembly (11) to the channel assemblies.
Position five tube assemblies (14) on the radiator. Install 20 bolts (13) and the washers that hold five tube assemblies (14) to the radiator.Note: Four tube assemblies (14) are located in front of the radiator. The remaining tube assembly (not shown) is located behind the radiator.
Illustration 4 g00652864
Position wire harness (8) on the clips, as shown. Install four tie straps (7) that hold wire harness (8) to the radiator.
Install a new gasket on elbow (5) and on elbow (9). Position elbow (5) and elbow (9) to the top of the radiator. Install four bolts (6) that hold elbow (5) in position. Install four bolts (10) that hold elbow (9) in position.
Illustration 5 g00652863
Install nut (3), the hard washers, and the clips that hold two hose assemblies (4) to the radiator.
Illustration 6 g00652862
Position refrigerant condenser (1) on the radiator, as shown. Install four bolts (2), the nuts, and the hard washers that hold refrigerant condenser (1) to the radiator.
Fill the radiator with coolant to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". The capacity of the radiator is 268 L (71 US gal).End By: Install the radiator cowling. Refer to Disassembly and Assembly, "Cowling (Radiator) - Remove and Install".