13111-94410-0ED Suzuki Inlet Case

1. Remove two bolts. Remove upper pump manifold (2). Check condition of O-ring and replace as necessary. Use 1U6395 O-ring Assembly Compound at assembly.2. Disconnect coolant fitting (3).3. Loosen two hose heater clamps and remove two hoses (4).4. Remove two bolts on pump end of lower pump manifold (5) and remove clamp from other end. Remove or rotate manifold away from pump. Check condition of o-ring. Replace as necessary. Use 1U6395 O-ring Assembly Compound at assembly.5. Loosen two lower radiator hose clamps and slide hose (6) away from pump. 6. Remove seven bolts marked "X" and remove water pump (1). The weight of the pump is 27 kg (60 lb). For installation of pump, replace all gaskets and reverse the order of the removal steps.End By:a. fill coolant to correct levelDisassemble Water Pump
Start By:a. remove water pump 1. Remove four bolts. Remove water pump manifold. The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.2. Remove O-ring seal (1) from the adapter.3. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.4. Remove bolt (3) and the retainer that hold the impeller on the shaft. 5. Use tooling (A) to remove impeller (4) from the shaft. 6. Remove the spring and seal (5) from the shaft. 7. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.8. Remove O-ring seal (8) from the housing. 9. Remove gear and shaft assembly (10) from the housing.10. Remove bolt (9) and the retainer from the shaft assembly. 11. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 12. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 13. Remove lip-type seal (15) from the housing.14. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer to clean shaft (8) and the seal counterbore in the pump housing.2. Install bearing (4), spacer (3) and bearing (2) on shaft (8).3. Put retainer (1) and gear (7) in position on the shaft assembly. Install retainer (6) and bolt (5). 4. Use tooling (A) to install the lip seal in the housing as shown. Put a small amount of clean SAE 30 Oil on the lip of the seal. 5. Install a new O-ring seal (10) on the housing.6. Put shaft assembly (9) in position in the housing. Install the bolts that hold the retainer to the housing.
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.
7. Put ceramic ring (12) in position in rubber seal (11). 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.8. Remove the spring from seal assembly (13). Use hand pressure and tool (B) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact. 9. Install spring (15) on the shaft.10. Put impeller (14) in position on the shaft. Install the washer and bolt that holds it. Tighten the bolt to a torque of 39 3 N m (29 2 lb ft). 11. Install O-ring seal (17) on the outside diameter of the adapter. Put a small amount of clean SAE 30 Oil on the O-ring seal.12. Install O-ring seal (18) on the adapter.13. Put adapter (16) in position on the housing. 14. Install water pump manifold and four bolts.End By:a. install water pumpb. add coolant to the correct level