99011-96J04-03A Suzuki MANUAL, OWNER'S

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - T25 Torx 1/4" Hexagon Drive 1
Ensure that all adjustments and repairs that are carried out to the Diesel Exhaust Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Exhaust Fluid (DEF) for the system 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 the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Illustration 1 g06147554
Remove the Diesel Exhaust Fluid (DEF) lines from connection (8) and connection (9) from manifold Diesel Exhaust Fluid (DEF) heater (4). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. Use Tooling (A) to cap the connections and plug DEF lines.
Remove the coolant lines from connection (7) and connection (10) from manifold DEF heater (4). Use Tooling (A) to cap the connections and plug the coolant lines.
Disconnect the Original Equipment Manufacturer (OEM) harness assembly from harness assembly (3) on manifold DEF heater (4).
Use Tooling (B) to remove Torx screws (2) from clamp (1).
Remove manifold DEF heater (4) from DEF tank (6).
Remove O-ring seal (5) and clamp (1) from manifold DEF heater (4).
Illustration 2 g06390703
If necessary, follow Step 9a through Step 9b to remove filter (12) from manifold DEF heater (4).
Use Tooling (B) to remove screw (11) from filter (12).
Remove filter (12) from manifold DEF heater (4).
Illustration 3 g06147757
If necessary, follow Step 10a through Step 10d to disassemble DEF tank (10).
Ensure that the area around cap on the DEF tank is clean. Drain DEF tank (10). Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Tank - Flush" the correct procedure.
Remove plug (16) from DEF tank (10). Remove O-ring seal (15) from the plug.
Remove filler cap (13) from DEF tank (10).
Use a suitable tool, to press locking tabs (17) and remove filter screen (14) from the neck of DEF tank (10).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A - T25 Torx 1/4" Hexagon Drive 1
B 247-5377 Torque Wrench 1
Ensure that the manifold DEF heater, DEF tank, filter, and filter screen are free from wear, damage, clean, and free from restriction. Replace any component that is not free from wear, damage, and free from restriction.
If necessary, clean DEF filler screen. Refer to Operation and Maintenance Manual, "DEF Filler Screen - Clean" the correct procedure.
Illustration 4 g06147757
If necessary, follow Step 3a through Step 3c to assemble DEF tank (10).
Install a new O-ring seal (15) to plug (16). Install the plug to DEF tank (10). Tighten the plug to a torque of 6 N m (53 lb in).
Install filter screen (14) to the neck of DEF tank (10).Ensure that locking tabs (17) are correctly engaged into the neck of DEF tank.
Install filler cap (13) to DEF tank (10).
Illustration 5 g06390703
If necessary, follow Step 4a through Step 4b to install filter (12) to manifold DEF heater (4).
Install filter (12) to manifold DEF heater (4). Ensure that the filter is correctly positioned onto the manifold DEF heater.
Install screw (11) to filter (12). Tighten the screw to a torque of 2 N m (16 lb in).
Illustration 6 g06147554