61635-98602 Suzuki Pin

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.
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 correct procedure.
Illustration 1 g03795137
Disconnect harness assembly (3) from coolant temperature sensor (4).
Remove bolt (2) and clip (1).
Illustration 2 g03795140
Remove bolt (6).
Remove water temperature regulator connection (5) and gasket (7) from water temperature regulator housing (9).
Illustration 3 g06558807
Identify the location of the jiggle pin in Position (X) and the orientation of water temperature regulator (8) for installation purposes. Remove the water temperature regulator from water temperature regulator housing (9).
If necessary, follow Step 7a through Step 7f to remove the water temperature regulator housing from the cylinder head.
Remove nuts (10) and bolts (11).
Loosen the hose clamp (14) and disconnect the hose assembly (15) from water temperature regulator housing (9).
Remove water temperature regulator housing (9) from the cylinder head.
Remove gasket (13) (not shown).
If necessary, remove studs (12) from the cylinder head. Note position of studs for installation purposes.
If necessary, remove coolant temperature sensor (4) from water temperature regulator housing (9). Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install" for the correct procedure.Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components are clean and free from wear or damage. Replace and component the are worn or damaged.
Ensure that the gasket surfaces of the cylinder head and the water temperature regulator housing are clean and free from damage.
Illustration 4 g03795140
Illustration 5 g03795137
If necessary, follow Step 3a through Step 3h to install the water temperature regulator housing to the cylinder head.
If necessary, install coolant temperature sensor (4) to water temperature regulator housing (9). Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install" for the correct procedure.
If necessary, install studs (12) to the cylinder head. Ensure that the studs are installed into the correct positions.
Tighten studs (12) to a torque of 10 N m (89 lb in).
Position a new gasket (13) (not shown) onto studs (12). Ensure that the gasket is correctly orientated.
Install water temperature regulator housing (9) onto the cylinder head.
Install nuts (10) and bolts (11) to water temperature regulator housing (9).
Tighten nuts (10) and bolts (11) to a torque of 10 N m (89 lb in).
Connect hose assembly (15) to water temperature regulator housing (9). Tighten hose clamp (14) securely.
Check water temperature regulator (8) for correct operation. Refer to System, Operation, Testing and Adjusting, "Water Temperature Regulator - Test" and Specifications, "Water Temperature Regulator" for the correct procedure and the correct information. If the water temperature regulator is not operating correctly, the complete assembly must be replaced.
Ensure that the gasket surfaces of water temperature regulator housing (9) and water temperature regulator connection (5) are clean and free from damage.
Illustration 6 g06558788
Illustration 7 g06558831
Install water temperature regulator (8) to water temperature regulator housing (9).Ensure that the jiggle pin in Position (X) is correctly located in Position (Y) in the water temperature regulator housing.Ensure that the water temperature regulator is correctly orientated and is seated correctly in the recess of the water temperature regulator housing.
Position a new gasket (7) onto water temperature regulator housing (9). Ensure that the gasket is correctly orientated.
Install water temperature regulator connection (5) onto water temperature regulator housing (9). Ensure that the water temperature regulator connection is correctly orientated.
Install bolt (6) finger tight.
Install harness assembly (3) to coolant temperature sensor (4). Install clip (1) and install bolt (2) finger tight.
Tighten bolt (2) and bolt (6) to a torque of 15 N m (133 lb in) .
Connect the hose assembly to water temperature regulator connection (1). Tighten the hose clamp securely.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.