12100-96103-050 Suzuki PISTON SET (OS:0.50)

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.
Mark and identify all hose assemblies for installation purposes. Cap and plug all hose assemblies to avoid system contamination. 1. Position a suitable container under drain plug (2) to contain the coolant for storage or disposal. Loosen drain plug (2) on plug adapter (1). Repeat this procedure on remaining drain plug. The capacity of the cooling system is 300 L (79 U.S. gal). 2. Turn valve (6) to the "Off" position.3. Remove two bolts (3), the washers, and two retainers (6) from elbow (5).4. Loosen hose clamp (7) and remove hose (8) from valve (6). 5. Disconnect hose assembly (10) from water pump (9). 6. Remove four bolts (11) that hold elbow (13) and the gasket to radiator (12). 7. For installation purposes, mark and identify bolts (14). Remove four bolts (14) that hold elbow (5) to water pump (9). Remove elbow (5) and the O-ring seal. 8. Remove four bolts (15) and the washers that hold water pump (9) to lines adapter (16).9. Remove four bolts (17) from water pump (9). Remove water pump (9), the O-ring seal, and the gasket from accessory drive (18) and lines adapter (16). The weight of water pump (9) is 20 Kg (45 lb). The following steps are for the installation of the water pump. Inspect all O-ring seals for wear or damage and replace as necessary. Clean all gasket material off all mating surfaces of accessory drive (15).10. Put water pump (9), the O-ring seal, and the gasket in position on accessory drive (15) and lines adapter (16). Install four bolts (17). The weight of water pump (9) is 20 Kg (45 lb).11. Install four bolts (15) and the washers that hold water pump (9) to the lines adapter (16). 12. Put elbow (5) in position on water pump (9). Install four bolts (14) that hold elbow (5) to water pump (9). 13. Clean all gasket material off mating surfaces of elbow (13).14. Position elbow (13) and the gasket on radiator (12). Install four bolts (11) that hold elbow (13) to radiator (12). 15. Connect hose assembly (10) to water pump (9). 16. Position hose (8) on valve (6), as shown. Tighten hose clamp (7) on hose (8).17. Put two retainers (4) on elbow (5), as shown. Install two bolts (3) and the washers.18. Turn valve (6) to the "On" position. 19. Close drain plug (2) on plug adapter (1). Repeat this procedure on the remaining drain plug. Fill the engine cooling system. The capacity of the cooling system is 300 L (79 U.S. gal).Disassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (4) from the back of pump housing assembly (3).2. Remove thrust washer (1) that holds pump drive shaft assembly (2) in pump housing assembly (3). 3. Remove pump inlet cover (5) from pump housing assembly (3). Remove the O-ring seal from pump inlet cover (5). 4. Loosen locknut (7) holding pump impeller (6) to the pump drive shaft. Use Tooling (A) to loosen pump impeller (6) from the end of the pump drive shaft. Remove Tooling (A), locknut (7), the washer and pump impeller (6) from the pump drive shaft assembly and pump housing assembly (3). 5. Remove spring (9) from face seal group (8) and pump drive shaft assembly (2).6. Use a soft hammer and push pump drive shaft assembly (2) out of face seal group (8) and pump housing assembly (3). Remove face seal group (8) from pump housing assembly (3). 7. Remove ceramic seal (10) from the rubber ring. Remove the rubber ring from pump housing assembly (3). 8. Remove lip seal (11) from the back of pump housing assembly (3).Assemble Water Pump
1. If necessary, replace the two filters in the pump housing assembly at location (12).2. If necessary, replace plug (13) and the seal beneath plug (13).3. Use Tooling (A) to install lip seal (11) in pump housing assembly (3). Make sure the lip of the seal faces toward the outside as shown. Lubricate lip seal (11) with the fluid being sealed. 4. Install pump drive shaft assembly (2) in pump housing assembly (3). Install thrust washer (1) and the bolts to hold pump drive shaft assembly (2) in position.
Use clean water as the only lubricant when installing face seal group (8). Use care when handling face seal group (8) during installation on pump drive shaft assembly (2). Touching the wear surfaces of the carbon or ceramic rings can cause contamination or damage. Install the smoothest face of the ceramic ring toward the carbon seal assembly.
5. Put ceramic seal (10) in position in the rubber ring. Use hand pressure and Tool (B) to install the ceramic seal and the rubber ring in the pump housing assembly. 6. Remove the spring from face seal group (8). Use hand pressure and Tool (B) to install the face seal group. Push the face seal group on the pump drive shaft assembly until the seal faces make light contact. 7. Install spring (9) on the face seal group.8. Put pump impeller (6) in position on the pump drive shaft assembly as shown. 9. Install the washer and locknut (7). Tighten locknut (7) to a torque of 200 25 N m (150 18 lb. ft.). 10. Install the O-ring seal on pump inlet cover (5). Lubricate the O-ring seal with the fluid being sealed. Position pump inlet