48601-94501 Suzuki Piston, Piston Rod Assembly

2. Remove the bolts, elbow (1) and the gaskets from the cover assembly and the cover.3. Disconnect hose assembly (3) from the housing assembly.4. Disconnect heater hose (4) from cover (2).5. Remove the bolts and cover (2) from the housing assembly. 6. Remove bolts (7) that hold the water pump to the bonnet.7. Remove four nuts (5), one bolt and water pump (6) from the front timing gear cover.Install Water Pump
1. Inspect all O-ring seals and gaskets for wear or damage and make a replacement if necessary. 2. Make sure the O-ring seal is in position on water pump (1) and the gasket is in position on the bonnet. Install water pump (1) on the timing gear cover. Install the bolt and the nuts that hold it.3. Install the bolts that hold the water pump to the bonnet. 4. Install cover (3) on the housing assembly.5. Connect heat hose (4) to the cover.6. Connect hose assembly (5) to the housing assembly.7. Install the gaskets and elbow (2) on the cover assembly and the cover.8. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.Disassemble Water Pump
START BY:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and the washer. 4. Remove impeller (4) from the water pump housing with tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and the bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove the lip type seal from the gear side of the water pump. Remove the ring and seal from the impeller side of the water pump.Assemble Water Pump
1. Put clean engine oil or glycerine on the lip of seal (1). Use tooling (A) to install seal (1). Install the seal with the lip up as shown. 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install the washer and bolt that hold gear (6) to shaft (2).
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.
5. Put ceramic ring (10) in position in rubber seal (9). Use hand pressure and tool (11) (which is with the replacement ring) to install the ceramic ring in the housing. 6. Remove the spring from seal assembly (12). Use hand pressure and tool (11) (which is with the replacement ring) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact. 7. Install spring (13) on the seal assembly and impeller (14) on the shaft. Install the bolt and washer on the shaft. Tighten the bolt to a torque of 39 3 N m (29 2 lb. ft.). 8. Install O-ring seals (15) on adapter (16). Put clean engine oil on the O-ring seals.9. Install adapter (16) in the pump housing. Make sure the notch in the adapter is in alignment with dowel (17).END BY:a. install water pump