16400-96J00 Suzuki PUMP ASSY, OIL

Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
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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.
Turn the battery disconnect switch to the OFF position.
Disconnect harness assembly (5) from harness assembly (4).
Release clip (7) from adaptor (6) and position harness assembly (5) away from pre-exhaust gas valve cooler (8).
Cut cable strap (9) and position harness assembly (11) away from pre-exhaust gas valve cooler (8).
Remove bolts (1) and heat shield (2) from manifold (3).
Remove bolts (12) from manifold (3).
Remove bolt (10) from pre-exhaust gas valve cooler (8).
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Remove bolts (15) and remove adaptor (6) from the cylinder head.Note: The pre-exhaust gas valve cooler (8) should be supported as the bolts are removed.
Remove gasket (14) (not shown) and O-ring seal (19) (not shown).
Prior to and during removal of bolts (18) apply releasing fluid to the bolts. Remove the bolts from pre-exhaust gas valve cooler (8).Note: The pre-exhaust gas valve cooler (8) should be supported as the bolts are removed.
Remove the pre-exhaust gas valve cooler from exhaust manifold (16) and exhaust gas valve (3).
Remove gasket (17) (not shown) and gasket (20) (not shown) from pre-exhaust gas valve cooler (8).
Remove O-ring seal (13) (not shown) from pre-exhaust gas valve cooler (8).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - P-80 Emulsion Rubber Assembly Lubricant 1
B - Anti-Seize Compound 1
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that the pre-exhaust gas valve cooler is clean and free from restriction. Ensure that the pre-exhaust gas valve cooler is free from wear and damage. If necessary, replace any components that are worn or damaged.
Ensure that all tube assemblies are free from restriction and damage.
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Apply Tooling (A) new O-ring seal (13) (not shown) and new O-ring seal (20) (not shown). Install the new O-ring seals to pre-exhaust gas valve cooler (8).
Install new gasket (20) (not shown) and new gasket (17) (not shown) to pre-exhaust gas valve cooler (8).
Apply Tooling (B) to the threads of bolts (12).
Position the pre-exhaust gas valve cooler onto exhaust gas valve (3) and exhaust manifold (16). Install bolts (12) and bolt (10) finger tight.
Install new bolts (18) finger tight.
Install new gasket (14) (not shown) onto adaptor (6). Position the adaptor onto the cylinder head and pre-exhaust gas valve cooler (8). Install bolts (15) finger tight.
Tighten bolts (12) to a torque of 22 N m (195 lb in).
Tighten bolts (18) to a torque of 22 N m (195 lb in).
Tighten bolts (15) and bolt (10) to a torque of 22 N m (195 lb in).
Position heat shield (2) onto exhaust gas valve (3) and install bolts (1). Tighten the bolts to a torque of 5 N m (44 lb in).
Position harness assembly (11) onto the bracket for the pre-exhaust gas valve cooler and install cable strap (9).Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specification.
Connect harness assembly (5) to harness assembly (4).
Install clip (7) to adaptor (6).
Turn the battery disconnect switch to the ON position.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.