48720-94521 Suzuki Pipe, tilt inlet

Table 1
Required Tools
Tool Part Number Part Description Qty
A - P-80 Emulsion Rubber Assembly Lubricant 1
B - Anti-seize compound 1 Start By:
Remove the fuel filter bracket. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
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.
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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: When three or more components of the NOx Reduction System (NRS) have been removed, the first component to be installed must be the NRS manifold.
Illustration 1 g06220745
Illustration 2 g06221497
Illustration 3 g06221505
Position NOx Reduction System (NRS) manifold (4) onto the cylinder head. Install bolts (5) and bolt (6) finger tight.
Install gasket (8) (not shown) to NRS manifold (4).
Position exhaust gas valve (2) onto NRS manifold (4). Install bolts (7) finger tight.
Illustration 4 g06221560
Ensure that the exhaust gas cooler is clean and free from restriction. Ensure that the exhaust 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.Note: The internal components of the NRS exhaust gas cooler should not be disassembled or cleaned.
Apply Tooling (A) to new O-ring seal (12) (not shown). Install new O-ring seal (12) to exhaust gas valve (2).
Install bolts (9) and gasket (10) (not shown) to post-exhaust gas valve cooler (1).Note: The gasket should be fitted so the side tab is on the left-hand side with part number facing inwards.
Install bolts (11) and gasket (13) (not shown) to exhaust cooler (1).
Position post-exhaust gas valve cooler (1) onto exhaust gas valve (2).
Tighten bolts (9) and bolts (11) finger tight.
Illustration 5 g06221618
Illustration 6 g06221619
Apply Tooling (A) to new O-ring seal (22) (not shown). Install new O-ring seal (22) to NRS manifold (4).
Install gasket (18) (not shown) to pre-exhaust gas valve cooler (3).
Install gasket (23) (not shown) to pre-exhaust gas valve cooler (3).
Position pre-exhaust gas valve cooler (3) onto NRS manifold (4) and exhaust manifold (17). Install bolts (24) and bolt (20) finger tight.Apply Tooling (B) to the threads of bolts (19). Install bolts (19) finger tight.
Apply Tooling (A) to new O-ring seal (21) (not shown). Install new O-ring seal (21) (not shown) to adaptor (16).
Install gasket (14) (not shown) to adaptor (16).
Install adaptor (16) to pre-exhaust gas valve cooler (3) and the cylinder head. Install bolts (15) finger tight.
Illustration 7 g06222247
Bolt (1) is M8.
Bolts (2) and (3) are M10.