41153-94500 Suzuki Cap

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - De-ionized Water 1
Ensure that all adjustments and repairs that are carried out to the Diesel Exhaust Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Exhaust Fluid (DEF) for the system is 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.
Refer to the Original Equipment Manufacture (OEM) for the location of the DEF pump.
Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.Note: If the DEF tank is to be drained, ensure that the Electronic Control Module (ECM) is powered off before commencing the draining procedure. Failure to ensure that the ECM is powered off will cause the DEF level gauge to read incorrectly during the draining procedure and will not be accurate until the tank has been refilled.
Turn turning the battery disconnect switch to the OFF position.
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Coolant - Change" for the correct procedure.
Illustration 1 g06464850
Ensure that the area around Diesel Exhaust Fluid (DEF) pump (7) is clean and free dirt and debris. If necessary, clean the area around the DEF pump. Clean the area around the DEF pump with Tooling (B) and a suitable tool.
Make temporary marks on the DEF lines for installation purposes. Remove the DEF line from connection (1), connection (3), and connection (4) from DEF pump (7). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Use Tooling (A) to plug the DEF lines. Use Tooling (A) to cap connection (1), connection (3), and connection (4).
Make temporary marks on the coolant lines for installation purposes. Remove the coolant lines from connections (2).
Ensure that no Diesel Exhaust Fluid (DEF) or coolant enters the harness assembly or the harness connections.
Disconnect Original Equipment Manufacture (OEM) harness assembly (8) from DEF pump (7).
Use Tooling (A) to the coolant lines. Use tooling (A) to cap connections (2).
Remove bolts (5) from DEF pump (7). Support the weight of the DEF pump as the bolts are removed. Remove the DEF pump from the OEM bracket.
If necessary, remove DEF filter (6) (not shown), see illustration 4. Refer to Operation and Maintenance Manual, "Diesel Exhaust Fluid Filter - Clean/Replace" for the correct procedure.
Illustration 2 g06147130
If necessary, follow Step 13a through Step 13c to remove the connections from DEF pump (7).Note: The removal of the connections from the diesel exhaust fluid pump new connections must be installed to the DEF pump.
Place identification marks on connections (2) for the coolant lines and DEF pump (7) for installation purpose. Remove the connections from the DEF pump. Use suitable plugs to plug the open ports on the DEF pump. Discard the connections.
Place identification marks on connection (1) and DEF pump (7) for installation purpose. Remove the connection from the DEF pump. Use suitable plugs to plug the open port on the DEF pump. Discard the connection.Note: The connections are not interchangeable.
Place identification marks on connection (3), connection (4), and DEF pump (7) for installation purpose. Remove the connections from the DEF pump. Use suitable plugs to plug the open ports on the DEF pump. Discard the connections.Note: The connections are not interchangeable.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B - De-ionized Water 1
Ensure that the DEF pump is free from wear or damage. Replace the DEF pump as an assembly if any component of the DEF pump is not free from wear or damage.
Illustration 3 g06147130
If necessary, follow Step 2a through Step 2c to install new connections to DEF pump (7).
Remove plugs from the open ports on DEF pump (7). Install new coolant connections (2) to the DEF pump. Tighten the connection to a torque of 5.5 N m (49 lb in).
Remove plugs from the open port on DEF pump (7). Install new connection (1) to the DEF pump. Tighten the connection to a torque of 4.5 N m (40 lb in).
Remove plugs from the open ports on DEF pump (7). Install new connection (3) and a new connection (4) to the DEF pump. Tighten the connections to a torque of 4.5 N m (40 lb in).
Illustration 4