09162-12005 Suzuki Washer

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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06187390
Turn the battery disconnect switch to the OFF position.
If the Clean Emissions Module (CEM) assembly is mounted on the valve mechanism cover, removal of the CEM will be necessary to access the NRS valve. Refer to Disassembly and Assembly, "Clean Emissions Module - Remove and Install" for the correct procedure.
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.
If necessary, remove secondary fuel filter base and bracket. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
Disconnect harness (6) from pressure sensor (7).
Disconnect harness (5) from NOx Reduction System (NRS) valve (4).
Remove the tube assembly (not shown) from connection (2).
Remove bolts (3) from exhaust gas cooler (1).
Remove bolts (8) from NRS valve assembly (4).
Remove NRS valve assembly (4) from NRS manifold (9).
Remove gasket (10) (not shown) and gasket (11) (not shown).
Remove O-ring seal (12) (not shown).
If necessary, follow Step 13a through Step 13f to remove the NRS manifold from the cylinder head.
Illustration 2 g06463712
Illustration 3 g06463721
Cut cable strap (15) and disconnect harness assembly (16).
If necessary, remove cooled exhaust gas temperature sensor (17). Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Remove bolts (14). Remove heat shield (13) from the NRS manifold.
Remove bolts (22) and bolt (23).
Remove bolts (18) and disconnect the NRS manifold from the NRS cooler (20).Note: Support the weight of the NRS manifold as the bolts are removed.
Remove O-ring seal (19) (not shown) and gasket (21) (not shown).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - P-80 Emulsion Rubber Assembly Lubricant 1
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
If necessary, follow Step 2a through Step 2j to install the NRS manifold to the cylinder head.
Illustration 4 g06463721
Illustration 5 g06463712
Apply Tooling (A) to new O-ring seal (19) (not shown). Install new O-ring seal (19) (not shown) and to NRS cooler (20).
Install new gasket (21) (not shown) to NRS cooler (20).
Install NRS manifold (9) to NRS cooler (20).
Install bolts (18) to the NRS manifold finger tight.
Install bolts (22) and bolt (23) to the NRS manifold finger tight.
Tighten bolts (22) to a torque of 22 N m (195 lb in).Tighten bolts (18) to a torque of 44 N m (33 lb ft).Tighten bolts (23) to a torque of 22 N m (195 lb in).
If necessary, install cooled exhaust gas temperature sensor (17). Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Install new cable strap (15) and reconnect harness assembly (16).
Position heat shield (13) onto the NRS manifold.
Install bolts (14) and tighten the bolts to a torque of 5 N m (44 lb in).
Illustration 6 g06187842
Illustration 7 g06187390
Apply Tooling (A) to new O-ring seal (12). Install new O-ring seal (12) to NOx Reduction System (NRS) assembly (4).
Install bolts (3) to exhaust gas cooler (1). Position new gasket (11) onto bolts (3).
Position new gasket (10) onto NRS manifold (9).
Install NRS assembly (4) to NRS manifold (9) and exhaust gas cooler (1). Tighten bolts (3) finger tight.
Install bolts (8) to NRS assembly (4). Tighten the bolts finger tight.
Tighten the bolts (3) to a torque of 22 N&middo