Low Range Off-Road SER-CHK Installation Instructions Manual Download Page 2

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Carburetor

Choke Heater
Inlet Hose

Heater Core

Coolant
By-Pass
Hose

Lower Radiator Hose
(No 1)

Lower
Radiator
Pipe

Water Inlet Pipe

Lower Radiator
Hose (No 2)

Wire Type Hose Clamp

Spring Type
Hose Clamp

Choke Heater
Outlet Hose

Temperature
Valve

Heater Core
Outlet Hose

Upper
Radiator
Hose

Thermostat

Temperature
Valve Inlet
Hose

Heater Core
Inlet Hose

Coolant (Water) Hoses &
Related Components

Thermostat
Housing

Figure A

Summary of Contents for SER-CHK

Page 1: ...oolant If Being Changed Drain Pan Funnel CAUTION Safety glasses should be worn at all times when working with vehicles and related tools and equipment Suzuki Samurai Coolant and Water Hose Kit SKU SER...

Page 2: ...Pipe Water Inlet Pipe Lower Radiator Hose No 2 Wire Type Hose Clamp Spring Type Hose Clamp Choke Heater Outlet Hose Temperature Valve Heater Core Outlet Hose Upper Radiator Hose Thermostat Temperature...

Page 3: ...l down Step 3 Open the drain valve by tuning it counter clockwise Step 2 Place a clean drain pan under the radiator drain valve Note This valve is located at the bottom of the radiator on the driver s...

Page 4: ...s than 2 yrs old and clean If it is too old or dirty it should be replaced Be sure to dispose of old fluid in accordance with local state and federal laws Step 6 Loosen the hose clamp using a 10 mm so...

Page 5: ...e radiator inlet pipe Do not squeeze too tight Step 9 It may be helpful to use a hook tool to loosen the hose Work the tool between the radiator neck and the hose all the way around the hose Step 10 W...

Page 6: ...ve seized hoses is by splitting it with a utility knife Caution Be careful These knives can cause serious injury if not used with caution and care Step 14 Repeat Steps 6 through 13 on the other end of...

Page 7: ...amps are oriented such that a tool can be easily fitted on the clamp after the hose is in place Step 15 Remove both hose clamps from the old hose Step 18 Install the other end of the hose on the therm...

Page 8: ...t housing end Step 20 Slide the hose clamp into position at the radiator end Step 21 Snug both radiator clamps using a 10 mm socket or a standard screwdriver Caution Do not over tighten these clamps S...

Page 9: ...ne Splash Panel Engine Splash Panel Figure B Step 23 Remove the driver side mounting screw using a phillips screwdriver Note The easiest way to access this screw is down through the engine compartment...

Page 10: ...through a hole in the splash panel Tech Tip 26 B In order to remove both hoses at once you will need to remove the 2 bolts securing the lower radiator pipe using a 10 mm socket Tech Tip 26 A We recom...

Page 11: ...Note It may be necessary to use some of the Tech Tips shown earlier to remove Step 29 This is what the lower hose assembly should look like when ready for installation Note The two hose claps securing...

Page 12: ...lower hose assembly in reverse order of removal Step 31 Position and secure the 2 clamps one at the radiator and one the inlet pipe Step 32 Re attach the lower radiator pipe by installing the two bol...

Page 13: ...ginally But are a popular replacement To loosen these hose clamp all that is required is to turn the screw in a counterclockwise direction using a standard screwdriver or a socket usually a 5 16 Tech...

Page 14: ...it helpful to split the hose using a utility knife Then peal the hose off Caution Be careful when using a utility knife If these knives are not used properly accidents can happen resulting in serious...

Page 15: ...tlet Hose 3 Heater Core Outlet Hose 1 Temperature Valve Inlet Hose 2 Heater Core Inlet Hose Figure D Step 33 Replace all the hoses shown in Figure D Shown Below Note The numbering shows the order in w...

Page 16: ...k all the hose clamps to see that they are in place and tight Step 35 Install the engine splash shield in reverse order of removal Note See Step 22 for details Step 36 Close the radiator drain valve a...

Page 17: ...ix of full strength coolant and water to approximately half way between the FULL and LOW marks See Figure E Cooling System Refill Procedures See Figure E Step 39 Add a 50 50 mix of full strength coola...

Page 18: ...rectly over the radiator at anytime during the refill procedure Hot coolant can belch out unexpectedly Step 40 Place the heater temperature control in the HOT position Do NOT exceed this mark Operatin...

Page 19: ...you are done Congratulations One more thing It is almost impossible to get all the air out of the system in the procedure outlined above So after several warm up and cool down cycles check the overflo...

Page 20: ...arm and death Please operate equipment carefully and observe proper safety procedures Rock crawling and off road driving are inherently dangerous activities Some modifications will adversely affect th...

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Low Range Off-Road SER-CHK, Installation Instructions Manual

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