Low Range Off-Road SER-CHK Installation Instructions Manual

Coolant and water hose kit for suzuki samurai

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Suzuki Samurai Coolant and Water Hose Kit

(SKU# SER-CHK)

SER-WPI

CAUTION:

Safety glasses should be

worn at all times when working with

vehicles and related tools and

equipment.

For additional copies of these

and other instructions go to:

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"Instructions"

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Installation Instructions

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Suggested Tools:

• Standard Screwdriver

• Phillips Screwdriver

• Slip-joint pliers

• Channel Lock Plier

• Sockets: 10, 12 mm

• Ratchet

• Radiator Hose Hook Tool

• Utility Knife

• Wire Brush

• Coolant (If Being Changed)

• Drain Pan

• Funnel

SER-HHCK

SER-ROP

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Summary of Contents for Low Range Off-Road SER-CHK

Page 1 Suzuki Samurai Coolant and Water Hose Kit (SKU# SER-CHK) Installation Instructions SER-HHCK SER-WPI SER-ROP CAUTION: Safety glasses should be Suggested Tools: worn at all times when working with vehicles and related tools and • Standard Screwdriver equipment. • Phillips Screwdriver •...
Page 2 Coolant (Water) Hoses & Choke Heater Related Components Outlet Hose Carburetor Choke Heater Inlet Hose Thermostat Housing Spring Type Hose Clamp Upper Temperature Radiator Valve Hose Temperature Valve Inlet Hose Heater Core Thermostat Inlet Hose Coolant By-Pass Hose Lower Radiator Hose (No 2) Heater Core Outlet Hose...
Page 3: Draining The Coolant
Step 1 Let the engine cool down. Draining the Coolant Step 2 Step 3 Place a clean drain pan under the Open the drain valve by tuning it counter radiator drain valve. clockwise. Note: This valve is located at the bottom of the radiator on the driver side.
Page 4 Step 5 Step 4 Let the coolant drain until it stops coming out. Remove the radiator cap to allow the coolant to drain faster. Inspect the cap Note: Green coolant can be reused if it and replace if needed. is less than 2 yrs. old and clean. If it is too old or dirty it should be replaced.
Page 5 Step 8 Step 7 Loosen the hose using channel lock Slide the hose clamp back on the pliers as shown. radiator hose. Caution: Be careful not to damage the radiator inlet pipe. Do not squeeze too tight. Step 9 Step 10 It may be helpful to use a hook tool to Work the hose off the radiator neck.
Page 6 Step 11 Step12 In some cases it may be necessary to Another way to remove seized hoses is cut the hose with a sharp pocket knife by splitting it with a utility knife. as shown here. Caution: Be careful! These knives can cause serious injury if not used with caution and care.
Page 7 Step 16 Step 15 Compare the shape of the new hose Remove both hose clamps from the old with the shape of the old hose to insure hose. you have the correct hose and it is oriented properly. Install the (2) hose clamps on the new hose 2 or 3 inches from the ends of the hose.
Page 8 Step 20 Step 19 Slide the hose clamp into position at the Slide the hose clamp into position at the radiator end. thermostat housing end. Step 21 Snug both radiator clamps using a 10 mm socket or a standard screwdriver. Caution: Do not over-tighten these clamps.
Page 9 Removing the Engine Splash Panel Engine Splash Panel Figure B Step 22 Unclip the brake line as shown. Step 24 Step 23 Remove the passenger side screw in Remove the driver side mounting screw the same way. using a phillips screwdriver. Note: The easiest way to access this screw is down through the engine...
Page 10 Step 25 Remove the splash panel by lifting up, sliding rearward and down. Then set the panel aside. Note: Be careful not to damage the radiator drain hose that extends down through a hole in the splash panel. Replacing Lower Radiator Hose No. 1 and No. 2 Tech Tip 26 A Tech Tip 26 B We recommend replacing these two...
Page 11 Step 27 Step 26 Disconnect the hoses from the water Once the lower radiator hose assembly inlet pipe. Inspect the water inlet pipe has been removed, loosen the other 2 and replace if needed. Click HERE hose clamps. see what is available from Low Range. Note: It may be necessary to use some of the Tech Tips shown earlier to remove Step 28...
Page 12 Step 31 Step 30 Position and secure the (2) clamps, one Install the lower hose assembly in at the radiator and one the inlet pipe. reverse order of removal. Step 32 Re-attach the lower radiator pipe by installing the two bolts removed earlier.
Page 13 Tips for replacing Passenger Heater, Choke Heater & By-Pass Hoses. (See Figure D) Tech Tip 33 A Tech Tip 33 B This shows proper worm gear hose These are stainless steel worm gear clamp removal. hose clamps. They were not used on the Samurai originally.
Page 14 Nozzles Figure C Tech Tip 33 E In some cases the heater hoses can Caution: become very difﬁcult to remove. They seem to be melted to the metal parts. Be very careful when removing and We ﬁnd it helpful to split the hose using replacing the hoses that are connected a utility knife.
Page 15 Step 33 Choke Heater Replace all the hoses shown in Figure D Outlet Hose (Shown Below). Choke Heater Inlet Hose Note: The numbering shows the order in which we recommend you remove each hose. Installation should be Temperature in reverse order. Valve Inlet Hose Heater Core...
Page 16 Step 35 Step 34 Install the engine splash shield in reverse order of removal. Once all the hoses have been replaced, check all the hose clamps to see that Note: See Step 22 for details. they are in place and tight. Step 36 Close the radiator drain valve and proceed to the Cooling System Reﬁll...
Page 17 Cooling System Reﬁll Procedures Step 37 If you are replacing the ﬂuid, empty the overﬂow tank and reﬁll it with a 50/50 mix of full strength coolant and water to approximately half way between the See Figure E “FULL” and “LOW” marks. See Figure Step 38 Step 39...
Page 18 Do NOT exceed this mark Operating Temperature Step 41 Step 40 Start the engine and let it idle. While Place the heater temperature control in idling, monitor the temperature gage on the “HOT” position. the instrument cluster. Caution: If the engine overheats at anytime during the reﬁll procedure, turn the engine off and let it cool.
Page 19 Step 43 Step 44 When the coolant level remains Leave the engine running and check all constant, without dropping, install the the hose connections for leaks. If leaks cap. are observed, turn the engine off and repair as needed. Small hose leaks can often be remedied by snugging the clamps.
Page 20 Low Range Off-Road Technical Support at 801-805-6644 M-F 7:30am-5:30pm MST. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting.

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