Low Range Off-Road SER-CHK User manual

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
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-CHK)
Installation Instructions
For additional copies of these
and other instructions go to:
www.lowrangeoffroad and click on the
“Instructions” tab.
SER-ROP
SER-HHCK
SER-WPI

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

Step 1
Let the engine cool 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 side.
Draining the Coolant

Step 4
Remove the radiator cap to allow the
coolant to drain faster. Inspect the cap
and replace if needed.
Note: Click HERE to see what Low
Range has to offer.
Step 5
Let the coolant drain until it stops
coming out.
Note: Green coolant can be reused if it
is less 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
socket.
Tech Tip 6
These hose clamps are removed using
a screwdriver or a socket. It is best to
thread the screw all the way loose as is
shown here. Inspect the clamp and
replace if needed. Click HERE to see
what Low Range has to offer.
Upper Radiator Hose Removal

Step 7
Slide the hose clamp back on the
radiator hose.
Step 8
Loosen the hose using channel lock
pliers as shown.
Caution: Be careful not to damage the
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
Work the hose off the radiator neck. If it
is seized, continue to the next tech tips
for some helpful hints about how to
remove a seized radiator hose.

Step 11
In some cases it may be necessary to
cut the hose with a sharp pocket knife
as shown here.
Step12
Another way to remove 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 the upper radiator hose.
Step 13
Once the hose has been removed,
clean the radiator neck with a wire brush
or fine sandpaper.

Step 16
Compare the shape of the new hose
with the shape of the old hose to insure
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.
Note: Insure the clamps 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
thermostat housing following the same
procedure as the previous step.
Step 17
Install the new hose on the radiator neck
as shown.
Note: Applying a small amount of full
strength coolant to the inside of the
hose will make installation much easier.

Step 19
Slide the hose clamp into position at the
thermostat 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. Stop when the wires of the
clamp being to sink into the hose.

Step 22
Unclip the brake line as shown.
Removing the Engine 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.
Step 24
Remove the passenger side screw in
the same way.

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.
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 recommend replacing these two
hoses by disconnecting the hoses at the
radiator and at the inlet water pipe.
(See Figure Aon Page 2)
Replacing Lower Radiator Hose No. 1 and No. 2