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

Step 26
Once the lower radiator hose assembly
has been removed, loosen the other 2
hose clamps.
Step 27
Disconnect the hoses from the water
inlet pipe. Inspect the water inlet pipe
and replace if needed. Click HERE to
see what is available from Low Range.
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 the
hoses to the water inlet pipe should be
tight with the other 2 hose clamps left
loose.
Step 28
Install the hose camps on the new
hoses as shown here.
Note: Be sure the new hoses are
positioned and oriented exactly as the
old ones were. (See Step 26 & 29)

Step 30
Install the 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 bolts removed earlier.

Tech Tip 33 C
This is a spring steel self-tightening
hose clamp similar to the ones used on
many Suzuki vehicles. It is loosened by
pinching the tabs together with pliers.
Tech Tip 33 A
These are stainless steel worm gear
hose clamps. They were not used on
the Samurai originally. 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 Tip 33 D
Self tightening hose clamp removal.
Once the hose clamp is released
(pinched) slide it back on the hose at
least an inch or so.
Tech Tip 33 B
This shows proper worm gear hose
clamp removal.
Tips for replacing Passenger Heater, Choke Heater &
By-Pass Hoses. (See Figure D)

Caution:
Be very careful when removing and
replacing the hoses that are connected
to the heater core (See Figure C). These
nozzles are made of thin brass and If
excessive force is used they can be
bent or broken.
Tech Tip 33 E
In some cases the heater hoses can
become very difficult to remove. They
seem to be melted to the metal parts.
We find 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 injury.
Figure C
Nozzles
Tech Tip 33 F
This shows the heater hoses connected
to the heater core nozzles. Access to
these hoses is very limited and can be
very difficult to remove.
Caution: Be gentle when removing
these hoses. Heater cores are fragile
and can be easily damaged. If broken
they are expensive to purchase and
difficult to replace.

5.
Choke Heater
Inlet Hose
Heater Core
6.
Coolant
By-Pass
Hose
4.
Choke Heater
Outlet 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
which we recommend
you remove each hose.
Installation should be
in reverse order.

Step 34
Once all the hoses have been replaced,
check 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 and
proceed to the 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
“FULL” and “LOW” marks. See Figure
E.
Cooling System Refill Procedures
See Figure E
Step 39
Add a 50/50 mix of full strength coolant
and water to the radiator until it is full.
Step 38
If installed, remove the radiator cap.

Step 41
Start the engine and let it idle. While
idling, monitor the temperature gage on
the instrument cluster.
Caution: If the engine overheats at
anytime during the refill procedure, turn
the engine off and let it cool.
Caution:
NEVER stand directly 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
Operating
Temperature
Step 42
When the engine reaches operating
temperature (usually within 15 to 20
minutes) the thermostat will open and
the coolant level in the radiator will drop.
As the coolant level drops, add coolant,
keeping the radiator full.

Step 43
When the coolant level remains
constant, without dropping, install the
cap.
Step 44
Leave the engine running and check all
the hose connections for leaks. If leaks
are observed, turn the engine off and
repair as needed. Small hose leaks can
often be remedied by snugging the
clamps.
Warning: If hoses have to be removed
to make needed repairs, be sure to let
the engine (and coolant) cool down
(usually 30 to 45 minutes) before
removing the cap or hoses.
Congratulations!!!
Once the radiator and overflow bottle is full and you are sure there are no leaks . . . 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
overflow bottle (NOT THE RADIATOR) and add coolant if needed. This can be done
with the engine hot. There should be no need to have to check the radiator as it is kept
full by the overflow bottle. However, if you think the radiator could be low, it is okay to
check and add coolant if needed. Just be sure the engine is cool when you remove the
radiator cap to check coolant level at the radiator.
We hope these instructions have been helpful. If you have suggestions on how we can
improve our instructions (or products) please email us at [email protected].

As always, If you experience any difficulty during the installation of this product
please contact 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. If you have any questions or are unsure about how to proceed, please contact
our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such
as welders, torches and grinders can cause serious bodily harm 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 the on-road handling characteristics of your vehicle. All products sold by Low
Range Off-Road are sold for off road use only. Any other use or application is the responsibility
of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may
under certain circumstances void your original dealer warranty. Modification of your vehicle may
create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or
death. Buyers and users of these products hereby expressly assume all risks associated with any
such modifications and use.
Revised 02/21/14© Copyright 2014 Low Range Off-Road, LC!!!!!! All Rights Reserved