Radiator Install

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with Jeff Pollock

Radiator Replacement

My original stock radiator and I have been through a lot of adventures together and it has served me well over the years but after a few leaks, some radiator �stop leak�, motor swap and an endo it was beginning to shows signs of fatigue. I noticed after a recent trip that the radiator had separated from the mounting brackets. The brackets that I am referring to are not the braces that attach the radiator to the Zook but the pieces that actually hold the radiator to the mounting braces. It was also dented and leaking again so I decided it was time for an upgrade. I decided to go with Trail Tough�s new (not re-cored), three-core radiator. A quick call to Trail Tough and my order was on its way.

The radiator is a quality piece of work that should fill the need quite nicely! Later that week a fellow Zooker, Steve Birchler, had come up for the weekend so we decided to install it. I just wanted to thank Steve for helping with install of this radiator so I could take pictures as it progressed.

Here are the steps for Removing and Installing a radiator in your Samurai:

Removing the stock Suzuki Samurai Radiator:

Drain the radiator fluid into a container. (Do not forget the reservoir too!)

Remove the reservoir container and it�s hoses.

Loosen the lower radiator hose clamp and slide the hose off of the radiator.

Loosen the upper radiator hose clamp and slide the hose off of the radiator.

Locate the 4 fan shroud bolts and remove them using a 10mm wrench or ratchet.

Locate the 4 radiator bolts and remove them using a 10mm wrench or ratchet

Lift the radiator out of the Zook.

Reinstalling the stock sized Suzuki Samurai Radiator:

Carefully lower the new radiator into the Zook.

Reinstall the 4 radiator bolts using a 10mm wrench or ratchet

Slide the fan shroud off of the clutch fan and reinstall the 4 fan shroud bolts using a 10mm wrench or ratchet.

Click through for a closer look...

Note: You will need to find bolts to reinstall the fan shroud with the Trail Tough radiator since it does not have the nuts attached to the radiator like the stock radiator.

	Reinstall the upper radiator hose and tighten the hose clamp. (Do not over tighten the clamp)
	Reinstall the lower radiator hose and tighten the hose clamp. (Do not over tighten the clamp)
	Reinstall the reservoir container and it�s hoses.
	Fill the radiator with antifreeze and water. (Do not forget to add some fluid to the reservoir too!)

For information on other Trail Tough Products, visit:
Trail Tough Products
1031 Narregan St
Medford, OR 97501
1-877-SUZUKIS (789-8547)
info@trailtough.com

11/30/06 23:46:33

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