09260-10003 Suzuki Ball, Clutch Notch

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-6640     Sealant     1    
B     -     Guide Bolt
(M8 by 80 mm)     2    
C     319-6486     Alignment Tool     1    
- Bolts
(M10 by 50 mm)     3    
D     -     Straight Edge     1    
E     1U-6396     O-Ring Assembly Compound     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing.Install blanking plugs to a new front housing. Use Tooling (A) to seal all D-plugs.
Check the condition of the crankshaft front seal. If the front seal is damaged, remove the front seal from the front housing.
Clean all the mating surfaces of the cylinder block.
Illustration 1 g01337987
Install thrust washer (10) into the recess in the cylinder block. Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Illustration 2 g01338000
Install Tooling (B) to the cylinder block. Refer to Illustration 2.
Align a new joint (6) with Tooling (B) . Install the joint to the cylinder block.Note: Ensure that two circular tabs (X) on the joint are engaged in two holes (Y) in the cylinder block.
Illustration 3 g01338001
Typical example
Install Tooling (C) to the cylinder block.
Install the front housing over Tooling (B) and Tooling (C) onto the cylinder block.
Illustration 4 g01338002
(7) M8 by 20 mm (8) M8 by 35 mm (9) M8 by 25 mm
Install bolts (9) to front housing (3) finger tight.
Remove Tooling (B) .
Loosely install bolts (7) and (8) . Refer to Illustration 4 for the correct position of the bolts.
Align the bottom face of front housing (3) to the lower machined face of the cylinder block. Use a Tooling (D) and a feeler gauge in order to check the alignment between the front housing and the cylinder block. Refer to Illustration 3. Refer to Specifications, "Front Housing and Covers" for further information.
Illustration 5 g01338003
Tighten bolts (7) , (8) and (9) in the sequence that is shown in illustration 5 to a torque of 28 N m (20 lb ft). Note: Ensure that the housing and the cylinder block are correctly aligned.
Remove Tooling (C) from the cylinder block.
If necessary, install a new crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove and Install".
Illustration 6 g01337982
Typical example
Install new O-ring seals (4) and (5) to bypass tube (1) . Use Tooling (E) in order to lubricate the O-ring seals. Install bypass tube (2) to the cylinder head. Install bolts (1) . Tighten the bolts to a torque of 22 N m (16 lb ft).End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".
If the engine has an accessory drive, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install".
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".
Install the front pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Install".
If necessary, install the alternator. Refer to Disassembly and Assembly, "Alternator - Install".
Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.