01107-05162 Suzuki Bolt

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Drain the coolant from the cooling system. 2. Remove bolts (1), (2) and (4) and adapter (3). 3. Remove four bolts (8). Remove elbow (5) and tube (6).4. Remove the flange and tube (7) from the oil cooler bonnet. 5. Using tool (A), attach a hoist to oil pump (9).6. Remove bolts (10) and (11). Remove wiring harness clip (12). Remove oil pump (9). The weight of the oil pump is 39 Kg (85 lb.). The following steps are for the installation of the oil pump.7. Put clean engine oil on the O-ring seals. Using tool (A) and a hoist, install oil pump (9). Make sure the splines on the pump shaft are correctly engaged with the splines of the oil pump drive. Install bolts (10) and (11).8. Put clean engine oil on the O-ring seals and install tube (6) in the by-pass elbow. Install elbow (5) on tube (6) with the bolts.9. Put clean engine oil on the O-ring seals and install tube (7) and the flange as a unit in the oil cooler bonnet.10. Install the gaskets and adapter (3) with bolts (1), (2) and (4).11. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual.Disassemble & Assemble Oil Pump
Start By:a. remove oil pump
Cover (2) has spring tension under it. To prevent personal injury, loosen bolts (1) slowly and evenly to remove the tension under the cover.
1. Remove bolts (1), cover (2), gasket (3), spring (4) and valve spool (5) from the pump body. 2. Remove cover assembly (6) and the gasket from the pump body. 3. Remove cover assembly (7) from the pump body. 4. Use tooling (A) to remove bearings (8) from cover assembly (7). 5. Remove shaft assemblies (10) from body assembly (9). 6. Use a press to remove gears (11) from the shaft assemblies. 7. Use tooling (A) to remove bearings (12) from body assembly (9). The following steps are for assembly of the oil pump. 8. Make an alignment of bearings (12) so that the joints are 45 15° from a line through the center of the bearing bores as shown.9. Use tooling (A) to install bearing (12) in the body assembly until they are 1.5 0.5 mm (.06 .02 in) below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The diameter must be 31.811 0.013 mm (1.2524 .0005 in).10. Heat gears (11) to a maximum temperature of 316° C (600° F).11. Install the gears on shaft assemblies (10) until they are 34.0 0.5 mm (1.34 .02 in) from the cover end of the shaft assemblies to the face of the gears and 47.0 0.5 mm (1.85 .02 in) from the fuel pump drive end of shaft assembly (10). 12. Install shaft assemblies (10) in the body assembly. 13. Make sure dowels (13) and (14) are installed in cover assembly (8) so they extend 6.0 0.5 mm (.24 .02 in) above the surface of the cover assembly.14. Use tooling (A) to install bearings (8) in cover assembly (6) with the joints of the bearings in the positions as shown. Put cover assembly (6) in position, and tighten the bolts to hold it to the body assembly.15. Make sure the two pins in cover assembly (6) are installed so they extend 6.0 1.0 mm (.24 .04 in) above the surface of the cover assembly. Install the gasket and cover assembly (6) on the body assembly.16. Put clean engine oil on valve spool (5). Install valve spool (5), spring (4), gasket (3), cover (2) and the bolts in the body assembly.End By:a. install oil pump