01107-06403 Suzuki Bolt

Table 1
Required Tools
Tool Part Number Part Description Qty
A 276-7018 Plug Cap Kit 1
B 5F-4764 Prybar 1
C 467-0158 Abrasive Material 1
8T-7765 Surface Reconditioning Pad 1
D 339-9352 Cap Kit 1
265-2256 Wipers 1
E 510-4187 Impact Socket 1 Start By:
Remove the air inlet manifold.
This fuel system may contain high-pressure fuel for extended periods after engine shutdown. Do not open the high-pressure fuel system without first releasing the high-pressure fuel from the system. Refer to the Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" to properly release fuel pressure. Exposure to high-pressure fuel may result in personal injury.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Use Tooling (D) to cap tube assemblies, fittings, ports, and any openings in the fuel system to prevent contamination.
Illustration 1 g06446377
Loosen plug (1) one full turn, do not remove plug (1). After 30 seconds, use Cat® Electronic Technician (Cat ET) to verify that the fuel rail pressure is below 2.0 MPa (290 psi). Refer to Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" for more information.
Illustration 2 g06202890
Remove bolts (6) and (8), the washers, and clamps (5) and (9). Remove tube assemblies (4) and (7).Note: Use Tooling (A) on the tube assemblies and place the tube assemblies in a clean new resalable bag.Note: If the tube assemblies and accumulators will be reused, assembly will be easier if the parts are installed in their original locations. Mark the tube assemblies and accumulators for orientation.
Illustration 3 g06202893Note: Ensure that the area around the accumulator is free of dirt and debris. If necessary, clean the area with compressed air before exposing the high pressure sealing areas.
Mark the accumulator studs to ensure that they do not rotate. If the studs rotate, retorque the studs with Tooling (E) prior to installing the accumulator.
Remove nuts (11) and the spherical washers. Use Tooling (B) to remove accumulator (10).Note: Cap the tip of the accumulator and place in a clean new resealable bag.Note: Cap the HP ports of the other two accumulators that are now exposed.
Illustration 4 g06202895
If required, use Tooling (E) to remove studs (12).
Illustration 5 g06202897
Remove O-ring seal (13) from accumulator (10).
If necessary, use Tooling (C) to remove any rust scale from the outer rim of the accumulator bore.Note: It is not necessary to polish the surface.
Carefully remove any remaining debris from the outer edge of the accumulator bore using a new lint-free towel moistened with brake cleaner.
Use Tooling (A) to plug the open accumulator bore in the cylinder head.Note: If replacing accumulator at either cylinder #19 or #20, ensure that a new end-plug and a new ball is available. Reuse of the end plug and ball in the accumulator is not recommended.Note: If removing accumulator at either cylinder #19 or #20 for inspection only, do not remove the end-plug.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
E 510-4187 Impact Socket 1