01421-0616A Suzuki BOLT, STUD

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-5718 T40 Torx Drive 1
D - Retaining Ring Pliers 1
E 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter 1
F 276-1216 Injector Pipe Nut Tool 1
G 247-5377 Torque Wrench 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
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.Dispose of all fluids according to local regulations and mandates.
Use a deep socket in order to install the electrical connections to the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Use Tooling (E) in order to remove any fuel from the cylinder. Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
Illustration 1 g03398322
Follow Step 2.a through Step 2.e in order to install harness assembly (4) to valve mechanism cover base (14).
Install a new O-ring seal (15) to harness assembly (4). Note: Do not lubricate the O-ring seal.
Install harness assembly (4) to valve mechanism cover base (14). Ensure that the harness assembly is correctly orientated and correctly seated into the valve mechanism cover base.
Use Tooling (D) to install circlip (13) valve mechanism cover base (14).
Install a new cable strap (12) (not shown) to valve mechanism cover base (14). Note: Ensure that the cable straps meet the Original Equipment Manufacture (OEM) specification.
Connect harness assembly (11) to harness assembly (4).
If necessary, repeat Step 2.a through Step 2.e in order to install the remaining harness assemblies to the valve mechanism cover base.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 2 g03398316
New sealing washer (10) should only be installed if the original electronic unit injector (6) is to be reused.
On installing an original electronic unit injector, install a new O-ring seal (9). Note: Do not lubricate the O-ring seal.
Use a suitable tool in order to install a new sealing washer (10) to electronic unit injector (6). Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way on installation of the new sealing washer.
Ensure that O-ring seal (9) and sealing washer (10) on a new electronic unit injector are not damaged and in place. Note: Do not lubricate the O-ring seal.
Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
Illustration 3 g03398314
Position clamp (8) onto electronic unit injector (6). Align the assembly of electronic unit injector (6) to the bore for the electronic unit injector in the cylinder head. Note: Ensure that the clamp is correctly positioned onto the electronic unit injector.
Push only on injector clamp (8) in order to install electronic unit injector (6). Do not apply pressure on any other part of the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
Install a new Torx screw (7) to clamp (8). Tighten the Torx screw finger tight.
Remove the cap from electronic unit injector (6). Install a new seal (2) to electronic unit injector (6) and to the cylinder head. Ensure that the flange on the seal is flush with the valve mechanism cover base.
Remove the plugs from the new fuel injection line. Install the fuel injection line hand tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. Note: Ensure that the ends of the fuel injection line are seated into the electronic unit injector and the fuel manifold. Tighten the nuts hand tight.
Use Tooling (A) to tighten Torx screw (9) to a torque of 27 N m (239 lb in). Note: Tooling (A) must be used to ensure no damage to the electronic unit injector.
Use Tooling (F) to tighten the fuel injection line to a torque of 30 N m (266 lb in). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Use a deep socket to install harness assembly (4) to electronic unit injector (6). Use Tooling (G) to tighten connections (5) to a torque of 2.4 N m (21.24 lb in).
If necessary, repeat Step 1 through Step 16 in order to install the remaining electronic unit injectors.