01580-06207 Suzuki BOLT

start by:a) remove fuel pump drive gear and automatic timing advance Before any timing gears are removed, make sure the "Crdquo; mark on the crankshaft gear is in alignment with the "C" mark on the camshaft gear. 1. Remove bolts (1) and plate (3). Remove idler gear (2). 2. Remove idler gear bearing (4) from idler gear (2) with tooling (A) and a press. 3. Remove four bolts (5) and washers. Remove camshaft drive gear (6). If the camshaft drive gear is hard to remove, hit it with a soft hammer.4. Remove the three nuts and washers that hold the fuel injection housing to the timing gear plate. 5. Remove bolts (7) and locks (8) and (9).6. Remove timing gear plate (10).Install Timing Gears And Plate
Make sure the O-ring seal is in place on the front of the fuel injection pump housing.1. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan. 2. Put timing gear plate (1) against the cylinder block. Install the two locks and six bolts that hold the timing gear plate in place.3. Install the three nuts and washers that hold the fuel injection pump housing to the timing gear plate. 4. Install camshaft drive gear (2) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear as shown in the illustration. Install the four bolts and washers that hold it in place. 5. Use tooling (A) and a press and install the bearing in idler gear (3). Install the bearing to a depth of 1.52 mm (.060 in.) below the outside surface. The bearing diameter after installation must be 35.000 0.048 mm (1.3781 .0019 in.). 6. Install idler gear (3). Install the plate and bolts that hold the idler gear in place.end by:a) install fuel pump drive gear and automatic timing advanceRemove Flywheel
start by:a) remove flywheel clutch **This operation location is in the POWER TRAIN DIASSEMBLY AND ASSEMBLY section. This operation can be done in chassis or out of chassis. Use tool (A) for out of chassis removal and use tooling (B) for in chassis removal. Do Steps 1 and 2 for out of chassis removal.1. Remove three of the bolts that hold the flywheel to the crankshaft.
SHOWN OUT OF CHASSIS2. Fasten tool (A) to the flywheel as shown. Fasten a hoist to tool (A). Remove bolts (2). Remove flywheel (1). The weight of the flywheel is 56 kg (125 lb.). Do Steps 3 and 4 for in chassis removal.
SHOWN IN CHASSIS3. Fasten tooling (B) to the flywheel as shown. Fasten a hoist to tooling (B).4. Remove bolts (2). Remove flywheel (1). The weight is 56 kg (125 lb.).5. Remove gear (3) from the flywheel if replacement is necessary.
SHOWN OUT OF CHASSIS6. Remove ring gear (4) from the flywheel if replacement is necessary.Install Flywheel
SHOWN OUT OF CHASSIS This operation can be done in chassis or out of chassis. Use tool (A) for out of chassis removal and use tooling (B) for in chassis removal.1. Heat ring gear (1) to a maximum temperature of 320°C (640°F). Install ring gear (1) on flywheel (3) with the chamfer on the teeth of the ring gear toward the engine.2. Make an alignment of the dash mark on the flywheel with the dash mark on gear (2) and install gear (2). Do Steps 3 and 4 for out of chassis installation.3. For easier installation install two 5/8"-18 NF guide bolts (not shown) in the crankshaft. Install tool (A) on the flywheel and fasten a hoist to tool (A).
SHOWN OUT OF CHASSIS4. Make an alignment of the dash mark on the crankshaft with the dash mark on the flywheel and put flywheel (3) against the rear of the crankshaft. Install bolts (4) that hold it. Remove tool (A) and install the three other bolts that hold the flywheel in place. Do Steps 5 and 6 for chassis installation.5. For easier installation install two 5/8"-18 NF guide bolts (not shown) in the crankshaft. Install tooling (B) on the flywheel and fasten a hoist to tooling (B).
SHOWN IN CHASSIS6. Make an alignment of the dash mark on the crankshaft with the dash mark on the flywheel and put flywheel (3) against the rear of the crankshaft. Install bolts (4) that hold the flywheel in place. Tighten the bolts to a torque of 205 27 N m (150 20 lb.ft.). Remove tooling (B).end by:a) install flywheel clutch **This operation location is in the POWER TRAIN DISASSEMBLY AND ASSEMBLY section.