01907-08558 Suzuki Bolt

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 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.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Drain the secondary filters. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Illustration 1 g03598441
Make temporary identification marks on all the tube assemblies in order to show the correct position of the tube assemblies.On some engines the tube assemblies on the fuel filter assembly may be in a different location.
Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.
Remove banjo bolt (1) and remove sealing washers (3) (not shown).
Use Tooling (A) in order to plug tube assembly (2). Use Tooling (A) in order to cap the port of fuel filter head (5).
Disconnect tube assembly (8) from connection (7)
Use Tooling (A) in order to plug tube assembly (8). Use Tooling (A) in order to cap connection (7).
If necessary, remove connection (7) and remove sealing washer (6) (not shown). Use Tooling (A) in order to cap the port of fuel filter head (5).
Remove secondary filters (10) from canisters (9). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Remove bolts (4) from fuel filter base (5). Remove the fuel filter base from the mounting bracket. Note: Note the position of different length bolts.
Illustration 2 g03700080
If necessary, follow Step 13.a through Step 13.d in order to remove fuel filter bracket (11).
Remove hose clamp (14).
Disconnect tube assembly (13) from pipe assembly (15). Use Tooling (A) to plug and cap all open ports.
Remove bolts (16) from fuel filter bracket (12).
Remove fuel filter bracket (12) from cylinder head (11). Installation Procedure
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.
Illustration 3 g03700080
Ensure that fuel filter bracket (13) is clean and free from damage. If necessary, replace the complete fuel filter bracket.
If necessary, follow Step 2.a through Step 2.e in order to install fuel filter bracket (13).
Position fuel filter bracket (12) onto cylinder head (11).
Install bolts (16) to fuel filter bracket (12).
Tighten bolts (16) to a torque of 22 N m (195 lb in).
Position new hose clamp (14) to tube assembly (13).
Remove plugs and caps and Install tube assembly (13) immediately to pipe assembly (15). Tighten hose clamp (14) securely.
Illustration 4 g03598441
Position fuel filter base (5) onto the fuel filter bracket. Install bolts (4). Tighten the bolts to a torque of 44 N m (32 lb ft).
If necessary, install new fuel filters (9) to canisters (8). Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
If necessary, follow Step 5.a through Step 5.d to install connection (7) to fuel filter base (5).
Remove plug from fuel filter base (4).
Install a new sealing washer (6) (not shown) to connection (7).
Install connection (7) to fuel filter base (5).
Tighten connection (7) to a torque of 21 N m (186 lb in).
Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.
Install tube assembly (8) to connection (7).
Position a new sealing washer (3) (not shown) onto banjo bolt (1).
Remove plug from tube assembly (2) and install banjo bolt (1). Install remaining sealing washer (3) (not shown) onto banjo bolt (1).
Install banjo bolt (1) to fuel filter base (5).
Tighten banjo bolt (1) to a torque of 21 N m (186 lb in).
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position. End By:
Remove the a