09117-06037 Suzuki BOLT (6X35)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1860 Retaining Ring Pliers 1
B 1P-0510 Driver Group 1
C 6V-2016 Plate 1
0S-1594 Bolt 2
6V-4818 Driver 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Put clean engine oil on all parts before assembly. Ensure that all of the oil passages are clear.
Illustration 1 g00457491
Use Tool (B) in order to install large bearing (1) in the governor end of the fuel injection pump housing. Bearing joint (3) should be facing toward the top of the fuel injection pump housing. Install the bearing so the bearing is 0.25 0.20 mm (.010 .008 inch) below the surface of the fuel injection pump housing.
Use Tool (B) in order to install small bearing (2) in the governor end of the fuel injection pump so that Tool (B) is 7.16 0.13 mm (.282 .005 inch) below the surface of the fuel injection pump housing.
Illustration 2 g00457492
Use Tool (B) in order to install large bearing (4) in the drive end of the fuel injection pump housing. The bearing joint should be facing toward the top of the fuel injection pump housing. Install the bearing so the bearing is 1.00 0.25 mm (.039 .010 inch) below the surface of the fuel injection pump housing.
Illustration 3 g00457493
Install the plate of Tool (C) on the drive end of the fuel injection pump in order to install small bearing (5) for the rack. Use clean grease in order to hold the new driver for the rack bearing of Tool (C). Install the driver and the bearing in the plate. Ensure that the groove in the driver is aligned with the pin in the plate and use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against the plate.
Remove Tool (C) from the fuel injection pump housing. The fuel rack bearing must be installed so that the fuel rack bearing is 0.25 0.25 mm (.010 .010 inch) below the surface of the housing.
Illustration 4 g00457494
Install camshaft (6).
Illustration 5 g00458729
Put the fuel injection pump housing upright, as shown. Place a wood block under the camshaft.
Put washer (7) over the end of the camshaft. Use Tool (B) and spacer (8) in order to push the washer against the seat on the camshaft. Spacer (8) has an inside diameter of 38.1 mm (1.50 inch) and a length of 31.75 mm (1.250 inch). The camshaft must have an end play of 0.18 0.08 mm (.007 .003 inch) when the washer is pushed against the shoulder of the camshaft.
Illustration 6 g00457495
Use Tool (A) in order to install snap ring (9).
Illustration 7 g00458730Note: Check the condition of the new lifters. Replace the lifters, if necessary. If the original lifters are being reused, place the lifters in the original locations. New lifters are identical, and the new lifters can be placed in any order.
Install six lifters (10) in the fuel injection pump housing. Ensure that the groove in the lifter is aligned with the pin in the fuel injection pump housing.
Illustration 8 g00458731
Install rack (11). Ensure that the groove in the end of the rack is aligned with the ear (tab) of the fuel rack bearing that is at the drive end of the fuel injection pump housing.
Illustration 9 g00458732
Install the gasket and cover (12). End By:
Assemble the governor. Refer to Disassembly and Assembly, "Governor - Assemble".
Install the fuel injection pumps. Refer to Disassem