09117-08047 Suzuki BOLT (8X30)

1. Remove nuts (1). Remove cover (2) from the timing gear cover.2. Loosen bolt (4). Hit the bolt with a soft hammer until the automatic timing advance is loose. Some earlier engines have four bolts that hold the automatic timing advance.3. Remove bolt (4) and washer (5). Remove automatic timing advance (3). The following steps are for the installation of the automatic timing advance.4. Put automatic timing advance (3) in position on the drive shaft for the fuel injection pump.5. Install washer (5) and bolt (4). Tighten bolt (4) to a torque of 149 14 N m (110 10 lb.ft.).6. Put the No. 1 piston at top center on the compression stroke. Make reference to Finding Top Center Compression Position For No. 1 Piston in Testing And Adjusting. Remove the timing bolt from the flywheel, and use tool (A) to rotate the crankshaft clockwise (opposite the direction of engine rotation) 45°. 7. Remove plug (6) from the fuel injection pump housing. 8. Install tool (B) in the fuel injection pump housing as shown. Slowly rotate the crankshaft counterclockwise (direction of engine rotation) until the timing pin goes into the slot in the fuel injection pump camshaft.
Too much pressure on the timing pin can damage the fuel injection pump or the timing pin.
9. Put the timing bolt in the timing hole in the flywheel housing. Rotate the crankshaft counterclockwise (as seen from the flywheel end of the engine) until the fuel pump camshaft is tight against tool (B). This removes gear clearance from the drive train. If the bolt can be installed in the timing hole in the flywheel, the timing of the fuel injection pump is correct.10. If the timing bolt does not go into the timing hole in the flywheel, the timing is not correct. Do the steps that follow to adjust the fuel injection pump timing.a. Loosen four bolts (3). With tool (B) installed and the timing bolt removed, turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 45°. The reason for this step is to remove backlash from the timing gears when the engine is put on top center (TC).b. Tighten two bolts (3) 180° apart, evenly to a torque of 3 N m (27 lb.in.).c. Turn the flywheel slowly in the direction of engine rotation until the timing bolt can be installed in the flywheel. The No. 1 piston of the engine is now at top center (TC).d. Tighten four bolts (3) to a torque of 55 7 N m (41 5 lb.ft.). Remove the timing bolt from the flywheel and tool (B) from the fuel injection pump housing.11. Turn the flywheel clockwise (opposite the direction of normal engine rotation) a minimum of 45°. Now, turn the flywheel in the direction of engine rotation until tool (B) drops into slot of pump camshaft. Now turn the flywheel more, in the direction of normal engine rotation, until all gear clearance is removed from the drive train. Check to see that the timing bolt will go into the flywheel.12. If the timing is not correct, do the procedure in Steps 10a through 10d again. 13. If the timing is correct, remove the timing bolt from the flywheel and the timing pin [tool (B)] from the fuel injection pump housing. Install cover (2) and the plug in fuel injection pump housing.