09117-08087 Suzuki BOLT (8X40)

Start By: a. disassemble governor 1. Remove two screws (1) that hold block (2) to the bar (rack). Remove block (2) and link (3) as a unit.2. Remove seat (4) and spring (5) from the bar (rack). 3. Use tool (B) and remove sleeve (6). Remove timing pin. 4. Turn the fuel injection pump housing over as shown. Remove cover (7) and gasket from the bottom of the fuel injection pump housing. Photo shown is a typical example. Plugs (9) may be on the opposite side of the fuel injection pump housing.5. Remove mounting bolts (8). Remove six plugs (9) from the side of the fuel injection pump housing. 6. Install tooling (C) in the end of the fuel injection pump camshaft. Tooling (C) will be used to turn the fuel injection pump camshaft. 7. Turn the fuel injection pump camshaft until the lifter is as far down in the bore as possible. Install tooling (D) with the flat side toward the lifter. Tooling (D) will hold the lifter down when the fuel injection pump camshaft is removed. Do the other lifters the same way. 8. Remove bolts (10) that hold center bearing (11) in place. 9. Remove tooling (C).10. Remove bolts (12) that hold adapter (13) to the fuel injection pump housing. 11. Use tooling (E) and remove adapter (13). 12. Remove O-ring seal (14) and shims (15) from adapter (13).13. Remove lip type seal (16) and bearing cup (17) from adapter (13). 14. Pull fuel injection pump camshaft (18) forward just enough to remove center bearing (11). Remove fuel injection pump camshaft (18). 15. Remove cone bearings (19) and (20) from fuel injection pump camshaft (18) with tool (F) and a press. Remove shims (21) from behind bearing cone (20). 16. Use tool (G) and push down on the lifters and remove tooling (D) from the fuel injection pump housing. 17. Remove lifters (22) from the fuel injection pump housing. 18. Remove pins (23) that hold rollers (24) and bushings (25) in the lifters. Remove rollers (24) and bushings (25) from lifters (22). 19. Use a pair of needle nose pliers as shown and remove lower spring seats (26) and plungers (27) from the fuel injection pump housing.
Position the bar (rack) so the balls on the control sleeves are in alignment with the grooves in the fuel injection pump housing.
20. Use tool (P) and remove springs (28), control sleeves (29) and upper spring seats (30) from the fuel injection pump housing. 21. Remove plug (31) and gasket from the fuel injection pump housing.22. Remove guide (32). 23. Use tool (H) and remove the ring from the fuel injection pump housing that holds the bar (rack) in place. 24. Remove pin (33) from bar (rack) (34). Remove bar (rack) (34).25. If a replacement is needed, use a long brass punch and a hammer and remove guide (35) from the fuel injection pump housing. 26. Remove barrel housing flange nuts (36) and washers (37) that hold the barrel assemblies in the fuel injection pump housing. 27. Use tool (M) and remove barrel assemblies (38). Remove shims (39). 28. Remove O-ring seals (40), (41) and (42) from barrel assembly (38). 29. Use tool (J) to hold the barrel assembly and loosen bonnet (43) from barrel (44) with tool (K). 30. Remove bonnet (43), O-ring seal (45), spring guide (46), spring (47), valve (48), gasket (49) and seat (50) from barrel (44). 31. Remove ring (51) from barrel (44). Remove baffle sleeve (52) and washer (53) from barrel (44). Remove barrel (44) from barrel housing (54).32. Do Steps 28 through 31 for the other barrel assemblies. 33. Use tooling (L) and a press and remove bearing race (55). Do not remove bushing (56) from the fuel injection pump housing. Put identification on the fuel injection pump housing and the brackets of tooling (A) as to their location on the fuel injection pump housing. The fuel injection pump housing can be installed on tooling (A) incorrect when the adapter and governor housing are not installed. The two brackets of tooling (A) are not the same. The following steps are to assemble the fuel injection pump.34. Inspect all parts for damage and make replacements if necessary. Put clean diesel fuel on the parts during assembly. 35. Use tool (L) and a press and install bearing race (55) in bushing (56) until the bearing race is 0.3 mm (.012 in) above bushing (56). 36. Install original shims (60) on governor housing (58).37. Put gasket (57) in position and install governor housing (58) on the fuel injection pump housing. Install four bolts in holes (59) that hold the governor housing to the fuel injection pump housing. Do not tighten the bolts at this time. 38. Use tool (Q) and a press and install the bearing race and governor housing (58) on the fuel injection pump housing until the governor housing is against the fuel injection pump housing. Tighten the four bolts that hold the governor housing to the fuel injection pump housing to a torque of 8.8 to 10.8 N m (6.5 to 8.0 lb ft). 39. Put original shims (21) in position on the fuel injection pump camshaft. Heat bearing cones (19) and (20) to a maximum temperature of 135° C (275°F) and install the bearing cones on the fuel injection pump camshaft (18). 40. Use tooling (L) and a press and install bearing cup (17) in adapter (13).41. Use tooling (Q) and a press and install lip type seal (16) in adapter (13) with the lip of the seal toward bearing cup (17). 42. Put tool (R) on the end of the fuel injection pump camshaft that has splines. Install adapter (13) on fuel injection pump camshaft (18).43. Remove tool (R). 44. Put a straight edge (S) across the end of the fuel injection pump camshaft. Use a vernier caliper (T) and measure from the top of the straight edge to adapter (13). Subtract the thickness of the straight edge. The