61139-96301 Suzuki Cap, Drain

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 439–3940 Bracket Ast 2
6V-3668 12 MM Bolt 2
5P-8245 Hard Washer 2
B 484-3313 Fuel Pump Kit 1
(1) Use one to remove the fuel pump from the EPG engine.Start By:
Remove the fuel transfer pump.
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.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
This fuel system may contain high-pressure fuel for extended periods after engine shutdown. Do not open the high-pressure fuel system without first releasing the high-pressure fuel from the system. Refer to the Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" to properly release fuel pressure. Exposure to high-pressure fuel may result in personal injury.
Illustration 1 g06261853
Remove air manifold (1). Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove and Install" to remove air manifold (1).
Illustration 2 g06261967
Disconnect hose assemblies (2) and (3). Disconnect harness assembly (4).
Illustration 3 g06261968
Disconnect hose assembly (5) and harness assembly (8). Remove fuel pressure sensor (6) and fuel temperature sensor (7).Note: Discard the fuel pressure sensor (Rail) after use. Use new fuel pressure sensor (Rail) for installation.
Illustration 4 g06262676
Remove clamp assembly (10) and remove tube assembly (9).
Illustration 5 g06261977
Illustration 6 g06261982
Disconnect hose assembly (13).
Attach Tooling (A) and a suitable lifting device to high-pressure fuel pump (11). The weight of high-pressure fuel pump (11) is approximately 120 kg (265 lb).
Remove four bolts (12).
Rotate high-pressure fuel pump (11) as shown in Illustration 6 and add another Tooling (A).
Remove high-pressure fuel pump (11).Installation Procedure
Install high-pressure fuel pump (9) in the reverse order of removal.
Tighten fuel pressure sensor (6) to a torque of 45 6 N m (33 4 lb ft) with a 27 mm (1.0 inch) deep socket or crowfoot.
Tighten fuel temperature sensor (7) to a torque of 20 3 N m (177 27 lb in).
Lubricate O-ring seals of tube assembly (9). Connect tube assembly (9) and hand tighten nut (10).
Install clamp assembly (10). Hand tighten the bolt on clamp assembly (10).
Tighten the connection nuts of tube assembly (9) to a torque of 38 N m (28 lb ft). Tighten the connection nuts to a final torque of 100 N m (74 lb ft).
Tighten the bolt on clamp assembly (10) to a torque of 55 10 N m (41 7 lb ft).
Following repairs to the high-pressure fuel system, accumulator plugs on opened cylinders should be removed. A successful completion of the "Fuel Systems Function Test (FSFT)" using CATET must be performed. Upon completion of the FSFT, accumulator plugs are to be reinstalled.
After replacing the high-pressure fuel pump, perform a fuel system functional test. It is not necessary to remove any accumulator plugs to perform the fuel system functional test when only the high-pressure fuel pump has been replaced.