32900-87D51 Suzuki CDI UNIT ASSEMBLY

Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turns in the body.
1. Loosen the fuel injection line nut at the nozzle end with Tool (A) and a 7/8 5P-0328 Crowfoot Wrench (in).2. Loosen the fuel line nut at the fuel injection line adapter with Tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system. If necessary, use Tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with Tool (C) to remove the push rods.3. Put compression on the valve springs with Tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the intake valve lifter with Tooling (E) as follows:a. Install 5P-2685 Nut(3) and 5P-6601 Collet(4) on 5P-2408 Outer Handle Assembly(5).b. Install 5P-6599 Inner Handle Assembly(6) in 5P-2408 Outer Handle Assembly(5). c. Install Tooling (E) in the intake valve lifter. Hold the 5P-2408 Outer Handle Assembly,and tighten the 5P-6599 Inner Handle Assemblyuntil the 5P-6601 Colletis tight against the inside of the intake valve lifter. d. Remove intake valve lifters (7) from the cylinder block with Tooling (E). Put identification marks on the lifters as to their location in the engine. 6. Remove the exhaust valve lifters with Tooling (E) as follows:a. Install 5P-2685 Nut(3) and 5P-6601 Collet(4) on 5P-2408 Outer Handle Assembly(5). The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side.b. Install the outer handle assembly in the intake valve lifter side of the cylinder head assembly. Slide the flat area of 5P-2408 Outer Handle Assembly(5) through the head casting, and install the 5P-6601 Colletin the exhaust valve lifters. c. Install 5P-6599 Inner Handle Assembly(6) in 5P-2408 Outer Handle Assembly(5). Hold the 5P-2408 Handle Assembly, and tighten the 5P-6599 Handle Assemblyuntil the 5P-6601 Colletis tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.3. Remove the 5P-6599 Inner Handle Assembly.Slide the 5P-2408 Outer Handle Assemblythrough the head casting, and remove it from the intake valve lifter side of the cylinder head. f. Use a magnet, and remove exhaust valve lifters (8) from the intake valve lifter side of the cylinder head assembly. Put identification marks on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2 must be done to install intake or exhaust valve lifters.
When a valve lifter is removed, a new guide spring must be installed.
1. Install a new guide spring (1) on the valve lifters. 2. Put the intake or exhaust valve lifter in position in 5P2395 Holder (5) of Tooling (A). Install 5P-2685 Nut(4) and 5P-2400 Compressor(3) on 5P-2408 Outer Handle Assembly(2). Install the 5P-2400 Compressoron the lifter over the guide spring. Immerse the lifter assembly in engine oil before installing it in the cylinder block lifter bore. The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. All tooling and valve lifters must be installed and removed from the intake valve lifter side. 3. Install the exhaust valve lifters with Tooling (A) as follows: Be sure to install original valve lifters in their respective bores. New valve lifters can be mixed.a. Install exhaust valve lifter (6) and the handle assembly in the cylinder head opening on the intake valve lifter side. Slide the flat area of the 5P-2408 Outer Handle Assemblythrough the casting in the cylinder head assembly. b. Put the exhaust valve lifter in the valve lifter bore of the cylinder block. Install 5P-6599 Inner Handle Assembly(7) in the 5P-2408 Outer Handle Assembly, and push the exhaust valve lifter from Tooling (A).c. Remove the 5P-6599 Inner Handle Assembly from the 5P-2408 Outer Handle Assembly. Slide the 5P-2408 Outer Handle Assemblyto the intake valve lifter side of the cylinder head, and remove it.4. Install the intake valve lifters with Tooling (A) as follows: Be sure to install original valve lifters in their respective bores. New valve lifters can be mixed.a. Install 5P-6599 Inner Handle Assembly(7) in the 5P-2408 Outer Handle Assembly.b. Install the intake valve lifter into the valve lifter bore of the cylinder block with Tooling (A). Use the 5P-6599 Inner Handle Assemblyto push the lifter from Tooling (A). Remove Tooling (A).
If necessary, use Tool (C) to turn the engine so the valves do not make contact with the pistons when the valves are opened with Tool (B) to install the push rods.
5. Turn the rocker arms up, and use Tool (B) to install push rods (9).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
6. Install inner fuel lines (10). Use Tool (D) to tighten the nuts on the adapter assemblies in the cylinder head assembly, and use Tool (E) to tighten the nuts on the fuel injection nozzles to a torque of 40 7 N m (30 5 lb ft).End By:a. install valve covers