09404-06204 Suzuki Clamp Length: 65

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
B(1) 585-0005 Crankshaft Turning Tool 1
B(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
C 136-4632 Timing Pin Camshaft 1
592-9030 Adaptor 1
D 364-9107 Timing Pin (Fuel Injection Pump) 1
522-2016 Adapter 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (B) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Start By:
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Coolant - Change" for the correct procedure.
Remove the Def injector and mounting. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install" for correct procedure.
Remove the Exhaust cooler (NRS). Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for correct procedure.
Remove the throttle valve. Refer to Disassembly and Assembly, "Throttle Valve (Intake Air) - Remove and Install" for correct procedure.
Remove the low-pressure fuel system. Refer to Disassembly and Assembly, "Fuel Pressure Regulator - Remove and Install" for correct procedure.Note: Use tooling (A) to plug or cap all open ports. Ensure that the capping kit is new and free from debris.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Clean the fuel injection pump and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Illustration 1 g06324298
Disconnect harness assembly (2) from flow control valve (3).
Disconnect harness assembly (4) from fuel temperature sensor (5).
Remove fuel injection line (1) from fuel injection pump (6) and the fuel manifold. Refer to Disassembly and Assembly, Fuel Injection Lines - Remove for the correct procedure.
Illustration 2 g06324889
Illustration 3 g06326934
Use Tooling (B) to rotate the crankshaft so that number one piston is at top dead center. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
Remove plug (8) from cylinder block (7). Remove O-ring seal (9) (not shown) from the plug.
Use Tooling (C) in position (X), to ensure that the camshaft is locked with number one piston at top dead center.Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Remove plug (11) from fuel injection pump (6). Remove O-ring seal (12) (not shown) from the plug.
Install Tooling (D) in position (Y), to fuel injection pump (6).
Remove bolts (10) from fuel injection pump (6). Support the fuel injection pump as the bolts are removed.
Remove fuel injection pump (6) from cylinder block (7). Remove O-ring seal (13) (not shown).
If necessary, remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Remove" for the correct procedure.