32801-95200 Suzuki CONNECTOR

Table 1
Required Tools
Tool Part Number Part Description Qty
A 298-5564 T40 Torx Socket 1
D 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining 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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
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.
Use a deep socket to install the electrical connections to the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Illustration 1 g03364440
Injector code
If the original electronic unit injector (5) is installed , ensure that the electronic unit injector (5) is installed into the original position.
If a replacement electronic unit injector is installed, the correct injector code must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for more information. The code that is required is located at Position (X). Note: Record Code (X) before the electronic unit injector is installed.
Use Tooling (D) to remove any fuel from the cylinder. Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
Illustration 2 g03364228
If necessary, follow Step 4.a through Step 4.e in order to install a new harness assembly (3) to cylinder head (13).
Install a new harness assembly (3) to cylinder head (13). Note: Do not lubricate the O-ring seal.
Install a new bolt (11) to harness assembly (3). Tighten the bolt to a torque of 5.5 N m (49 lb in).
Install cable strap (10).
Connect harness assembly (12) to harness assembly (3).
If necessary, repeat Step 4.a through Step 4.e to install the remaining harness assemblies to the cylinder head.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 3 g03364222
New sealing washer (9) should only be installed if the original electronic unit injector (5) is to be reused.
For installing an original electronic unit injector, install a new O-ring seal (8). Note: Do not lubricate the O-ring seal.
Use a suitable tool to install a new sealing washer (9) to electronic unit injector (5). Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way on installation of the new sealing washer.
Ensure O-ring seal (8) and sealing washer (9) on a new electronic unit injector are not damaged and in place.
Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
Illustration 4 g03364219
Position clamp (7) onto electronic unit injector (5). Align the assembly of electronic unit injector (5) to the bore for the electronic unit injector in the cylinder head. Note: Ensure that the clamp is correctly positioned onto the electronic unit injector.
Push only on injector clamp (7) to install electronic unit injector (5). Do not apply pressure on any other part of the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
Install a new bolt (6) to clamp (7). Tighten the bolt finger tight.
Remove Tooling (C) from electronic unit injector (5). Install a new seal (1) to electronic unit injector (5) and to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.
Install new fuel injection line hand tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. Note: Ensure that the ends of the fuel injection line are seated into the electronic unit injector and the fuel manifold. Tighten the nuts hand tight.
Use Tooling (A) to tighten bolt (6) to a torque of 27 N m (239 lb in). Note: Tooling (A) must be used to ensure no damage to the electronic unit injector.
Tighten the fuel injection line to a torque of 50 N m (37 lb ft). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Install harness assembly (3) to electronic unit injector (5). Tighten harness assembly to a torque of 2.0 N m (18 lb in).
If necessary, repeat Step 1 through Step 18 to install the remaining electronic unit injectors.