67221-92E50 Suzuki SHIFT ASSEMBLY

start by: a) remove fuel injection pump housing and governor as a unitb) remove fuel transfer pumpc) remove governord) remove variable timing unite) remove fuel filter housing 1. Remove the timing pin from its storage position. Install a bolt up side down through one of the holes in the flange. Install the pin into timing hole, move the rack until the timing pin goes through the notch in rack. Push timing pin down until head of bolt (1) touches housing.
The fuel injection pumps can not be removed before the timing pin is installed.
1. Remove the fuel injection pumps. Put identification on the pumps as to their location in the pump housing. 3. Put the pump in a vise, and remove the retainer with tool (A). Remove spring and check valve. 4. Remove the plunger, washer and spring from the body.
During disassembly and assembly of fuel injection pumps, do not cause damage to plunger surfaces. The bodies and plunger are special fitted, and the parts can not be changed with other bodies or plungers.
5. Remove cover (2). Remove the rack position indicator lever. 6. Remove the timing pin. Remove rack (3) from fuel injection pump housing. 7. Remove lifters (4) from the pump housing. Put identification on the lifters for installation purpose.
Do not remove or install the spacers in the lifters. A spacer that has been installed wrong can cause an engine failure.
8. Remove the bolts and locks from the drive gear (5) for fuel transfer pump. Remove the gear. 9. Remove bolts and cover (6) from bottom of housing. Pull camshaft (7) out of the housing. 10. Remove the camshaft bearings with tooling (B). 11. Remove the rack bearings with tooling (C).12. Remove the bearing for the variable timing unit from the housing.Assemble Fuel Injection Pump Housing
1. Install the bearing for the variable timing unit with the oil hole in the bearing in alignment with the hole in the housing, with tooling (A). 2. Install the two rack bearings with tooling (B). The front rack bearing must be .38 in. (9.7 mm) from the front surface of housing. The rack rear bearing must be installed 6.372 in. (16.2 cm) in from the variable timing unit end of pump housing.3. Install the four camshaft bearings with tooling (C).4. Put clean engine oil on the camshaft and install in housing. Install the drive gear for the fuel transfer pump. Install the cover on bottom of housing. 5. Install lifters (1) in housing in the same place from which they were removed. If new lifters have been installed, it will be necessary to set the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING.6. Install the timing pin with a bolt up through the flange as shown. This will hold the rack in the correct position and will let the fuel injection camshaft turn.
Do not try to install the fuel injection pumps if the rack is not in the correct position.
7. Install rack position lever (2) and cover.8. Assemble the fuel injection pumps as follows: a) Put clean fuel oil on all of the parts.b) Install the spring, washer and plunger in the body.c) Install the check valve, spring and bonnet in body.d) Tighten bonnet to a torque of 145 5 lb.ft. (20.1 0.7 mkg).9. Install the fuel injection pumps in the housing in the same place from which they were removed as follows: a) Turn the camshaft until lifter is down.b) Put the pump in position over the opening in housing with the flat side of gear in alignment with pin in lifter. Push the pump down into the housing. If the pump gear is in correct alignment, there must be approximately .375 in. (9.5 mm) clearance between pump housing and pump with the spring not under compression.c) Install the bolts to hold the pump in place. 10. Remove the timing pin from timing hole and install in its storage position in housing.end by: a) install variable timing unitb) install governorc) install fuel transfer pumpd) install fuel filter housinge) install fuel injection pump housing and governor as a unit