61631-96300 Suzuki Rack, Under Cover

Table 1
Required Tools
Tool Part Number Part Description Qty
A 339-9354 Cap Kit 1
265-2256 Lint Free Wipes 1
B 513-8858 Wrench 1 Start By:
Remove air inlet manifold.
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, PERJ1017, "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.
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.
Use Tooling (A) to cap tube assemblies, fittings, ports, and any opening in the fuel system to prevent contamination. Use clean latex gloves before handling cleaned components.
Prior to loosening any high-pressure joints, use compressed air to remove any external debris.
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Loosen plug (1) one full turn, do not remove plug (1). After 30 seconds, use Cat® Electronic Technician (Cat ET) to verify that the fuel rail pressure is below 2.0 MPa (290 psi). Refer to Operation and Maintenance Manual, "High-Pressure Fuel System - Pressure Release" for more information.
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Remove clamp assemblies (3). Remove tube assembly (2) and place in a clean, new resealable bag. Continue removing tube assemblies until all the tubes have been removed from each side of the engine.
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Remove tube assembly (4) and place in a clean, new resealable bag. Remove clamp assembly (6). Remove tube assembly (5) and place in a clean, new resealable bag.
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Remove clamp assemblies (7) and tube assembly (8) and place in a clean, new resealable bag.
Remove tube assembly (9) and place in a clean, new resealable bag.Installation Procedure
Note: When Tooling (A) is removed, be careful to prevent contamination.
Illustration 6 g06260446
Illustration 7 g06260440
Lubricate the O-ring seals of tube assembly (9) lightly with clean engine oil.
Connect tube assembly (9) and hand tighten the nuts. Use Tooling (B) to tighten the nuts of tube assembly (9) to a torque of 38 3 N m (28 2 lb ft). Tighten the tube assembly nuts to a final torque of 105 5 N m (77 4 lb ft).
Lubricate the O-ring seals of tube assembly (8) lightly with clean engine oil. Connect tube assembly (8) and hand tighten the connection nuts.
Hand tighten the bolts on clamp assemblies (7).
Use Tooling (B) to tighten the nuts of tube assembly (8) to a torque of 38 3 N m (28 2 lb ft).
Tighten the bolts on clamp assemblies (7) to a torque of 55 10 N m (41 7 lb ft). Tighten the tube assembly nuts to a final torque of 105 5 N m (77 4 lb ft).