61581-98610 Suzuki MARK, SAFETY WARNING

Start By:a. remove fuel injection linesb. remove electric starting motorc. remove valve cover 1. Remove muffler clamp (1).2. Remove four bolts (2) and remove exhaust pipe (3). 3. Disconnect and remove lines (4) and (5).4. Remove pin (6) from the linkage.5. Remove two bolts (7) from the mounting plate.6. Disconnect four lines (8). 7. Remove six nuts (9) and cover (10) from the timing gear cover.8. Remove the two bolts and heat shield (11) from the engine. 9. Loosen bolt (12) until there is approximately 3.18 mm (.125 in.) gap between washer (13) and the fuel pump drive gear.10. Install tooling (A) as shown, and loosen the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove tooling (A), bolt (12), washer (13) and fuel pump drive gear (14). 11. Fasten a nylon strap and hoist to fuel injection pump housing and governor (15) as shown.12. Remove three nuts (16) that hold the fuel injection pump housing and governor to the timing gear plate. Remove fuel injection pump housing and governor (15) from the engine. The weight of the fuel injection pump housing and governor is 26 kg (58 lb.).Install Fuel Injection Pump Housing And Governor
Typical Example1. Put O-ring seals (17) and (18) in position on the fuel injection pump housing and governor. Put clean engine oil on the O-ring seals. 2. Fasten a nylon strap and hoist to fuel injection pump housing and governor (15) as shown.3. Put the fuel injection pump housing and governor in position on the timing gear plate, and install nuts (16) on the studs to hold it in place. 4. Remove bolts (19) and cover (20) from the fuel injection pump housing. 5. Install the bolt that holds the fuel pump drive gear to the fuel injection pump camshaft without the washer. This will allow the camshaft in the fuel system to be turned.6. Install tooling (B) in the fuel pump housing as shown. Put pressure on the end of tool (B) and turn the camshaft slowly until tool (B) drops into the groove (slot) in the camshaft. The fuel injection pump is in the No. 1 piston top dead center position. 7. With tooling (B) still in position, remove the bolt from the fuel injection pump camshaft.
Do not over tighten bolt (12) that holds the drive gear on the fuel injection pump. If the bolt is too tight, the gear will not be allowed to slip on the fuel injection pump shaft. This will cause the timing pin to break off in the notch of the camshaft when the flywheel is turned.
8. Install washer (13) and bolt (12) in the fuel injection pump camshaft with the large diameter of the washer toward the bolt head. Tighten the bolt to a torque of 6.8 N m (60 lb in). Make sure bolt (12) does not loosen as the flywheel is turned.9. Use tooling (C), and turn the flywheel in the direction of engine rotation, (clockwise from the front of the engine), until bolt (21) [3/8" - 16 NC x 4 in. (102 mm) long] can be installed in the flywheel. Do not turn the crankshaft counterclockwise to get the bolt aligned with the hole in the flywheel.10. If you go past the bolt hole in the flywheel, turn the crankshaft counterclockwise opposite the direction of engine rotation (as seen from the front of the engine) approximately 30 degrees. This procedure will permit the gear clearance (backlash) to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise).11. Repeat Step 9 again. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward.e. If both rocker arms can not be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°) and install the bolt again.12. When bolt rocker arms are loose, tighten bolt (12) that holds the fuel pump drive gear to the fuel injection pump camshaft to a torque of 270 25 N m (200 18 lb ft).13. Remove tooling (B) and (C) and bolt (21) from the flywheel.14. Install the valve cover. See the topic, Install Valve Cover in this module.15. Install the electric starting motor. See the topic, Remove And Install Electric Starting Motor in this module. 16. If studs (21) were removed, put 5P3413 Pipe Sealant with Teflon on them, and install them in the timing gear cover.17. Put the gasket and cover (10) in position, and install the washers and nuts (9) that hold them. Tighten the nuts to a torque of 27 7 N m (20 5 lb ft).18. Put the gasket and cover (20) in place on the fuel injection pump housing, and install four bolts (19) that hold the cover.19. Put heat shield (11) in position, and install the two bolts that hold it. 20. Install lines (4) and (5).21. Install two bolts (7) that hold the mounting plate.22. Install pin (6) and the cotter pin.23. Connect four lines (8). 24. Install exhaust pipe (3).25. Install four bolts (2).26. Install muffler clamp (1).End By:a. install fuel injection lines