33920-99E05 Suzuki MODULE, ENGINE CONTROL

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     278-4138     Fuel System Protection Gp (1)     1    
( 1 ) This tool can only be used one time. Start By:
Remove the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Remove and Install".Note: Cleanliness is an important factor. To prevent dirt from entering the internal mechanism, clean the exterior of the components thoroughly before you begin the removal procedureNote: To prevent fluid loss, and to keep contaminants from entering the system. Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies.
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
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.Dispose of all fluids according to local regulations and mandates.
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.
Note: Before opening the fuel system, the engine must be turned off for at least one minute.Note: Use Caterpillar Electronic Technician (ET) to verify that the fuel system pressure is at zero before opening the fuel system.Note: Use Tooling (A) after any fuel line has been disconnected.
Position the No. 1 piston at the top center of the compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Illustration 1 g01375105
Illustration 2 g02006074
(2) Fuel injection pump drive gear (3) Idler gearNote: The alignment of the gears may not match the illustration. The idler gear (3) has an odd number of gear teeth. Do not rotate the engine after the fuel injection pump has been removed.
Remove cover (1) .
Place a mark on pump drive gear (2) and idler gear (3) for assembly purposes.
If replacing pump drive gear (2) or the engine has been rotated with the fuel injection pump removed, refer to Testing and Adjusting, "Fuel Injection Timing-Check" for the correct procedure.
Illustration 3 g01383443
Disconnect hose assembly (4) .
Remove nut (5) .
Disconnect hose assemblies (6) and remove the washers. Discard the washers.
Disconnect harness assembly (7) .
Remove tube assembly (9) and remove bracket assembly (8) .
Illustration 4 g01383754
Remove bolt (10) .
Disconnect hose assembly (11) and remove the washers. Discard the washers.
Disconnect tube assembly (12) .
Disconnect harness assembly (13) .
Remove bolt (14) . Disconnect tube assembly (15) and remove the washers. Discard the washers.
Illustration 5 g01383777
Remove bolts (17) .
Remove two bolts (18) (not shown).
Remove bolts (19) .
Remove fuel injection pump (16) and the O-ring seal.
If you are reusing the pump drive gear, remove the pump drive gear and install the pump drive gear on the new fuel injection pump. The marks that were made during removal will be used to orient the fuel injection pump during installation.