65866-92D00 Suzuki NUT, PUSH

Start By:a. remove crankshaft pulleyb. remove alternatorc. remove oil pan1. Remove the oil pump suction pipe. 2. Remove the two bolts (4) that hold the front support to the frame. Loosen the two bolts that hold the rear of the engine to the frame.3. Put a hydraulic jack and wood blocks in position under the front of the cylinder block. Lift the front of the engine until the weight of the engine is off support (2). Remove the front support.4. Disconnect hose (3) and wiring (1) from the timing gear cover.5. Disconnect the hoses for the heater (if so equipped) from the timing gear cover.6. Disconnect the fuel lines from the fuel filter base. Remove the base and bracket as a unit. 7. Remove the clamps from the water sleeves in each cylinder head. Push the sleeves into the timing gear cover with tool (A). 8. Remove connector (5). Remove the tachometer drive adapter (6).9. Remove the bolts that hold the timing gear cover to the cylinder block. Be sure to remove the bolt that is behind elbow (7). Put identification of the bolts as to their location for use at assembly.
Be extra careful not to cause damage to the crankshaft front seal during removal and installation of the timing gear cover.
10. Install two 7/16" - 14 NC forged eyebolts in the timing gear cover. Fasten a hoist and remove timing gear cover (8) and the oil pump from the dowels on the cylinder block. The weight of the cover and pump is 40 kg (85 lb.).Install Timing Gear Cover And Oil Pump
1. Clean the contact surfaces of the cylinder block and timing gear cover. Install the timing gear cover gasket on the cylinder block. Make sure the water sleeves are installed in the timing gear cover. Put oil on the seals. 2. Install two 7/16" - 14 NC forged eyebolts in the timing gear cover. Fasten a hoist and put timing gear cover (2) and the oil pump in position on the engine. Make sure the oil pump gear and crankshaft gear are in alignment.3. Install the bolts that hold the cover in place.4. Install tachometer drive adapter (1). 5. Install connector (3) on timing gear cover.6. Push the water sleeves into the cylinder heads with tool (A). Install clamps (4).7. Put the engine front support in position and install the bolts that hold it in place. Lower the front of the engine and remove the hydraulic jack and blocks. Install the bolts that hold the support to the frame. 8. Tighten bolts (5) to a torque of 425 70 N m (315 50 lb.ft.).9. Connect the hose from the engine oil cooler to the timing gear cover. 10. Connect wire (6) to the water temperature sending unit.11. Install the fuel filter base and bracket (7). Connect the fuel lines to the filter base.12. Cut the timing gear cover gasket so it is even with the bottom of the engine block and timing gear cover.13. Install the oil pump suction pipe.End By:a. install oil panb. install alternatorc. install crankshaft pulley