99011-94774-03A Suzuki OWNERS MANUAL

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     9U-6862     Tapered Brush     1    
C     9U-6863     Small Bore Brush     1    
D     9U-7237     Brush Extension     1    
E     4C-5552     Large Bore Brush     1    
F     8T-2998     Lubricant     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01054374
Use Tooling (B) and Tooling (D) in order to clean electronic unit injector seat (8) .
Use Tooling (C) and Tooling (D) in order to clean electronic unit injector bore (9) .
Use Tooling (E) and Tooling (D) in order to clean the unit injector sleeve.
Illustration 2 g01039929
Do not reuse O-ring seals. New O-ring seals must be used.
Install O-ring seals (7) . Lubricate the top two O-ring seals with a 50/50 mixture of clean engine oil and Tooling (F) .
Illustration 3 g01019373
When a fuel injector group is serviced, the new fuel injector group's electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new fuel injector group's electronic code is not entered, the previous fuel injector group's characteristics are assumed.If it is not possible to immediately reprogram the electronic injector code of the injector into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.
Note: Injector code (10) will be located on either the side, as illustrated, or on the top of the injector. Should the code be located in both places, use the code that is located on the side.
If the injectors have been replaced, record injector code (10) for programming.
Illustration 4 g01026993
Install electronic unit injector (2) into the original location in the cylinder head.
Install clamp (6) and spacer (5) .
Do not reuse the injector hold down bolts. New injector hold down bolts must be used.
If the injector hold down bolt is loose during the removal procedure, inspect the injector bore for wear and debris. Replace the clamp and spacer.
Note: Use new bolt (4) .
Install bolt (4) . Tighten bolt (4) according to the following procedure.
Tighten the bolt for the electronic unit injector to 50 10 N m (37 7 lb ft).
Loosen the bolt until you can turn the bolt by hand.
Tighten the bolt for the electronic unit injector again to 50 10 N m (37 7 lb ft).
Install bridge assemblies (3) in the respective locations.
Connect harness assembly (1) on electronic unit injector (2) . Install the nuts. Tighten the nuts to a torque of 2.5 0.25 N m (22 2 lb in).
Install the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install".
Adjust the height of the electronic unit injector. Refer to Testing and Adjusting, "Electronic Unit Injector - Adjust" for information on adjusting the height of the injector.
Calibrate the electronic unit injector.
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Open the "Injector Codes Calibration" in "Calibrations" under the "Service" menu on Cat ET.
Enter the new injector code (10) for the electronic unit injector in each cylinder.