09202-07002 Suzuki PIN (7X48)

START BY:a. remove governor from fuel injection pump housing (new scroll fuel system effective in production with 10X5411-UP, 45V36536-UP) 1. Remove cover (1).2. Install tooling (B). Engage the timing pin in the center groove of the fuel rack. Move the fuel rack in the direction of the arrow to find the center groove. 3. Install tooling (D), and remove bushing (2). 4. Install tooling (E), and remove the fuel injection pump. 5. Remove spacer (3).
Do not mix components from fuel injection pump assemblies.
6. Remove the remainder of the fuel injection pumps and spacers with Steps 2-5 done again for each fuel injection pump. 7. Remove cover (4). 8. Remove fuel rack (5). 9. Use a bar magnet to remove lifter assembly (6). 10. Use tooling (A) to remove snap ring (7). 11. Use a plastic hammer to move camshaft (8) out of washer (9).
Do not let the camshaft fall because the machined surfaces will be scratched.
12. Remove camshaft (8). 13. Remove rack rear bearing (10) and camshaft rear bearing (11). 14. Install location plate from tooling (B). Align the bore in the plate with the O-ring seal counterbore in the fuel injection pump housing. Make a mark for alignment.15. Remove tooling (B). 16. Remove rack bearing (12) and camshaft bearing (13).Assemble Fuel Injection Pump Housing (New Scroll Fuel System Effective In Production With 10X5411-Up, 45V36536-Up)
Be sure all oil passages are clear, and put clean oil on all parts before assembly. 1. Use tool (A) to install the camshaft front bearing. Install the bearing with the joint toward the top of the fuel injection pump housing. Install the bearing so it is 1.00 0.25 mm (.039 .010 in.) below the surface of the housing. The inside diameter of the bearing must be 55.090 0.039 mm (2.1688 .0015 in.) after assembly. Install the camshaft rear bearing with tooling (A). Install the bearing with joint toward the top of the fuel injection pump housing. Install the bearing so it is 0.25 0.20 mm (.0098 .0078 in.) below the surface of the housing. The inside diameter of the bearing must be 68.339 0.039 mm (2.6905 .0015 in.) after assembly. 2. Use tooling (A) to install the fuel rack rear (governor end) bearing. Install the bearing so it is 7.16 0.13 mm (.282 .005 in.) below the surface of the housing. 3. Install the locator plate from tooling (B) on the drive end of the fuel injection pump housing to install the bearing for the fuel rack. Use clean grease to hold the new fuel rack bearing on the driver from tooling (C). Install the driver and bearing in the plate with the groove in the driver in alignment with the pin in the plate, and use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against the plate.4. Remove tooling (B) from the fuel injection pump housing. The rack bearing must be installed so it is 0.25 0.25 mm (0.010 0.010 in.) below the surface of the housing. 5. Install fuel injection pump camshaft (1) in the fuel injection pump housing.6. Put the fuel injection pump housing on end, and put a block under the camshaft. 7. Put washer (2) over the end of the camshaft, and use tooling (A) and (C) to push washer (2) against its seat on the camshaft. The camshaft must have 0.285 0.235 mm (0.0112 0.0093 in.) end play when the washer is pushed against the cam shoulder. 8. Use tool (D) to install snap ring (3) in the groove in the camshaft. 9. Install four lifter assemblies (4) in the fuel injection pump housing with the groove in the lifter in alignment with the pin in the housing. The four lifters are all the same, and can be mixed. 10. Install fuel rack (5) in the fuel injection pump housing with the groove in the end of fuel rack in alignment with the ear (tab) of the rack bearing at the drive end of the fuel injection pump housing. 11. Install the timing pin from tooling (B). Engage the timing pin in the center groove of the fuel rack. Move the fuel rack in the direction of the arrow to locate the center groove.12. Install spacer (6). 13. Put the (slot) groove (8) in the gear segment 180° away from groove (7) in the barrel. When the fuel injection pump is installed, groove (7) must engage with dowel (9). 14. Use tool (E) to install the fuel injection pump. Installation is made easier by rotation of the cam lobe away from the lifter assembly. 15. Install O-ring seal (10). 16. Install bushing (11). Tighten bushing (11) by hand until the bushing is even with the top of the housing. If installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again, and install the bushing again.17. Use tool (F) and a torque wrench to tighten the bushing to a torque of 190 14 N m (140 10 lb.ft.).18. Remove tooling (B). 19. Install tooling (G) and (H) to measure total rack travel. Correct rack travel is 15.70 mm (.618 in.). A smaller measurement is an indication of incorrect fuel injection pump installation.20. Complete the installation of the remainder of fuel injection pumps as given in Steps 11-19. 21. Install cover and gasket (12).END BY:a. install governor on fuel injection pump housing (new scroll fuel system effective in production with 10X5411-UP, 45V36536-UP)