09205-11001 Suzuki Dowel Pin, Gear Case

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     1P-0510     Driver Group     1    
C     FT-2398     Oil Pump Shaft Tool     1    
0S-1627 Bolts     2    
2J-3506 Full Nuts     2    Note: Use 8T-0447 Dial Calipers to measure the dimensions in the following procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.
Illustration 1 g01209057
Note: On the lower bearing, align the hole in the bearing with the hole in the oil pump's body.
Apply a coat of clean engine oil to the outside of each bearing. Use Tooling (B) and a suitable press in order to install bearings (11) into pump body (9). Install the bearings 12.30 0.25 mm (0.484 0.010 inch) below the surface of pump body (9). The inside diameter of the bearings must be 60.039 0.040 mm (2.3637 0.0016 inch) after installation.
Illustration 2 g01209062
Apply a coat of clean engine oil to the outside of each bearing. Use Tooling (B) and a suitable press in order to install bearings (7) into cover (6). Align the hole in the bearing with the hole in the cover. Install the bearings 7.50 0.25 mm (0.230 0.010 inch) below the surface of cover (6). The inside diameter of the bearings must be 60.039 0.040 mm (2.3637 0.0016 inch) after installation.
Illustration 3 g01209063
Ensure that dowels (14) are installed to a height of 12.0 1.0 mm (0.47 0.04 inch).
Place O-ring seal (12) and O-ring seals (13) in position on cover (6). Apply clean engine oil to the O-ring seals.
Apply a coat of clean engine oil to the bearings and the gear pockets in pump body (9) .
Place drive shaft (8) and idler shaft (10) in pump body (9). Ensure that the gears are 0.14 to 0.16 mm (0.006 to 0.010 inch) below the surface of the pump body.
Apply clean engine oil to the bearings in cover (6). Apply clean engine oil to the top surface of the gears in pump body (9) .
Place cover (6) in position on pump body (9) .
Illustration 4 g01209072
Ensure that cover (6) is against the pump body. Ensure that all of the O-ring seals are in place. Install the bolts that hold cover (6) to the pump body.
Ensure that plug (15) is installed in the idler shaft.
Ensure that plug (16) is installed in the cover.
Illustration 5 g01209075
Illustration 6 g00628384
Note: Ensure that dowel (17) is installed at the location that is shown in Illustration 5 for a SAE standard rotation engine.
Install dowel (17) to a height of 8.0 1.0 mm (0.32 0.04 inch).
Ensure that plugs (18) are installed.
Use Tooling (C) in order to install gear (5) and the washer. Install bolt (4) .
Strike the head of the bolt with a hammer. Tighten the bolt again.
Install drive gear (3) .
Illustration 7 g01209076
Ensure that plug (19) is installed in the drive shaft.
Ensure that hollow dowel (20) is installed to a height of 4.0 0.5 mm (0.16 0.02 inch).
Place the O-ring seal on the dowel. Apply a coat of clean engine oil to the O-ring seal.
Install the O-ring seals on cover (1) and cover (2). Apply a coat of clean engine oil to the O-ring seals.
Install cover (1), cover (2), and the bolts.
Rotate the pump by hand. The pump must rotate freely. If the pump does not rotate freely, disassemble the pump in order to determine the cause.End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".