48401-94501 Suzuki PISTON & PISTON ROD SUB ASSY

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Drain the coolant from the cooling system. 2. Remove fuel transfer pump (3). See the topic, Remove And Install Fuel Transfer Pump.3. Disconnect wire harness (4).4. Loosen the hose clamp that holds the hose in position on elbow (5). Move the hose away from the elbow.5. Remove the bolts, and remove water line adapter (1) and tube (2) from the engine. 6. Remove the bolts, and remove elbow (7) from the top of the oil pump and tube (6).7. Remove the bolts, and disconnect elbow (8) from the bottom of the oil pump. 8. Fasten a hoist and tooling (A) to oil pump (9). Remove the bolts, and remove oil pump (9) from the pump drive. The weight of the oil pump is 39 kg (86 lb).9. Remove O-ring seal (10) from the pump drive. The following steps are for installation of the oil pump.
The oil pump must turn freely by hand, and the pump must have oil for lubrication before it is installed.
10. Put O-ring seal (10) in position on the pump drive. Put clean engine oil on the O-ring seal.11. Fasten a hoist and tooling (A) to oil pump (9). Align the splines on the oil pump shaft with the splines in the oil pump drive. Install the oil pump.12. Install the bolts to connect elbow (8) to the oil pump.13. Put elbow (7) in position on tube (6) and the top of the oil pump. Install the bolts to hold it in place.14. Make sure the O-ring seal is in position on the end of tube (2). Put clean oil on the O-ring seal. Put the gasket, water line adapter (1) and tube (2) in position, and install the bolts that hold it.15. Put the hose in position on elbow (5), and tighten the clamps that hold it.16. Connect wire harness (4).17. Install fuel transfer pump (3). See Remove And Install Fuel Transfer Pump.18. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble And Assemble Oil Pump
Start By:a. remove oil pump
Cover (2) has spring tension under it. To prevent personal injury, loosen bolts (1) slowly and the same amount to remove the tension under the cover.
1. Remove bolts (1), cover (2), gasket (3), spring (4) and valve spool (5) from the pump body. 2. Remove cover assembly (6) and the gasket from the pump body. 3. Remove cover assembly (7) from the pump body. 4. Use tooling (A) to remove bearings (8) from cover assembly (7). 5. Remove shaft assemblies (10) from body assembly (9). 6. Use a press to remove gears (11) from the shaft assemblies. 7. Use tooling (A) to remove bearings (12) from body assembly (9). The following steps are for assembly of the oil pump. 8. Make an alignment of bearings (12) so that the joints are 45 15° from a line through the center of the bearing bores as shown.9. Use tooling (A) to install bearing (12) in the body assembly until they are 1.5 0.5 mm (.06 .02 in) below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The diameter must be 31.811 0.013 mm (1.2524 .0005 in).10. Heat gears (11) to a maximum temperature of 316° C (600° F).11. Install the gears on shaft assemblies (10) until they are 34.0 0.5 mm (1.34 .02 in) from the cover end of the shaft assemblies to the face of the gears and 47.0 0.5 mm (1.85 .02 in) from the fuel pump drive end of shaft assembly (10). 12. Install shaft assemblies (10) in the body assembly. 13. Make sure dowels (13) and (14) are installed in cover assembly (8) so they extend 6.0 0.5 mm (.24 .02 in) above the surface of the cover assembly.14. Use tooling (A) to install bearings (8) in cover assembly (6) with the joints of the bearings in the positions as shown. Put cover assembly (6) in position, and tighten the bolts to hold it to the body assembly.15. Make sure the two pins in cover assembly (6) are installed so they extend 6.0 1.0 mm (.24 .04 in) above the surface of the cover assembly. Install the gasket and cover assembly (6) on the body assembly.16. Put clean engine oil on valve spool (5). Install valve spool (5), spring (4), gasket (3), cover (2) and the bolts in the body assembly.End By:a. install oil pump