48601-95200 Suzuki PISTON

start by: a) remove fuel injection pump housing and governor as a unitb) remove governorc) remove variable timing unit1. Remove the cover from the front of the fuel injection pump housing.2. Put identification on each of the fuel injection pumps by its location in the fuel injection pump housing. 3. Loosen the fuel injection pumps by using tool (A).
The fuel rack must be held in the center position while removing pumps.
4. Remove fuel injection pumps (1) by using tool (B).
When disassembling the fuel injection pumps, use caution to prevent damage to plunger surfaces. Do not mix the body and plunger assemblies of one pump with the body and plunger assemblies of another pump.
5. Disassemble the fuel injection pump as follows: Remove retainer ring (9), washer (2), bonnet (3), check valve (5), spring (4). Remove plunger (7). Remove pin (12) to remove sleeve (8). Remove spring (6) and washer (11). Remove barrel (10). 6. Remove cover (14), spring (16), and pin (15) for fuel rack centering.7. Remove cover (13) for the position indicator of the fuel rack. 8. Remove the fuel rack (20) from the front of the housing. 9. Put identification on each lifter by its location in the housing. Remove the lifters (22).
Do not remove or install new spacers in the lifters. A spacer that is not correctly assembled can cause engine failure. Spacers and lifters must also be installed in their original locations.
10. Remove two bolts (24) and plate (23) that holds the camshaft in the housing. Remove camshaft.11. Remove camshaft bearing using tool (C).12. Remove the rack bearing (21). 13. Remove the variable timing bearing (25) with tooling (D). 14. Remove the sleeve (26) from the housing with tooling (E).15. Remove two bolts (17), pin (18) and spacer (19).Assemble Fuel Injection Pump Housing
1. Heat sleeve (1) in oil to a maximum temperature of 275°F (135°C) and install it on the housing.2. Install the variable timing bearing with tooling (A). When installing, put the hole in the bearing in alignment with the hole in the housing.3. Install the two rack bearings. 4. Install the camshaft bearings using tool (B). Install the rear bearings .010 .005 in. (0.25 0.13 mm) inside the rear face of the bearing bore. Install the front bearing .015 .005 in. (0.25 0.13 mm) inside the front face of the housing. When installing, put the holes in the camshaft bearings in alignment with the holes in the bores in the housing. 5. Put clean engine oil on the camshaft and install it in the housing.6. Put the plate that holds the camshaft in position on the housing and install the lock and bolts.7. Install the lifters in their respective locations in the housing.8. Put clean fuel oil on the rack and install it in the housing. If new lifters and pumps are to be installed the fuel injection pump must be put in time. See FUEL INJECTION PUMP TIMING DIMENSION SETTING OFF ENGINE in TESTING AND ADJUSTING.9. Install the spacer and timing pin in the housing. Move the rack backward and forward until the timing pin is engaged in the groove in the rack.
Do not install fuel injection pumps if rack is not in the correct position.
10. Install the lever and cover (2) for the rack position indicator.11. Install the spring (5), pin (4), and cover (3) for getting center position of fuel rack.12. Put clean fuel oil on all parts of the fuel pumps and assemble as follows: Assemble barrel (8), washer (15) and spring (14). Install plunger (9) in barrel. Install sleeve (10) on plunger and install pin (16) in sleeve. Install check valve (7), and spring (6) in barrel. Install bonnet (12) and ring (13) on the bonnet. Install washer (11) on bonnet. Put pumps in their respective locations with tool (C). For installation of pumps, see REMOVING AND INSTALLING FUEL INJECTION PUMP ASSEMBLIES in TESTING AND ADJUSTING.13. Install felt washers around the fuel pump openings.14. Install the cover on the front of the housing for fuel injection pump.end by: a) install variable timing unitb) install governorc) install fuel injection pump housing and governor as a unit