48500-95290-0ED Suzuki POWER UNIT ASSEMBLY

preparatory step: a) separate governor from fuel injection pump housing1. Remove the fuel injection pumps as follows: a) Remove the protective cap and the felt washer (1). b) Install wrench (A) and remove retaining bushing (2) from housing. c) Install extractor (B).d) Remove the retaining bushing (2).e) Remove the seal (3).f) Lift the fuel injection pump out of the housing.g) Remove the spacer (4). Keep the spacers (4) and pumps together, and identified as to their location in the fuel injection pump housing.2. Disassemble the fuel injection pumps as follows: a) Remove the bonnet (5), ring (6), spring (7), and check valve (8) from the barrel (9).b) Remove the plunger assembly (10), washer (11), and spring (12) from the barrel (9).
While disassembling and assembling fuel injection pumps, exercise considerable care to prevent damage to plunger surfaces. The barrel and plunger assemblies are matched, and the individual parts are not interchangeable with other barrels or plunger assemblies.
3. Remove the rack (13).4. Remove the lifters (14). Keep the lifters identified and together with their respective pumps and spacers. 5. Remove the camshaft retaining plate (15), bolt, and lock. 6. Remove the spring (16) and the gear assembly (17) from the camshaft. 7. Remove the camshaft (19). 8. Using tool group (C), remove the camshaft bearings from the fuel injection pump housing.9. Remove the two rack bearings (18) from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Using tool group (C), install the camshaft bearings in the fuel injection pump housing. Install the bearing in governor end of housing so that the oil hole in bearing is aligned with oil hole in housing. Install the two end camshaft bearings flush with their respective ends of fuel injection pump housing. 2. Using tool setup (D), install the two rack bearings in the fuel injection pump housing. Install the bearing in governor end of housing so that it will be recessed .195 .005 in. (4,953 0,127 mm) from face of housing. Install the rack bearing in accessory drive end of housing so that it will be flush with face of fuel injection pump housing. 3. Lubricate the camshaft with clean SAE 30 engine oil. Install the camshaft in fuel injection pump housing. 4. Position the governor drive gear (1) and spring (2) on the camshaft. Install the camshaft retaining plate (3), bolt, and lock. 5. Install the lifters (4) in their respective positions in housing. Lubricate the rack generously with clean fuel oil. Install the rack (5) in fuel injection pump housing with the slot in rack toward the governor end of housing. 6. Install the spacers in their respective positions in housing. If new lifters and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL INJECTION PUMP TIMING DIMENSION SETTING-OFF ENGINE in TESTING AND ADJUSTING.7. Assemble the fuel injection pumps as follows: a) Lubricate all parts generously with clean fuel oil.b) Install the spring, washer, and plunger in the barrel.c) Install the spring, check valve, bonnet, and ring on the barrel.
Do not attempt to install fuel injection pumps until the rack has been centered.
8. Using tool setup (E), center the rack as follows: a) Install locating fixture (6) on the fuel injection pump housing.b) Install the rack setting gauge (7). Set the gauge (7) at zero. Push the rack (5) against the gauge. c) Install the clamp (8) on pump housing as illustrated. This will keep the rack centered while installing the fuel injection pumps.With the rack centered, install the fuel injection pumps as follows:a) Rotate the camshaft until lobe of camshaft is down for pump to be installed. b) Install the extractor (B) on the pump.c) Sight down the pump, and align the notches (9) in bonnet and barrel with the slot (10) in pump gear segment. The slot should be in line with the center of these notches. Position the pump so the notches align with the guide pins in housing bore. Install the pump in its respective position in housing. d) Install the seal and retaining bushing (11). Apply a downward force to extractor (B), and tighten the bushing by hand (finger tight only) until bushing is flush with top of housing. If the bushing can not be installed this far by hand, remove it. Remove pump, realign components, and install again.
Do not force bushing flush with face of pump housing by using wrench. If pump has been properly installed, bushing can be finger tightened flush with face of pump housing.
e) After each pump has been installed, check the rack travel in the following manner. Swing the clamp (8) away from end of rack. Using rack setting gauge (7), check the rack travel. If the pump gear has been installed correctly with respect to the rack, total rack travel should be approximately .800 in. (10,32 mm). If total rack travel can not be obtained, remove the pump, realign components, and re-install pump. f) Remove the extractor (B) and tool setup (E). Install wrench (A), and tighten retaining bushing to 150 10 lb. ft. (20,7 1,4 mkg). Remove wrench (A). Install the felt washers and protective caps.concluding steps: a) connect governor to fuel injection pump housingb) install fuel injection pump housing and governor as a unitc) adjust governor and set rack (See GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING)