48570-94600-0ED Suzuki RESERVOIR ASSEMBLY

start by:a) separation of governor from fuel injection pump housing 1. Remove the fuel injection pumps as follows: a) Remove the protection cap and washer (1).b) Install tool (A) and remove bushing (2) from housing. c) Use tool (B) to lift the fuel injection pump out of the housing.d) Remove spacer (4) from the pump housing.
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
2. Disassemble the fuel injection pumps as follows: a) Remove seal (3) from bonnet (5).b) Remove ring (6) to make a separation of bonnet (5) from barrel (9).c) Remove spring (7) and check valve (8) from bonnet (5).d) Remove the gear segment, plunger (10), washer (11) and spring (12) from barrel (9).
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
3. Remove rack (13) from the pump housing.4. Remove lifters (14) from the pump housing. 5. Remove the camshaft plate (15), bolt and lock. 6. Remove spring (16) and gear assembly (17) from the camshaft. 7. Remove camshaft (19) from the pump housing. 8. Remove the camshaft bearings from the fuel injection pump housing with tool (C).9. Remove the two bearings (18) from the fuel injection pump housing if necessary.Assemble Fuel Injection Pump Housing
1. Install the camshaft bearings in the fuel injection pump housing with tool (C). Install the bearing in governor end of housing so the lubrication hole in the bearing is in alignment with lubrication hole in housing. Install the camshaft bearings even with outside ends of fuel injection pump housing. 2. Install the two rack bearings in the fuel injection pump housing with tooling (D). Install the bearing in governor end of housing so it will be .195 .005 in. (4.953 0.127 mm) lower than face of housing. Install the rack bearing in accessory drive end of housing so it will be even with face of fuel injection pump housing. 3. Put clean engine oil on camshaft. Install the camshaft in fuel injection pump housing. 4. Put the governor drive gear (1) and spring (2) in position on the camshaft. Install the camshaft plate (3), bolt and lock. 5. Install lifters (4) in their correct positions in the housing. Put clean engine oil on the rack. Install rack (5) in the fuel injection pump housing with the opening in the rack near the governor end of the housing.6. Install the spacers in their respective positions in the housing. When new lifters and pumps are installed, it is necessary to make adjustment of the fuel pump timing. See FUEL INJECTION PUMP TIMING DIMENSIONS SETTING, OFFENGINE in TESTING AND ADJUSTING.7. Assemble the fuel injection pumps as follows: a) Put clean fuel oil on all parts.b) Install the spring on the barrel.c) Install the washer on the plunger and gear segment. Install the plunger in the barrel.d) Install the spring and check valve in the bonnet.e) Put the bonnet in position on the barrel and install the ring to hold the unit together.f) Install the seal on the bonnet.
Make sure the fuel rack is in the center (zero) position before the fuel injection pumps are installed.
8. Put the rack in the center position with tooling (E) as follows: a) Install location fixture (6) on the fuel injection pump housing.b) Install the gauge (7). Move the gauge (7) to zero. Push the rack (5) against the gauge.c) Install the clamp (8) on pump housing as illustrated. This will keep the rack in the center when the fuel injection pumps are installed.9. With the rack in the center, install the fuel injection pumps as follows: a) Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.b) Install tool (B) on the pump.c) Put the grooves (9) inthe bonnet and barrel in alignment with the groove (10) in the pump gear segment. Put the pump in position so the grooves are in alignment with the guide pins in the housing bore. Install the pump in its correct position in the housing. d) Install bushing (11) over the bonnet. Install tool (B) on the bonnet and push down on tool (B). Tighten bushing (11) by hand until the bushing is even with top of 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.
If installation of pump is correct, the bushing can be tightened by hand until it is even with face of pump housing.
e) Make a check of the rack travel after each pump is installed as follows: Move clamp (8) away from the end of the rack. Use gauge (7) to measure the rack movement. The total rack movement must be .800 in. (20.32 mm). If the rack can not be moved this distance, the pump gear segment is not in the correct position and the pump must be removed and installed again. f) Remove tool (B) and tool (E). Install tool (A) and tighten the bushing to a torque of 150 10 lb.ft. (205 14 N m). Remove tool (A). Install the washers and protection caps for the fuel injection pumps.end by:a) connection of governor to fuel injection pump housing.b) install fuel injection pump housing and governorc) adjust governor and set the rack (See GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING)