25111-94510 Suzuki ROD, SHIFT (X)

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be thoroughly clean.
1. Disconnect the two fuel lines from fittings (1). Put caps or plugs in all the fuel line openings to keep dirt out of the fuel system. 2. Remove two bolts (3), fuel transfer pump (2) and the gasket.Install Fuel Transfer Pump
1. Put gasket (2) and fuel transfer pump (1) in position and install the bolts that hold it. 2. Connect the fuel lines on fittings (3).Disassemble Fuel Transfer Pump
START BY:a) remove fuel transfer pump 1. Remove the bolts, cover (3) and the gasket from cover (4).2. Remove bolts (1). Make a separation between cover (4) and pump body (2). 3. Remove lip type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip type seals and the bottom bearing from pump body (2).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with tooling (A). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with tooling (A).3. Install lip type seal (5) with tooling (A). Install the seal until it is 24.6 0.5 mm (.97 .02 in.) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip type seal (6) with tooling (A). Install the seal until it is 14.2 0.5 mm (.56 .02 in.) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with tooling (A). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 316°C (600°F). Install gear (8) on shaft (11) until dimension (X) is 49.71 mm (1.957 in.).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 28 7 N m (22 5 lb.ft.).8. Install idler gear (12) in body (3).9. Install the lip type seal with tooling (A). Install the seal until it is 3.8 0.5 mm (.15 .02 in.) from the top surface of cover (1) and with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15), seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 38 4 N m (27 3 lb.ft.).
Do not let the liquid gasket enter the pump.
11. Put 7M7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3). The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened. 12. Install cover (16) on cover (1).END BY:a. install fuel transfer pump