09202-06019 Suzuki Shear Pin

Table 1
Required Tools
Tool Part Number Part Description Qty
A 360-8376 Capping Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Note: Plug or cap all open ports with new plugs or new caps.
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Disconnect the Original Equipment Manufacturers (OEM) harness assembly from engine harness assembly (1).
Remove nut (3) and washer (2) from harness assembly (1).
Position harness assembly (1) away from bracket (5).
Remove bolts (4) and bracket (5) from bracket (6).
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Thoroughly clean fuel manifold (9) and the area around the fuel manifold.
Disconnect wiring harness (8) from Exhaust Gas Recirculation (EGR) valve assembly (7)
Disconnect wiring harness (10) from fuel pressure sensor (9).
Remove banjo bolt (11) and sealing washers (13) (not shown) from banjo connection (12). Use Tooling (A) to plug fuel pressure relief valve (14) and cap the banjo connection.
Remove bolts (16) from fuel manifold (15). Remove the fuel manifold from the cylinder head.
If necessary, remove relief valve (14) from fuel manifold (15). Refer to Disassembly and Assembly, Relief Valve (Fuel) - Remove and Install for the correct procedure.Installation Procedure
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage.Note: Do not install a fuel manifold that has not been plugged. All plugs and caps must be left in place until the fuel injection lines are about to be installed.
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If necessary, install relief valve (14) to fuel manifold (15). Refer to Disassembly and Assembly, Relief Valve (Fuel) - Remove and Install for the correct procedure.
Position fuel manifold (15) onto the cylinder head. Loosely install bolts (16) to the fuel manifold.
Install new fuel injection lines finger tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct installation procedure.Note: Do not torque the nuts for the fuel injection lines at this stage of the assembly procedure.
Tighten bolts (16) to a torque of 22 N m (195 lb in).
Tighten the nuts for the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Remove the plug from relief valve (14) and cap from banjo connection (12).
Install a new sealing washers (13) (not shown) onto banjo bolt (11). Position banjo connection (12) onto relief valve (14). Install the banjo bolt and the remaining new sealing washer. Tighten the banjo bolt to a torque of 15 N m (133 lb in). Ensure that the fuel line is not strained as the banjo bolt is tightened.
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