57621-90J00 Suzuki SHIFTER, CLUTCH DOG

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1 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.
The Electronic Control Module (ECM) can be a fuel cooled ECM or air cooled ECM. The removal procedure is similar for a fuel cooled ECM or air cooled ECM.
Turn the battery disconnect switch to the OFF position.
Turn the fuel supply to the OFF position.
If necessary, remove the secondary filter assembly. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, remove the primary fuel filter assembly. Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
If necessary, remove the dipstick tube assembly. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.
Illustration 1 g03738323
Typical example
Illustration 2 g03738325
Typical example
Illustration 3 g03738326
Typical example
Cut cable strap (2) and cable strap (6) from plastic tube assembly (1).
Remove plastic tube assembly (1) from the crankcase breather canister. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.
Disconnected harness assembly (3) from the fuel temperature sensor. Refer to Disassembly and Assembly, "Fuel Temperature Sensor- Remove and Install" for the correct procedure.
Disconnected harness assembly (4) from the engine oil pressure sensor. Refer to Disassembly and Assembly, "Engine Oil Pressure Sensor - Remove and Install" for the correct procedure.
Disconnect the harness assembly from crankshaft position sensor (5) (not shown). Refer to Disassembly and Assembly, "Crankshaft Position Sensor - Remove and Install" for the correct procedure.
Cut cable straps (7) from harness assembly for camshaft position sensor (8) (not shown). Disconnect the harness assembly from camshaft position sensor (9) (not shown). Refer to Disassembly and Assembly, "Camshaft Position Sensor - Remove and Install" for the correct procedure.
Disconnect harness assembly (9) from atmospheric pressure sensor (10). Refer to Disassembly and Assembly, "Atmospheric Pressure Sensor - Remove and Install" for the correct procedure.
Illustration 4 g03738863
Typical example
Disconnect plastic tube assembly (11) and plastic tube assembly (14) from tube assembly (12). Use Tooling (A) in order to plug the plastic tube assemblies and to cap the tube assembly.
Use a suitable tool in Position (X) in order to hold and disconnect hose assembly (16) from connection on tube assembly (13). Remove O-ring seal (17) (not shown). Use Tooling (A) in order to plug the hose assembly and to cap the tube assembly.
Use a suitable tool in Position (X) in order to hold tube assembly (12) as nut (15) is loosened. Remove bolt (13) from tube assembly (12).
Remove tube assembly (12) from the bracket and the cylinder head.
Remove O-ring seal (18) (not shown) from tube assembly (12).
Use Tooling (A) in order to plug the cylinder head and to cap the tube assembly.
Illustration 5 g03738899
Typical example
Cut cable straps (19) from engine harness assembly. Ensure that all the cable straps are removed.
Remove bolt (24) from ECM plug (20).
Loosen the allen head bolt (22) that secures ECM plug (20) for engine harness assembly (26) to ECM (28).
Position engine harness assembly (26) away from the ECM.
Remove bolt (25) from Original Equipment Manufacture (OEM) plug (21).
Loosen the allen head bolt (23) that secures OEM plug (21) for the OEM harness assembly (27) to ECM (28).
Position OEM harness assembly (27) away from the ECM.
Illustration 6 g03738900
Typical example
Make temporary identification marks on the plastic tube assembly (37) and plastic tube assembly (36) for installation purposes.
Place a suitable container below the ECM (28) in order to catch any fuel that might be spilled.
Disconnect plastic tube assembly (37) and plastic tube assembly (36). Drain the fuel from ECM (28).
Use Tooling (A) in order to plug plastic tube assembly (37) and plastic tube assembly (36).
Use Tooling (A) in order to cap connections on the ECM for plastic tube assemblies.
Remove plastic tube assembly (33) and plastic tube assembly (34) from clips (35).
Disconnect the plastic tube assembly from valve (31) Use Tooling (A) in order to cap connection on valve (31) and the plastic tube assembly.
Remove bolt (29) spacer (30) for valve (31).
Remove bolts (38) and washer (39) (not shown) from bracket (32) and from ECM (28). Ensure that earth strap (40) is not damaged as the bolts are removed. Support the weight of the ECM as the bolts are removed. Note: Note the orientation and position of the brackets
Remove bracket (32) and ECM (28) from the engine. Note: When removing the bolts from the ECM, ensure that the fuel injection line from the fuel injection pump to the fuel manifold is not damaged.
Illustration 7 g03738901