09181-37002 Suzuki SHIM

START BY:a) remove timing gear cover Before any timing gears are removed, make sure the "C" mark on the crankshaft gear is in alignment with the "C" mark on the camshaft gear. 1. Loosen bolt (1) 125" (3.18 mm) from the gear face. 2. Install tooling (A) on gear (3) and loosen the gear from the shaft. Remove tooling (A) and remove bolt (1) and washer (2). Remove gear (3). 3. Remove the two bolts that hold plate (4) to the idler shaft. Remove plate (4). Remove idler gear (5). 4. Remove bearing (6) from idler gear (5) with tooling (B). 5. Remove four bolts (7) and remove gear (8) from the camshaft.6. Remove the three nuts that hold the fuel injection housing to the timing gear plate. 7. Remove bolts (9) and remove timing gear plate (10) from the engine.Install Timing Gears And Plate
Make sure the O-ring seal is in place on the front of the fuel injection pump housing.1. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan. 2. Put timing gear plate (1) against the cylinder block and install the six bolts that hold the timing gear plate in place.3. Install the three nuts that hold the fuel injection pump housing to the timing gear plate. 4. Install camshaft drive gear (2) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear as shown in the illustration. Install four bolts (3) that hold it in place. 5. Remove the starting motor. See REMOVE STARTING MOTOR. 6. Install tooling (A) on the flywheel housing.7. Put No. 1 piston at the top center compression position as follows:a) With the "C" on the crankshaft already in alignment with the "C" mark on the camshaft, use tool (A) and turn the flywheel counterclockwise (as seen from the front of the engine) approximately 30 degrees. The reason this is done is to be sure the play is removed from the timing gears when the engine is put on top center.b) Turn the flywheel clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt can be installed on the flywheel through hole (4) in the flywheel housing. If the flywheel is turned beyond the point where the 3/8"-16 NC bolt can be installed in the flywheel steps 7a and 7b must be done again. 8. Use tooling (B) and install the bearing in idler gear (5). Install the bearing to a depth of .060 in. (1.52 mm) below the outside surface. The bearing diameter after installation must be 1.3781 .0019 in. (35.000 0.048 mm). 9. Put idler gear (5) in position on the idler shaft. Install plate (7) and install the two bolts that hold it to the idler shaft.10. Install the washer and bolt (6) that hold the fuel pump drive gear in place in the fuel injection pump camshaft. Turn the camshaft clockwise (as seen from the front of the engine) until tool (C) can be installed in the notch in the camshaft.11. Remove the washer and bolt (6) from the fuel injection pump. 12. Put fuel injection pump drive gear (8) in position and install the washer and bolt finger tight.13. Install tool (D) on the drive gear as shown. Put a torque of approximately 50 lb.ft. (70 N m) on the pump drive gear in a clockwise direction (as seen from the front of the engine). With the clockwise torque on the pump drive gear, tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).14. Remove tool (C) from the fuel pump and install the bolt and O-ring seal.END BY:a) install starting motorb) install timing gear cover