09181-45005 Suzuki SHIM (T:1.2)

START BY:a. remove fuel injection lines (new scroll fuel system effective in production with 10X5411-UP, 45V36536)b. remove fuel transfer pump (new scroll fuel system effective in production with 10X5411-UP, 45V36536) 1. Remove bolt (2) and fuel line (1). 2. Remove three bolts (3) that fasten manifold (4) to the governor housing. 3. Remove bolt (6) and plug (5) from the timing gear cover. 4. Loosen bolt (7) in the fuel pump drive gear a maximum of one turn. 5. Loosen two lower nuts (8) that fasten the fuel injection pump housing to the timing gear plate. Turn the nuts till they are even with the end of the studs. 6. Loosen upper fuel injection pump mounting nut (9).7. Pull the fuel injection pump housing away from the timing gear plate. 8. Install tooling (A) or (B) in the timing gear cover to push the pump drive shaft, and loosen the timing gear on the shaft. If tooling (A) is used, proceed as follows:
The tooling must be installed in the position shown so the locks will not damage the water passage in the timing gear cover.
a. Install tooling (A) in the position shown, and tighten the locks to hold the tooling in place.b. Turn the extension counterclockwise to loosen the bolt in the timing gear. As the bolt is loosened, it will push against tooling (A) and push the shaft of the pump drive through the timing gear to loosen the timing gear on the shaft.c. Remove tooling (A) from the timing gear cover. Remove the bolt and washer from the timing gear.9. If tooling (B) was used, proceed as follows:a. Loosen bolt (7) approximately 3.20 mm (.125 in.).b. Install tooling (B) as shown to remove the gear from the pump. 10. Remove fuel pump mounting nuts (8). Remove fuel injection pump housing and governor (10).Install Fuel Injection Pump Housing And Governor (New Scroll Fuel System Effective In Production With 10X5411-UP, 45V36536-UP)
1. Inspect all O-ring seals (1), and make any replacements if necessary. Put engine oil on seals prior to installation. 2. Put the fuel injection pump housing and governor (2) in position in the timing gear plate. 3. Install nuts (3) and (4). 4. Install bolt (5) and the washer to hold the timing gear on the shaft. Tighten the bolt finger tight. Bolt (5) must be tight enough to hold the gear clearance (backlash) out of the timing gears when the engine is turned, but the timing gear must be able to turn on the shaft when the engine is turned to put the No. 1 piston on top center compression position (TDC). 5. Remove breather (6) from the flywheel housing. 6. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (7) at lease two inches long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft backwards to install the timing bolt in the flywheel. 7. Remove valve cover (8) from its base. Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°), and install the bolt again. 8. Remove three bolts and cover (9). 9. With timing pin (A) installed in the fuel pump housing and timing pin (7) in the flywheel, tighten bolt (5) to a torque of 175 7 N m (130 5 lb.ft.).10. Check the timing as follows:a. Remove both the timing pin and timing bolt.b. Turn the crankshaft clockwise (as seen from the front of the engine) two full turns, and install the timing pin and bolt again.c. The timing is correct if both the timing pin and timing bolt can be installed at the same time. The timing procedure must be done again if the timing pin and timing bolt cannot be installed at the same time.d. Remove the timing pin and timing bolt when the timing is correct. 11. Install plug (10) in the timing gear cover. 12. Install cover (11) on the fuel injection pump housing. Install bolts (12) to fasten the manifold to the governor housing. 13. Install breather (13) in the flywheel housing. 14. Install fuel line (14). 15. Install valve cover (15) on its base.END BY:a. install fuel transfer pump (new scroll fuel system effective in production with 10X5411-UP, 45V36536)b. install fuel injection lines (new scroll fuel system effective in production with 10X5411-UP, 45V36536)