09181-45008 Suzuki SHIM (T:1.5)

START BY:a. remove fuel injection lines (interim scroll fuel system) The radiator guard, engine enclosure and fan were removed for better photo illustration only. 1. Close the fuel valve on the fuel tank. Remove fuel lines (1) and (2).2. Disconnect governor linkage (3) from the governor.3. Disconnect the two wires from fuel pressure switch (4) on the fuel filter base. 4. Remove fuel lines (5) and (6). Put plugs or caps on all fuel line openings. 5. Step 5 is for earlier 943's. Remove four bolts (7), and remove bracket (8) and the fuel filter base. Move plate (9) and the fuel lines clear of the engine. 6. Step 6 is for later 943's and 953's. Remove the fuel filter. Remove the two bolts that hold bracket (10) in place, and move the bracket and fuel lines clear of the engine. 7. Remove bolts (11) that hold the fuel injection pump housing to the oil manifold for the engine oil cooler. When bolt (12) is removed, do not let the spacer on the back side between the fuel block and the alternator bracket fall under the engine.8. Remove bolt (12) from the alternator bracket, and remove the spacer from the back side of the alternator bracket.9. Remove bolt (13) and plug (14) from the timing gear cover. Use tool (B), if necessary, to remove the timing gear cover. 10. Loosen bolt (15) in the timing gear a maximum of one turn. 11. Loosen three nuts (16) that hold the pump drive to the timing gear plate until the nuts are even with the end of the studs.12. Pull the fuel injection pump housing and pump drive away from the timing gear plate until the timing gear is against the front side of the timing gear plate. 13. Install tooling (A) in the timing gear cover to push the pump drive shaft, and loosen the timing gear on the shaft 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. 14. Remove three nuts (16), and remove the pump drive, fuel injection pump housing and governor (17) as a unit from the engine. Weight is 23 kg (50 lb.).Install Fuel Injection Pump Housing And Governor (Interim Scroll Fuel System)
1. Install the bolt and washer in shaft (1) in the pump drive. Remove the plug from the pump drive housing, and install tool (A) in the plug hole. Turn shaft (1) until timing pin (1) engages in the notch in the shaft. Tool (A) will hold the fuel injection pump camshaft in the correct position to set the fuel injection timing of the engine. 2. Be sure O-ring seals (2) are in position on the oil manifold for the engine oil cooler. Be sure the O-ring seal is in position on the pump drive housing.
Be extra careful not to damage O-ring seals (2) when the fuel injection pump housing and governor are installed.
3. Put the governor, fuel injection pump housing (3) and the pump drive in position on the engine as a unit. Install the three nuts that hold the pump drive to the timing gear plate. 4. Be sure the threads on bolt (4) and the threads in the shaft of the pump drive are not damaged. Put clean oil on the threads.5. Install bolt (4) and the washer to hold the timing gear on the shaft. Tighten bolt (4) finger tight only. Bolt (4) 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). 6. Put No. 1 piston at the top center compression position (TDC) with the following procedure:a. Remove plug (5) from the flywheel housing. Never turn the crankshaft backward to install the timing bolt in the flywheel.b. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (6) at least two inches long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. c. Remove cover (7) from the valve cover. 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. 7. With the timing pin in the fuel injection pump housing and the timing bolt in the flywheel, tighten the bolt in the timing gear to a torque of 149 7 N m (110 5 lb.ft.).8. 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