18271-98100 Suzuki Spring, Friction

Introduction
This Special Instruction provides information on installation of the newly designed HEUI pump. The new HEUI pump helps to prevent drive bearing spalling due to inconsistent force that is applied to the bearing in certain operating conditions.The overall length of the new HEUI pump is 15 mm (0.6 inch) longer. New fluid connections are required.Safety
Personal injury can result from hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.
Contact to high pressure fuel can cause personal injury or death. Do not allow high pressure fuel to contact your skin.
Parts List
Note: Table 1 has a list of parts associated with the new pump. Not all of these parts are needed for your engine. Select the parts needed for your engine. Additional parts will be necessary for this repair, utilize existing parts information for your specific engine.
Table 1
Old Part Number     New Part Number     Description    
All     384-0678 or 20R-1636     Unit Injector Hydraulic Pump Gp    
209-3171     387-7159     Tube As (Single wall high pressure)    
241-6923     378-8430     Tube As (Dual wall high pressure )    
221-3463 or 263-1785     387-9500     Tube As (Low-pressure oil line)    
Components for Fuel Hose    
192-2184     339-1587 (1)
    Hose As    
6V-8724 (1) Elbow    
214-7568 (1) O-Ring Seal    
228-7089 (1) O-Ring Seal    
Components for Pressure Sensor Fitting    
None     205-3079 (2)
    Adapter    
9S-8003 (2) Plug    
214-7568 (2) O-Ring Seal    
214-7567 (2) O-Ring Seal    
( 1 ) Use only on the following serial number prefixes: S/N:C9A00001-00196, ; S/N:CSN00001-00898, and ; S/N:C9B00001-00168.
( 2 ) Use only on the following serial number prefixes: S/N:C9A00001-00500, ; S/N:C9B00001-UP, ; S/N:CSN00001-UP, ; S/N:X9X00001-00488, ; S/N:Z9X00001-00245, and ; S/N:SJB00001-00169Installation Procedure
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Perform a cylinder cutout test to identify any injectors that are not operating properly.
If the engine is equipped with a rectangular aftercooler, drain and remove the aftercooler. Refer to Disassembly and Assembly, SENR9664, "Aftercooler - Remove" for more information, if needed.
Remove the crankcase breather.
Illustration 1 g01867833
Draining the oil from the pump for the HEUI
Clean the exterior area of the pump for the HEUI. Clean the cover, between the cover and the housing, and around the inlet oil line and the fitting to remove any dirt, debris, and oil. Remove inlet oil line and adapter fitting from the pump cover. Use 1U-5718 Vacuum Pump in order to drain the oil out of the pump for the HEUI. Insert the tube on the vacuum pump into the opening in the pump for the HEUI. Refer to Illustration 1 for the correct location. Ensure that the tube is inserted as far as possible into the pump. Once five bottles of oil are removed from the pump, the pump is drained.Note: DO NOT proceed to Step 5 without draining the oil from the pump for the HEUI.
Illustration 2 g01866496
Back out the cover bolts from the threads in the pump housing.The joint that is between the cover and the housing must be free of any dirt, debris, or oil.Back out the cover bolts from the threads in the pump housing. Do not remove the bolts from the pump cover.Note: Ensure that no debris falls into the pump when the cover is loosened.Note: Pulling the bolts out of the cover can result in losing the bolts. Also, the pump cover may fall.