18100-94410 Suzuki Starter Assembly, Recoil

Start By:a. remove loader armb. remove tilt cylinderc. remove ROPSd. remove radiator and guarde. remove rear bottom guardf. remove floor plateg. remove air cleaner housingh. remove muffler Prior to the disconnection or removal of any wires, wiring harnesses, hoses or cables insure that all are clearly marked and identified. The particular machine displayed in this story was equipped with a ROPS and not a cab. Some models may be equipped with a cab. If this is the case, the engine removal will require a slightly different removal and installation procedure. The D4C engine removal and installation in this publication can be used as a model. 1. Disconnect battery. Remove two tie wraps (1) from wiring harness located at the left front side of the firewall. Identify and label five connectors (2) and disconnect. 2. Remove one bolt and washer (3) and remove ground wire terminal (4) from firewall. 3. Remove tie wraps (5) and disconnect wire connector (6) located under the dash on the left side. 4. Remove two tie wraps (7). Identify and label three wire connectors (8) and disconnect. Remove two tie wraps (9) from wiring harness clips (10). Wire connectors and tie wraps located under firewall at the rear of the engine. 5. Drain hydraulic fluid from the hydraulic tank. Disconnect two lines (11) and (12) from implement pump (13). Plug and cap all fittings. 6. Identify and label wires at starter motor (14). Slide back terminal cover (15) and remove one nut from positive battery cable and remove positive cable from starter motor (14). Raise cover at wire terminal (16) and remove one screw and wire from starter motor (14). 7. Shut off fuel supply at the fuel tank. Loosen clamp (17) on fuel line and remove fuel line from injection pump. Remove one bolt, washer and clip (18) that holds fuel lines.8. Loosen clamp (19) below priming pump and remove fuel line from priming pump. Plug all fuel lines. Set aside both fuel lines. 9. Remove cotter pin and pin (20) from governor control linkage.10. Loosen one jam nut (21) on cable bracket (22) and slide cable assembly out of bracket (22) and set cable assembly aside. 11. Attach tooling (A) to engine lifting group as shown. For ease of removal it may be desirable to put a transmission jack under the transmission during removal. 12. Remove twelve bolts (23), two clips (10) and ground wire terminal (4) from the flywheel housing. 13. Remove two bolts, nuts, washers sleeves and mount assemblies (24) from engine mount support.14. Carefully remove engine from transmission and slowly raise engine. Check to make sure all wires, hoses and tubes have been disconnected and are clear from the engine.15. Remove engine from the machine. Weight of the engine is 511 kg (1,125 lb). Use the following procedure for installation. 16. Check O-ring seal on transmission for wear or damage. Replace if necessary. Install engine into machine. Install mount assembly (24). 17. Install twelve bolts (23), two clips (10) and ground wire terminal (4) at flywheel housing. Tighten bolts (23) to torque of 28 7 N m (20 5 lb ft). 18. Remove tooling (A) from engine lifting group. Remove transmission jack from under the transmission if it was used.19. Install cable assembly into cable bracket (22) and adjust and tighten jam nut to a torque of 38 2 N m (28 5 lb ft). 20. Install pin and cotter pin (20) to governor control linkage. 21. Install two fuel lines and clamps, (17) and (18) to priming pump and injection pump. Install bolt, washer and clip (18) to the engine. 22. Install starter motor wires (15) and (16) to starter motor (14). Tighten positive cable nut to a torque of 55 10 N m (40 7 lb ft). 23. Install two hydraulic lines (11) and (12) to implement pump (13). 24. Connect three wire connectors (8). Replace tie wraps (7) and (9). 25. Connect wire connector (6) under dash and replace tie wraps (5). 26. Install bolt and washer (3) to ground terminal (4) at firewall. 27. Connect five wire connectors (2) at firewall. Replace two tie wraps (1).28. Turn fuel supply on at the fuel tank.29. Fill hydraulic tank. See Operation And Maintenance Manual for proper fluid and capacity.30. Insure that all wires, wiring harnesses, hoses and cables are connected properly. Connect battery terminals to the battery.End By:a. install mufflerb. install air cleaner housingc. install floor platesd. install bottom rear guarde. install radiator and guardf. install ROPSg. install tilt cylindersh. install loader arms