09160-25035 Suzuki Washer Thickness: 1.4

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Illustration 1 g02673936
Typical example
Thoroughly clean the area around fuel manifold (1) and fuel pressure relief valve (2).
Remove banjo bolt (5) and remove sealing washers (4) (not shown).
Position plastic tube assembly (3) away from fuel pressure relief valve (2).Immediately cap the open port in fuel pressure relief valve (2) with a new cap from Tooling (A). Immediately plug the open end of plastic tube assembly (3) with a new plug from Tooling (A).
Follow Step 4.a through Step 4.c to remove the fuel pressure relief valve from the fuel manifold.
Ensure that the area around the fuel pressure relief valve (2) and fuel manifold (1) is still thoroughly clean.
Use a deep socket to remove the fuel pressure relief valve (2) from fuel manifold (1).
Immediately plug the open port in fuel manifold (1) with a new cap from Tooling (A). Immediately cap the fuel pressure relief valve (2) with a new cap from Tooling (A).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 8T-3052 Degree Wheel 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Illustration 2 g02673936
Typical example
Follow Step 1.a through Step 1.f to install the fuel pressure relief valve to the fuel manifold.
Remove the plug from the port in fuel manifold (1).
Immediately clean the threads in fuel manifold (1) for fuel pressure relief valve (2). Ensure that the thread is clean and free from debris. Ensure that the thread in the fuel manifold (2) is free from damage.
Immediately plug the open port in fuel manifold (1) with a new cap after cleaning and inspection.
Remove the cap from the threaded end of fuel pressure relief valve (2). lubricate the thread of the pressure relief valve with clean fuel.
Remove the plug from the port of fuel manifold (1). Use a deep socket to install the fuel pressure relief valve (2) into fuel manifold (1) hand tight.
Tighten fuel pressure relief valve (2) to a snug torque of 30 N m (266 lb in). Use Tooling (B) to rotate the fuel pressure relief valve in a clockwise direction for another 24 degrees to achieve the final torque.
Remove the plug from plastic tube assembly (3).
Install a new sealing washer (4) (not shown) onto banjo bolt (5). Position banjo bolt (5) onto plastic tube assembly (3) and install remaining new sealing washer (4) (not shown) onto the banjo bolt.
Remove the plug from fuel pressure relief valve (2).
Position plastic tube assembly (3) onto fuel pressure relief valve (2). Tighten banjo bolt (5) hand tight.
Tighten banjo bolt (5) to a torque of 15 N m (133 lb in).
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.