06111-10003 Suzuki Ball

Table 1
Tools Needed Quantity
1U-9895 Crossblock (1) 1
3H-0465 Push-Puller Plate (1) 3
8F-6123 Bolt (2) 2
1P-2396 Adapter Plate 1
8T-4193 Bolt 28
2S-5658 Hard Washer 28
8F-1484 Washer 28
7K-1977 Washer 28
8T-0455 Liner Projection Tool Group 1
(1) This item is part of the 8B-7548 Push-puller.
(2) Bolt size is 3/4 16 NF and 140 mm (5.5 inch).
Illustration 1 g00769678
(1) 8T-4193 Bolt
(2) 2S-5658 Hard Washer
(3) 8F-1484 Washer
(4) 7K-1977 Washer
(5) Spacer plate
(6) 1P-2396 Adapter Plate
(7) 3H-0465 Push-Puller Plate
Ensure that the top surface of the cylinder block is clean. Install a new plate gasket onto the cylinder block. Place spacer plate (5) onto the plate gasket.
Illustration 2 g00770644
(1) 8T-4193 Bolt
(2) 2S-5658 Hard Washer
(3) 8F-1484 Washer
(4) 7K-1977 Washer Note: The 7K-1977 Washer (4) is made of a plastic material that will not damage the sealing surface of the cylinder block.
Secure the spacer plate to the cylinder block with bolts (1) and gaskets (2), (3) and (4). Use two bolts on each side of each cylinder. Use three gaskets for each bolt. Tighten the bolts evenly in four steps:
Tighten the bolts to a torque of 14 N m (10 lb ft).
Tighten the bolts to a torque of 35 N m (25 lb ft).
Tighten the bolts to a torque of 70 N m (50 lb ft).
Tighten the bolts to a torque of 95 N m (70 lb ft). Note: Use the bare cylinder liners. Do not install the filler bands or the O-ring seals onto the cylinder liners yet.
Ensure that the surfaces of the engine block, the cylinder liner, and the spacer plate are clean. Remove any nicks from the surface of the spacer plate.
Place a cylinder liner into a bore. Fit adapter (6) onto the cylinder liner. Place plate (7) onto the adapter.
Illustration 3 g00740417
(7) 3H-0465 Push-Puller Plate
(8) 1U-9895 Crossblock
(9) 8F-6123 Bolt
(10) 8T-0455 Liner Projection Tool Group
Use crossblock (8), the two plates (7), and the two bolts (9) to seat the cylinder liner in the bore. Tighten the bolts evenly in four steps:
Tighten the bolts to a torque of 7 N m (5 lb ft).
Tighten the bolts to a torque of 20 N m (15 lb ft).
Tighten the bolts to a torque of 35 N m (25 lb ft).
Tighten the bolts to a torque of 70 N m (50 lb ft). After the bolts are tightened, measure the distance from the bottom edge of the crossbar to the surface of the spacer plate. The distance must be equal on both sides of the cylinder liner. If the distance is not equal, repeat the bolt tightening.
Use 8T-0455 Liner Projection Tool Group (10) to measure the cylinder liner projection. Note: Refer to Special Instruction, SMHS7727 that is provided with the tool group.
Illustration 4 g00770022
8T-0455 Liner Projection Tool Group
(11) Bolt
(12) Dial indicator
(13) Gauge body
(14) Gauge block
Loosen bolt (11) until dial indicator (12) can be moved. Place gauge body (13) and dial indicator (12) on the long side of gauge block (14).
Slide dial indicator (12) downward until the point contacts gauge block (14) and the needle of the dial indicator moves to the vertical position. Tighten bolt (11). Zero the dial indicator.
Place gauge block (14) on the spacer plate with the point of the dial indicator on the cylinder liner flange. Read the dial indicator in order to find the amount of cylinder liner projection.
Illustration 5 g00769831
Points to measure around each cylinder liner
Measure the projection of four points that are equally distant around each cylinder liner. If the projection is not within specifications for the cylinder liner projection that is listed in Table 6, remove the cylinder liner. Turn the cylinder liner to a different position and seat the cylinder liner into the cylinder bore. Measure the projection again. If the projection does not meet the specifications, install the cylinder liner into a different bore.
After the projection of the cylinder liner is within specifications, mark the radial position of the cylinder liner for the cylinder. Be sure to identify the particular cylinder liner with the corresponding cylinder.
Record the measurements in Table 2. Add the four measurements for each cylinder. Divide the sum by four in order to calculate the average projection for each cylinder liner. Record the averages in Table 2.
Table 2
Cylinder Liner Projection
Points Measurement
1A &nbs