01107-08602 Suzuki Bolt

1. Loosen the clamp and disconnect the water hose (1) from the valve on the cylinder head. Disconnect the water temperature gauge line (2) from the cylinder head. Disconnect glow plug wire (3) from the left end of the cylinder head. 2. Disconnect air cleaner gauge wire (5). Remove bolt (6) that holds the gauge line (5) to the cylinder head. Disconnect glow plug wire (7) from the right end of the cylinder head.3. Remove bolts (4) and (8) that hold the cylinder head to the cylinder block.4. Fasten a hoist and a spreader bar to the cylinder head. Remove cylinder head. Weight is 475 lb. (215 kg). Remove exhaust manifold from the cylinder head. Remove the turbocharger inlet elbow and air cleaner as a unit from the cylinder head.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See REMOVE and INSTALL SPACER PLATE. 1. Throughly clean the spacer plate and the bottom surface of the cylinder head. Install a new head gasket and new seals (1).2. Install the exhaust manifold on the cylinder head. Install the nuts that hold it. Install the turbocharger inlet elbow and air cleaner on the cylinder head. Install the bolts that hold them. 3. Fasten a hoist and a spreader bar to the cylinder head. Put cylinder head (2) in position on the cylinder block.4. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in following sequence: 1. Tighten bolts 1 through 29 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).2. Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).3. Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (447 20 N m) by hand.4. Install rocker shafts (3) and push rods.5. Tighten bolts 21 through 26 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).6. Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).7. Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (447 20 N m) by hand.8. Tighten the 3/8" bolts (5) to a torque of 32 5 lb.ft. (43 7 N m). If studs (4) were removed, install new studs and tighten to a torque of 20 5 lb.ft. (25 7 N m).5. Make an adjustment to the valves to have a clearance of .015 .003 in. (0.38 0.08 mm) for intake, and .030 .003 in. (0.76 0.08 mm) for exhaust. Install valve cover bases and the inner fuel lines.6. Connect the gauge wire for the air cleaner to the sending unit. Install the bolt and clip that hold the wire to the cylinder head. Connect the glow plug wires to each end of the cylinder head.7. Connect the water temperature gauge line to the cylinder head. Connect the water hose to the valve. Tighten the clamp that holds it.end by:a) install inlet manifold (precombustion chamber only)b) install fuel injection linesc) install water temperature regulatord) install the turbochargere) install aftercooler (direct injection only)