09116-08151 Suzuki BOLT (8X30)

1. Loosen the fuel injection line nut at the nozzle end with Tool (A).2. Loosen the fuel line nut at the fuel injection line adapter with Tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system. If necessary, use Tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with Tool (C) to remove the push rods.3. Put compression on the valve springs with Tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the inlet valve lifter with Tooling (E) as follows:a. Install 5P-2685 Nut(3) and 5P-6601 Collet(4) on 5P-2408 Outer Handle Assembly(5).b. Install 5P-6599 Inner Handle Assembly(6) in 5P-2408 Outer Handle Assembly(5). c. Install Tooling (E) in the inlet valve lifter. Hold the 5P-2408 Outer Handle Assembly, and tighten the 5P-6599 Inner Handle Assemblyuntil the 5P-6601 Colletis tight against the inside of the inlet valve lifter. d. Remove inlet valve lifters (7) from the cylinder block with Tooling (E). Put identification marks on the lifters as to their location in the engine. 6. Remove the exhaust valve lifters with Tooling (E) as follows:a. Install 5P-2685 Nut(3) and 5P-6601 Collet(4) on 5P-2408 Outer Handle Assembly(5). The opening in the cylinder head assembly for the inlet valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the inlet valve lifter side.b. Install the outer handle assembly in the inlet valve lifter side of the cylinder head assembly. Slide the flat area of 5P-2408 Outer Handle Assembly(5) through the head casting, and install the 5P-6601 Colletin the exhaust valve lifters. c. Install 5P-6599 Inner Handle Assembly(6) in 5P-2408 Outer Handle Assembly(5). Hold the 5P-2408 Handle Assembly, and tighten the 5P-6599 Handle Assemblyuntil the 5P-6601 Colletis tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e. Remove the 5P-6599 Inner Handle Assembly. Slide the 5P-2408 Outer Handle Assemblythrough the head casting, and remove it from the inlet valve lifter side of the cylinder head. f. Use a magnet, and remove exhaust valve lifters (8) from the inlet valve lifter side of the cylinder head assembly. Put identification marks on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2 must be done to install inlet or exhaust valve lifters.
Make sure guide spring (9) is not damaged or worn. If the guide spring is damaged or worn, replace the guide spring. See Guideline For Reusable Parts, SEBF8066.
1. Install guide spring (9) on the valve lifters. 2. Put the inlet or exhaust valve lifter in position in 5P-2395 Holder(10) of Tooling (E). Install 5P-2685 Nut(3) and 5P-2400 Compressor(11) on 5P-2408 Outer Handle Assembly(5). Install the 5P-2400 Compressoron the lifter over the guide spring. Immerse the lifter assembly in engine oil before installing it in the cylinder block lifter bore. The opening in the cylinder head assembly for the inlet valve lifter is larger than the opening in the exhaust valve lifter side. All tooling and valve lifters must be installed and removed from the inlet valve lifter side. 3. Install the exhaust valve lifters with Tooling (E) as follows: Be sure to install original valve lifters in their respective bores. New valve lifters can be mixed.a. Install exhaust valve lifter (8) and the handle assembly in the cylinder head opening on the inlet valve lifter side. Slide the flat area of the 5P-2408 Outer Handle Assemblythrough the casting in the cylinder head assembly. b. Put the exhaust valve lifter in the valve lifter bore of the cylinder block. Install 5P-6599 Inner Handle Assembly(6) in the 5P-2408 Outer Handle Assembly, and push the exhaust valve lifter from Tooling (E).c. Remove the 5P-6599 Inner Handle Assemblyfrom the 5P-2408 Outer Handle Assembly. Slide the 5P-2408 Outer Handle Assemblyto the inlet valve lifter side of the cylinder head, and remove it.4. Install the inlet valve lifters with Tooling (E) as follows: Be sure to install original valve lifters in their respective bores. New valve lifters can be mixed.a. Install 5P-6599 Inner Handle Assembly(6) in the 5P-2408 Outer Handle Assembly.b. Install the inlet valve lifter into the valve lifter bore of the cylinder block with Tooling (E). Use the 5P-6599 Inner Handle Assemblyto push the lifter from Tooling (E). Remove Tooling (E).
do not make contact with the pistons when the valves are opened with Tool (C) to install the push rods.
5. Turn the rocker arms up, and use Tool (C) to install push rods (2). 6. Install inner fuel lines (1). Use Tool (A) to tighten the nuts on the adapter assemblies in the cylinder head assembly, and use Tool (B), to tighten the nuts on the fuel injection nozzles to a torque of 40 7 N.m (30 5 lb ft).End By:a. install valve covers