09117-08074 Suzuki BOLT (8X22)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-0455 Liner Projection Tool 1
B 2P-8260 Cylinder Liner Installation Tool 1
C 486-1525 Lubricant 1 Regional alternatives of Tooling (C) are available at the following website:https://www.ipcol.com/assembly-lubricants/p80-emulsion
Note: The following procedure alleviates the need for the crossbar to hold the cylinder liners during cylinder liner projection measurements.
Clean the cylinder liner flange and the cylinder block surface. Remove any nicks on the top of the cylinder block.
Install clean cylinder liners without the rubber seals or the filler band. Install a new spacer plate gasket and the clean spacer plate.
Table 2
Required Components
Item Part Number Part Description Quantity For One Cylinder Quantity For Six Cylinders
1 0S-1589 Bolt 6 36
2 2S-0736 Washer 6 36
3 8F-1484 Washer 6 36
4 7K-1977 Washer 6 36
Illustration 1 g00544054
Install the bolts and washers in the order that is shown in Illustration 1 to seat the cylinder liner in the block. Tighten bolts (1) evenly to a torque of 95 N m (70 lb ft).
Illustration 2 g00544478
(5) Bolt
(6) Dial Indicator
(7) Gauge Body
(8) Gauge
Loosen bolt (5) until dial indicator (6) can be moved. Place gauge body (7) and dial indicator (6) on the long side of gauge (8).
Slide dial indicator (6) into position until the point contacts gauge (8). Slide dial indicator (6) until the needle of the dial indicator makes a quarter of a revolution clockwise. The needle should be in a vertical position. Tighten bolt (5) and zero dial indicator (6).
Place gauge body (7) on the spacer plate with the dial indicator point on the cylinder liner flange. Read the dial indicator to find the amount of liner projection. Check the liner projection at four locations (every 90 degrees) around each cylinder liner.
Table 3
Specifications
Liner Projection 0.033 mm (.0013 inch) to 0.175 mm (.0069 inch)
Maximum Variation in Each Cylinder 0.051 mm (.0020 inch)
Maximum Average Variation Between Adjacent Cylinders 0.051 mm (.0020 inch)
Maximum Variation Between All Cylinders 0.102 mm (.0040 inch)
If the cylinder liner projection is out of specification, rotate the cylinder liner in the bore and repeat the procedure. If the cylinder liner projection measurements are again out of specification, try installing the cylinder liner in a different cylinder bore to improve the measurements.Note: Do not exceed the maximum liner projection of 0.175 mm (0.0069 inch). Cracking in the flange of the cylinder liner results from excessive cylinder liner projection measurements.
If the maximum variation between cylinder liners is greater than the recommended specification, shims must be used to reach the correct specification.
When the cylinder liner projection for each cylinder liner is within the recommended specification, mark each cylinder liner for the proper location in the bore and remove the cylinder liners.
Lubricate the O-ring seals, the cylinder liner, and the upper filler band before installation.Note: If the lower O-ring seals are black, apply liquid soap on the lower O-ring seals and the cylinder block. Use clean engine oil on the upper filler band.Note: If the lower O-rings are brown in color, apply engine oil on the lower O-ring seals, the cylinder block, and the upper filler band.
Illustration 3 g00544889
Apply Tooling (C) on the grooves of the cylinder liner and on O-ring seals (4). Install O-ring seals (4) on the cylinder liner.
Lubricate filler band (5) with clean engine oil and install filler band (5) on cylinder liner (6). Install cylinder liner (6) into the engine block immediately after you lubricate the cylinder liner. This helps to prevent swelling of the filler band.
Illustration 4 g00478920
Ensure that the mark on the cylinder liner is in alignment with the mark on the cylinder block. Use Tool (B) to press each of the cylinder liners into position.End By:
Install the Pistons and Connecting Rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".
Install the cylinder head. Refer to Disassembly and Assembly, "Spacer Plate - Remove and Install".