45311-93900-0ED Suzuki RELEASE LEVER BRACKET

1. Remove coolant from the radiator and cylinder block.2. Remove fuel injection lines (5). Put a cap on all openings.3. Remove breather tube (6).4. Remove supply line (2) and drain line (4) for turbocharger.5. Remove air cleaner housing (1) and air inlet pipe.6. Remove nuts (3) from exhaust manifold.7. Remove turbocharger and exhaust manifold as a unit. Weight is 85 lb. (39 kg). 8. Remove water line (10) between air compressor and cylinder head.9. Remove air inlet line (11) for air compressor.10. Disconnect line (9) for water temperature.11. Remove water elbow (8), regulator, and hose.12. Remove bolts (7) that hold water elbow to the cylinder head.13. Remove valve cover from the engine. 14. Remove the rocker shaft (12) and push rods.15. Loosen the fan belts.16. Remove bolts from the fan drive. Install tool (A) to hold the fan drive in place.17. Remove the bolts and washers from the cylinder head.18. Fasten a hoist and remove the cylinder head. Weight is 210 lb. (95 kg).Install Cylinder Head
1. Install a new, dry cylinder head gasket. 2. Fasten a hoist and put cylinder head (1) in position on cylinder block. 3. Install push rods (3) and rocker shaft (2). The dowel pin (4) on each end of the rocker shaft must be in alignment with the hole (5) in the head. If the pins and holes are not in alignment when bolts are tightened, damage to the rocker shaft and arms can be the result.4. Put 5P3931 Anti-Seize Compound on the threads of cylinder head and rocker shaft bolts. Install the bolts and washers and tighten bolts in the following step sequence: Step 1. Tighten all bolts in number sequence to a torque of 115 lb.ft. (155 N m).Step 2. Tighten all bolts in number sequence to a torque of 185 13 lb.ft. (250 17 N m) again.Step 3. Tighten all bolts in number sequence (hand turn only) to a torque of 185 13 lb.ft. (250 17 N m) again.Step 4. Tighten all bolts in letter sequence to a torque of 22 lb.ft. (28 N m).Step 5. Tighten all bolts in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).Step 6. Tighten all bolts (hand turn only) in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).5. Make adjustments to the valves. The intake valve clearance is .015 in. (0.38 mm) and the exhaust valve clearance is .025 in. (0.64 mm).6. Connect fan drive to the cylinder head and remove tool (A).7. Tighten fan belts. See INSTALL ALTERNATOR for the correct belt tension adjustment.8. Install valve cover. Tighten bolts by number in sequence shown to 96 24 lb.in. (10.9 2.8 N m). 9. Install air cleaner housing (6) and bracket. 10. Install bolts (7) that hold water elbow to cylinder head.11. Install hose, regulator and water elbow.12. Install air inlet line (9) for air compressor.13. Install water line (8) between air compressor and cylinder head.14. Connect line (10) for water temperature.15. Install turbocharger and exhaust manifold. 16. Install supply line (11) and drain line (13) for turbocharger.17. Remove caps from fuel injection lines and install fuel injection lines (12). Tighten nuts on lines to a torque of 30 5 lb.ft. (40 7 N m).18. Fill cooling system to the correct level.end by:a) install hood