32150-87D00 Suzuki COUNTER COIL

start by: a) remove pistons1. Drain the coolant from the cooling system.2. Put covers on the crankshaft journals to keep foreign material away. 3. Pull the cylinder liner (1) from the cylinder block with tooling (A). Remove tooling (A) and the cylinder liner.Install Cylinder Liners (Later)
1. Make sure that the plate and the cylinder liner flange are clean.2. Install liners in the cylinder block without the seals and bands. 3. Install tooling (A), two bolts with washers on each side of the cylinder liner. Six bolts are shown, but the two bolts (1) to the sides of the cylinder block are not necessary. Two washers under the bolt head will prevent marks or scratches on the plate surface.4. Tighten the bolts of tooling (A) evenly, in four steps, to a torque of: 10 lb.ft. (14 N m), 25 lb.ft. (35 N m), 50 lb.ft. (70 N m) and finally to 70 lb.ft. (95 N m).5. Install tooling (B) and tighten bolts evenly in four steps, to a torque of: 5 lb.ft. (7 N m), 15 lb.ft. (20 N m), 25 lb.ft. (35 N m) and finally to 50 lb.ft. (70 N m). The distance from the bottom edge of the crossbar to the top plate, must be the same on both sides of cylinder liner.6. Check the liner projection with tool group (C) at four locations around the cylinder liner. The difference between the four measurements must be more than .001 in. (0.03 mm).7. The liner projection must be .0060 .0028 in. (0.152 0.071 mm). The measurements between the liners next to each other under each cylinder head must not be more than .001 in. (0.03 mm) difference. If the liner is turned in the bore it can make a difference in the liner projection.
TYPICAL EXAMPLE8. If the liner projection is not .0060 .0028 in. (0.152 0.071 mm), check the thickness of the following parts: a) Cylinder liner flange (2); .5050 .0008 in. (12.83 0.02 mm).b) Spacer plate (X): .492 .001 in. (12.50 0.03 mm).c) Spacer plate gasket (Y): .008 .001 in. (0.20 0.03 mm). If the counterbore is worn and/or the measurements are not correct, the counterbore can be corrected with a counterboring tool. See Special Instructions Form No. FMO55228.9. Put a mark on the cylinder liners and the cylinder block so the liners can be installed in the same position in the cylinder block. 10. Install new seals (5) on the cylinder liner. Put liquid soap on the seals and the bores in the cylinder block. 11. Put clean diesel fuel on band (6) and install it on the liner as shown. Put clean SAE 30 oil on the liner and install it in the cylinder block with tool group (D).
The liners must be installed in the cylinder block immediately after band (6) is installed. Make sure the marks on the liners and the cylinder block are in alignment when the liners are installed.
end by: a) install pistons