36895-87D10 Suzuki WIRE LEAD

1. Remove tube assembly (1). 2. Remove clamps (2) and tube assembly (3) from the bracket. 3. Remove water inlet line (4) and water outlet line (6) for the turbocharger.4. Remove bracket (5) from the rear of the cylinder head. 5. Remove support (7) from the cylinder head and governor housing (left cylinder head only). Disconnect the three brackets from the cylinder head that hold the fuel injection pump in place (right cylinder head only). 6. Remove two of the cylinder head bolts and install two 3/4"-10 NC guide pins (8) in the cylinder block. 7. Install tooling (A) and fasten a hoist. Remove cylinder head bolts (9) and remove cylinder head (10) and exhaust manifold (11) as a unit. The weight is 490 lb. (221 kg). Remove the head gasket.8. Remove exhaust manifold (11). See REMOVE EXHAUST MANIFOLD. Camshaft idler gear (12) can be removed without the removal of the cylinder head.9. Remove bolts (13), the lock, the washers and the O-ring seal. 10. Use a 3/8"-16 NC forged eyebolt in the shaft and remove shaft (14). Remove camshaft idler gear (12) from the cylinder head.Install Cylinder Heads (Later)
The left cylinder head is shown.1. Inspect all parts for damage and make replacements if needed. Put clean oil on the O-ring seals.
Make sure the grooves in gear (1) and in the bearing are in alignment 4°.
2. Use tooling (A) and a press to install the bearing in gear (1). Install the bearing to a depth of .030 in. (0.762 mm) below the outside surface. The inside diameter of the bearing after assembly must be 2.1308 .0019 in. (54.122 0.048 mm). 3. Put O-ring seal (2) in position on shaft (3).4. Install gear (1) and the shaft in the cylinder head. Install two O-ring seals, washers, lock and bolts to hold the shaft in position.5. Install the exhaust manifold. See INSTALL EXHAUST MANIFOLD. Be sure a new gasket has been installed between the spacer plate and the cylinder block. Install new seal and install the O-ring seals. See REMOVE AND INSTALL SPACER PLATES.6. Make sure the top surface of the spacer plate and the bottom surface of the cylinder head are clean.7. Install two 3/4"-10 NC guide pins (5) in the cylinder block. Install new cylinder head gasket (6). 8. Install tooling (A) on the cylinder head and fasten a hoist. Put cylinder head (4) and exhaust manifold (7) in position on the cylinder block. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head bolts. Tighten the cylinder head bolts in the following step sequence: a) Tighten all the bolts in number sequence to 175 10 lb.ft. (240 14 N m).b) Tighten all the bolts in number sequence to 250 10 lb.ft. (340 14 N m).c) Tighten all the bolts by hand in number sequence to 250 10 lb.ft. (340 14 N m). 8. Install support (8) to the governor housing and cylinder head (left cylinder head only). Connect the three brackets to the cylinder head that hold the fuel injection pump in place (right cylinder head only). 9. Install bracket (9) to the rear of the cylinder head. 10. Install water outlet line (11) and water inlet line (10) for the turbocharger. 12. Put tube assembly (13) in position on the bracket and install clamps (12). 13. Install tube assembly (14).end by:a) install water temperature regulator housingb) install exhaust manifold shieldsc) install camshaft housingd) install aftercooler housing