09162-05202 Suzuki LOCK WASHER

START BY:a. remove rocker shaft assembliesb. remove valve lifters and push rodsc. remove valve cover basesd. remove water temperature regulators and housingse. remove exhaust manifolds 1. Remove bolt (3) from support (1).2. Remove bolts (4), bracket (2) and support (1) from the cylinder head assembly.3. Remove the remainder of the 3/8" bolts from the cylinder head assembly.4. Disconnect hose (5) from the cylinder head assembly. 5. Remove all the cylinder head assembly bolts except bolt (6).6. Fasten tool (A) and a hoist on cylinder head assembly (7) as shown.7. Remove bolt (6), cylinder head assembly (7) and the gasket from the spacer plate. The weight of the cylinder head assembly is 150 kg (331 lb.).Install Cylinder Head Assemblies
Make sure a new gasket has been installed between the spacer plate and cylinder block. See Remove And Install Spacer Plates. 1. Thoroughly clean spacer plate (3) and the bottom of the cylinder head assembly.2. Install a new gasket (1) and water seals (2) as shown. Do not use any adhesives on the gasket or gasket surfaces. 3. Fasten tool (A) and hoist (4) on cylinder head assembly (5) as shown.
Do not cause damage to the water seals or the gasket when the cylinder head assembly is lowered into position.
4. Carefully put cylinder head assembly (5) in position on the spacer plate. Make sure the holes in the cylinder head assembly are in alignment with the dowels in the cylinder block. 5. Put clean engine oil on all bolt threads and tighten the bolts in the following sequence:a. Tighten bolts 1 through 20 in number sequence to a torque of 271 25 N m (200 18 lb.ft.).b. Tighten bolts 1 through 20 in number sequence to a torque of 447 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 20 in number sequence again to a torque of 447 20 N m (330 15 lb.ft.).6. Install the rocker shafts, valve lifters and push rods, and make the correct valve adjustments. See Install Rocker Shaft Assemblies And Push Rods. 7. Put clean engine oil on the threads of all 3/8" bolts.8. Put bracket (8) in position on the engine as shown. Install and tighten the three bracket bolts as follows:a. Install and tighten finger tight only the two bolts that hold bracket (8) to the cylinder head assembly.b. Install bolt (7) that holds bracket (8) to the fuel injection pump housing and tighten it to a torque of 43 7 N m (32 5 lb.ft.).c. Tighten the two bolts in step (a) to a torque of 43 7 N m (32 5 lb.ft.).9. Put support (9) in position on the cylinder head assembly and install the bolts that hold it. Tighten the bolts to a torque of 43 7 N m (32 5 lb.ft.).10. Install remaining 3/8" cylinder head bolts (6), and tighten them to a torque of 43 7 N m (32 5 lb.ft.).11. Install the bolt that holds support (9) to the automatic timing advance housing.12. Connect the hose to the cylinder head.END BY:a. install exhaust manifoldsb. install water temperature regulators and housingsc. install valve cover bases