99011-98J00-03A Suzuki MANUAL, OWNER'S

start by:a) remove rocker shaft and push rods1. Drain the coolant from the cooling system. 2. Remove oil supply line (1) and oil drain line (2) from the turbocharger.3. Put identification on each wire and screw on the magneto. 4. Remove bolt (3) and disconnect wires (4) from the magneto. 5. Remove tube (5) from the aftercooler to the auxiliary water pump.6. Remove tube (6) and water pump elbow (7). 7. Disconnect carburetor control rod (9) from lever (10).8. Remove oil pressure sensing line (8).9. Disconnect tube (11) from the engine oil cooler.10. Disconnect gas supply line to gas pressure regulator. 11. Remove covers (13) from the spark plugs and adapters.12. Remove bolts (12) that hold the cylinder head assembly to the cylinder block. 13. Fasten a hoist to the cylinder head assembly. Fasten tool (A) to the gas pressure regulator bracket and the hoist to give balance to the head assembly.14. Remove the head assembly. The weight of the cylinder head assembly is 510 lb. (229.5 kg).15. Remove the cylinder head gasket.Install Cylinder Head Assembly
1. Clean the machined surfaces of the cylinder head and cylinder block that make contact with the cylinder head gasket. 2. Put a new cylinder head gasket (1) in position on the cylinder block. Make sure the holes in the cylinder head gasket are in alignment with the holes in the cylinder block.3. Fasten a hoist to the cylinder head assembly. Fasten tool (A) to the gas pressure regulator bracket and the hoist. The weight of the cylinder head assembly is 510 lb. (229.5 kg).4. Put the cylinder head assembly in position on the cylinder block. 5. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head bolts (3). Install the cylinder head bolts and washers loosely.6. Install push rods (4). Put rocker shaft (2) in position on the cylinder head.
Make sure the dowels in the rocker shaft assembly are in alignment with the holes in the cylinder head before the bolts are installed and tightened.
7. Put 5P3931 Anti-Seize Compound on the threads of the rocker shaft bolts and install the rocker shaft bolts and washers. Tighten the cylinder head and rocker shaft as follows: a) Tighten all the bolts in number sequence to a torque of 115 lb.ft. (156 N m).b) Tighten all bolts in number sequence to a torque of 185 13 lb.ft. (250 17 N m).c) Tighten all bolts in number sequence (hand turn only) to a torque of 185 13 lb.ft. (250 17 N m). The minimum amount of torque on these bolts after the engine is warm must be 150 lb.ft. (203 N m).d) Tighten all bolts in letter sequence to a torque of 22 lb.ft. (30 N m).e) Tighten all bolts in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).f) Tighten all bolts in letter sequence (hand turn only) to a torque of 32 5 lb.ft. (43 7 N m). The minimum amount of torque on these bolts must be 27 lb.ft. (37 N m) after the engine is warm.8. Make adjustments until the intake valve clearance is .015 in. (0.38 mm) and the exhaust valve clearance is .030 in. (0.76 mm). See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING.9. Connect the spark plug covers to the adapters and spark plugs. 10. Install the turbocharger drain line (6) and oil supply line (5). 11. Connect wires (8) to the magneto. Each wire must be connected to the same terminal from which it was removed. Fasten clip (7) to the engine block. 12. Install water pump elbow (11) and tighten the clamp on the hose to the oil cooler.13. Install tube (9) from the aftercooler to the auxiliary water pump.14. Install tube (10) from water pump elbow (11) to the exhaust manifold. 15. Connect tube (14) to the engine oil cooler.16. Install oil pressure sensing line (12).17. Connect carburetor control rod (13) to the lever.18. Fill the cooling system with coolant to the correct level.end by:a) install valve cover