09280-10005 Suzuki O Ring, Gear Case

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     4C-5592     Anti-Seize Compound     -    
B     8T-2998     Lubricant     -    
C     9S-3263     Thread Lock Compound     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01712197
Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head and the top of the cylinder block. A new spacer plate gasket and a cylinder head gasket must be installed when the cylinder head is removed.
Install O-ring seal (18) on the dowel in the cylinder block.
Install spacer plate gasket (20) on the cylinder block.
Install spacer plate (17) .
Install seals (19) and seal (21) .
Install cylinder head gasket (16) on the spacer plate.
Illustration 2 g01712179
Attach a suitable lifting device to cylinder head (15). The weight of cylinder head (15) is approximately 235 kg (518 lb).
Carefully install the cylinder head on the dowel pins on the cylinder block.
Apply Tooling (A) to the threads of cylinder head bolts (14) and both sides of the washers. Install cylinder head bolts (14) .
Illustration 3 g01072801
Note: The bolts that are Marked "X" are 216 mm (8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24 and 26. The rest of the bolts are 194 mm (7.6 inch) long.
Tighten the cylinder head bolts according to the following procedure.
In a numerical sequence, tighten Bolts 1 through 26 to a torque of 270 15 N m (200 11 lb ft).
In a numerical sequence, tighten Bolts 1 through 26 to a torque of 450 15 N m (330 11 lb ft).
In a numerical sequence, again tighten Bolts 1 through 26 to a torque of 450 15 N m (330 11 lb ft).
Illustration 4 g01712061
Install coolant tube assemblies (13) and install tube assemblies (12) .
Illustration 5 g01710597
Install fuel manifold (11) and the bracket assembly.
Illustration 6 g01067192
Install O-ring seal (5) and O-ring seal (6) on sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (B) and clean engine oil.
Illustration 7 g01067193
Illustration 8 g01067195
Install adapter assembly (4) and sealing plate (3). Ensure that the dowel in adapter assembly (4) engages the hole in the camshaft.Note: Ensure that the O-ring seal stays in the groove in sealing plate (3) .
Install thrust plate (1) . Apply Tooling (C) to bolts (2). Hold the thrust plate in position and install bolts (2). Evenly tighten bolts (2) until sealing plate (3) and the O-ring seal are seated against the cylinder head.End By:
Install the water temperature regulator housing. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install".
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Install the control system. Refer to Disassembly and Assembly, "Control System - Remove and Install".
Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".
Install the aftercooler, if necessary. Refer to Disassembly and Assembly, "Aftercooler - Install".