09280-70004 Suzuki O-RING

Secure engine in swivelling mounting stand.1. Dismantle the following units and components: Air filter with holder, starter, air compressor with bracket and lubricating oil line, generator with holder, fuel-supply line to the flame-type heater plug or the pipe connecting with the pilot injector, induction manifold, exhaust manifold, cover plate on the exit air side, air cowling, fuel and lubricating oil filters with their supply lines, leak-off and delivery lines, vertical plate on the fly-wheel side, blower, front vertical plate, oil cooler, air cowling, vee-belt idler.
9-13 Immediately fuel line unions are dismantled plug or fit caps on the connecting stubs and pipe ends.Fig. 9-13
9-142. Dismantle the vee-belt pulley for the air compressor, main belt pulley and front cover. (Use retainer for vee-belt pulley, No. 143400).Fig. 9-14 The screw securing the vee-belt pulley has a left-hand thread.
9-153. Disassemble the nut on the fuel-injection pump's driving shaft. (Use the universal device No. 110340 or a 19 mm socket spanner).Fig. 9-15 Important:As from 1975, the hub was modified in the case of rigid drive. (The thread for attachment of tool No. 110340 with sleeve has been omitted). Remove gear-wheel fastening screws. (See Section 7)
9-164. Mount the tool without sleeve if the pump drive has on injection timer. If it has no injection timer mount the tool with sleeve (Universal device No. 110340).Fig. 9-16
9-175. Pull the injection pump drive from the pump shaft. Dismantle the pump and the securing flange.Fig. 9-17
9-186. Dismantle the injectors, upper cover plate, valve covers and rocker arm shaft brackets, remove the push-rods and unscrew the plugs. (Use socket spanner No. 120040, square socket insert No. 120060)Fig. 9-18, left7. Slacken the cylinder head studs in stages, in diagonal sequence. (Use socket spanner No. 120040)Fig. 9-18, right8. Dismantle the cylinder heads and pushrod sheaths.
9-199. Turn engine upside down. Dismantle the sump with sheet-metal partition, crankcase breather and oil strainer. Disassemble the big-end bearing bolts. (Use bent socket spanner No. 131540)Fig. 9-1910. Slacken and remove the big-end bearing caps. Withdraw the cylinders with pistons and connecting rods from the crankcase. Remove the halves of bearing shells and mark them on the back corresponding to the connecting rods with an electric scriber. Make sure that the bearing shells do not get damaged.11. Dismantle the oil pump and idler gear, camshaft and tappets, flywheel and main bearing caps.12. Remove the crankshaft and the halves of bearing shells. Mark the bearing shells on the back corresponding to the crankcase with an electric scriber. Unscrew the plugs, oil feeders and oil injection nozzles from the crankcase. Clean all parts and thouroughly wash out the oilways.
9-20 Remove horizontal oil nozzles. Fig. 9-2013. Check all parts for suitability for reuse.Assembling The Crankshaft Assembly (as from 3 cylinder engine)
It is assumed that the liner is fitted in the front camshaft bearing bore.
9-611. Place the crankcase with the cylinder head joint face downwards. Screw the dosing plugs in the oilways of the bearing webs.Fig. 9-61
9-622. Assemble the screwed sealing plugs, fitted with new gaskets, in the oilholes connecting with the bearing webs.Fig. 9-62 If the engine is to be fitted with an air compressor no plug should be assembled in the third hole viewed from the front plate.
9-633. If the engine is not to be equipped with a hydraulic pump, the core-hole cover plate should be flush-mounted with jointing compound. Then assemble a screwed plug, fitted with a new gasket, to seal the tapped hole in the side of the crankcase.Fig. 9-63
9-644. Replace missing or damaged locating sleeves in the joint face. Check the baffle and renew, if necessary.Fig. 9-64
9-655. Replace missing or damaged locating sleeve for the journal of the idler gearwheel. The dividing point must face in the direction of the cylinder head joint surface. Assemble the screwed plugs, fitted with a new gasket, in the main oil gallery on the near side of the engine.Fig. 9-656. Replace missing or damaged dipstick guide. Drive it in so that it seats.7. Assemble the screwed plugs, fitted with a new gasket, in the main oil gallery on the far side.
9-668. Fit the cover plate to the flywheel end of the camshaft bore. Apply jointing compound and caulk. (Use pressin device No. 143610).Fig. 9-66Oil Nozzles
9-679. Screw the oil nozzles, fitted with lock washers, in the bearing webs.Fig. 9-67
9-689.1.1. Install new oil nozzle in tool No. 151100 as shown (side with long slot), the dowel pin pointing toward the cylinder head (arrow).Fig. 9-68
9-699.1.2. Install oil nozzle properly located (arrow).Fig. 9-69 Before installation fill annular groove with sealant.10. Oil the tappets and fit them in the crankcase.
9-7011. Assemble the thrust washer to the camshaft, (see arrow). Oil the camshaft journals. Install the camshaft in the bearing bores.Fig. 9-70, left On recent engines place compression spring on camshaft journal.Fig. 9-70, right
9-7112. Check the locating pin in the crankshaft gearwheel. It should project 17 mm from the side opposite that bearing the identification mark. If necessary, fit a new locating pin or correct the position of the existing one.Fig. 9-71
9-7213. Fit the crankshaft gearwheel, with the face bearing the identification mark directed away from the crankshaft. If necessary, drive it on.Fig. 9-7214. Install the halves of bearing shells in the crankcase and bearing cap, making sure that the identification marks are correct.
9-7315. Coat the thrust ring halves with grease and stick them by their smooth faces to the first bearing web and first bearing cap.Fig. 9-73 A locating pin must be fitted in either side of the bearing cap. The halves of thrust ring should locate against these pins.16. Oil the crankshaft journals and install the crankshaft.17. A centring sleeve must seat in the main bearing cap and bearing web.
9-7418. The bearing cap must be fitted with its identification number corresponding to and in the same direction as that stamped on the crankcase.Fig. 9-74
9-7519. Assemble the bolts in