12110-94302 Suzuki PISTON

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Refer to the following documentation for liner projection and head bolt tightening. The 362-8264 Cylinder Head Gasket should only be used with the 519-7297 Spacer Plate.Do not use with any other spacer plates.Note: Refer to the Parts Manual for the correct parts for your engine arrangement.Safety Section
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Liner Projection Allowance
Due to the thickness change of the spacer plate, a new specification for allowable cylinder liner projection is published in Table 1.
Table 1
Part Dimension Value
519-7297 Spacer Plate 12.338 to 12.388 mm (0.48575 to 0.4877 inch) X
454-9920 Cylinder Liner flange
211-7826 Cylinder Liner flange 12.630 to 12.670 mm (0.4972 to 0.4988 inch) Z
144-5692 Plate Gasket 0.170 to 0.230 mm (0.0067 to 0.0091 inch) Y
Allowable Liner Projection 0.050 to 0.120 mm (0.0020 to 0.0047 inch)
Illustration 1 g02657236
(X) Average thickness of the spacer plate
(Y) Nominal thickness of the spacer plate gasket
(Z) Average thickness of the cylinder liner flangeCylinder Head Bolt Tightening Procedures
The new spacer plate requires a new torque procedure for cylinder head bolts. There are two different torque procedures that vary based on the depth of threaded head bolt holes in the block.Tightening Procedure 1 ( 7N-1961 Head Bolt)
Engines that utilize a B series cylinder block require a 7N-1961 Head Bolt ( 216 mm (8.5 inch)).Note: The bolt length is measured from under the bolt head to the end of the bolt shaft.
Illustration 2 g06265576
Use the number in the illustration above to torque the bolts in the order that is required for this procedure.
Note: Apply clean engine oil to the bolt threads and underneath the bolt head before installation.
Torque bolts number 1 through 8 to 30 5 N m (22 4 lb ft).
Torque bolts number 1 through 8 to 145 15 N m (107 11 lb ft).
Retorque bolts number 1 through 8 to 145 15 N m (107 11 lb ft).
Turn bolts 1 through 8 180 5 degrees.
Torque bolts 9 and 10 to 55 10 N m (41 7 lb ft).Tightening Procedure 2 ( 236-0486 Head Bolt)
Engines that utilize an E series cylinder block require a 236-0486 Head Bolt ( 254 mm (10 inch)).Note: The bolt length is measured from under the bolt head to the end of the bolt shaft.
Illustration 3 g06265576
Use the number in the illustration above to torque the bolts in the order that is required for this procedure.
Note: Apply clean engine oil to the bolt threads and underneath the bolt head before installation.
Torque bolts number 1 through 8 to 30 5 N m (22 4 lb ft).
Torque bolts number 1 through 8 to 200 15 N m (148 11 lb ft).
Retorque bolts number 1 through 8 to 200 15 N m (148 11 lb ft).
Turn bolts 1 through 8 180 5 degrees.
Torque bolts 9 and 10 to 55 10 N m (41 7 lb ft).