09125-05075 Suzuki SCREW

1. Make an adjustment of the legs on Tool (A) for the length of the cylinder liner. Be careful not to damage cooling tube at the bottom of the cylinder liner. 2. Turn the nut on Tool (A) until cylinder liner (1) is free of the cylinder block. 3. Remove seals (3) and filler band (2) from the cylinder liner.Install Cylinder Liners
1. Install the gasket and spacer plate.2. Clean the cylinder liners and liner bores in the cylinder block. 3. Install the cylinder liners (1) in the cylinder block without seals or bands.4. Check the cylinder liner projection as follows: a. Install four bolts (4) and eight seals (washers) from Tool (A) around each cylinder liner as shown. Tighten the bolts evenly, in four steps: 14 N m (5 lb ft), 35 N m (25 lb ft), 70 N m (50 lb ft) and then to 95 N m (70 lb ft). To keep from moving bolts and seals as each liner is checked, install two bolts with seals on each side to each cylinder liner, along the complete length of the top plate.b. Install plate (3), crossbar (6), plates (5) from Tool (A) and bolts (2) and washers from Tool (C). Be sure the crossbar is in position at the center of the liner and the liner surface is clean. Tighten the bolts evenly, in four steps. 7 N m (5 lb ft), 20 N m (15 lb ft), 35 N m (25 lb ft) and then to 70 N m (50 lb ft).c. Check the distance from the bottom edge of crossbar (6) to the top edge of the spacer plate. The distance on each end of the crossbar must be the same.d. Check the liner projection with Tool (B) at four locations around the liner flange. Liner projection must be 0.03 to 0.15 mm (.001 to .006 in). The difference between the four measurements on the same liner must not be more than 0.05 mm (.022 in). The difference between average liner projection for liners next to each other must not be more than 0.05 mm (.002 in). The maximum difference in the average projection of the cylinder liners under each cylinder head must not be more than 0.10 mm (.004 in). If the liner projection changes too much from point to point around the liner turn the liner to a new position in the bore. If the projection measurements are still within specifications, move the liner to a different bore in the cylinder block and check the projection again.5. If a liner does not measure with the correct projection specifications, the projection can be changed with a counterbore operation to the top surface of the cylinder block. The counterbore depth must be a range from a minimum of 0.76 mm (.030 in) to a maximum of 1.14 mm (.045 in). Shims are available to then adjust the liner to the correct projection. See Special Instruction Form No. FM055228 for procedure to use the 8S3140 Cylinder Block Counterboring Tool Arrangement. See Cylinder Liner Projection in Testing & Adjusting section of Service Manual to find shim thickness, part number and installation. 6. Put a mark (7) on the cylinder liners and block so the liners can be installed in same position.7. Remove Tool (A) and Tool (B). Remove one liner. 8. Put liquid soap on seals (8), grooves of the liner and the bore of the block. Install the seals on the cylinder liner.9. Put filler band (9) in clean SAE 30 oil for a short time. Install the filler band on the liner.10. Install the liner immediately after the filler band is installed. Make sure the mark on liner is in alignment with the mark on the block. Use Tool (C) to push the liner into position.11. Do steps 7 through 10 for the remainder of the liners.End By:a. install pistons