09160-15033 Suzuki Washer Thickness: 2.1

Table 1
Dimensions for Acceptable Cylinder Liner Projection with the 362-8264 Cylinder Head Gasket
Part Dimension Value
211-7826 Cylinder Block Liner flange 12.65 0.02 mm (0.498 0.0001 inch) Z
519-7297 Spacer Plate 12.36 0.03 mm (0.4867 0.0012 inch) X
110-6994 Spacer Plate 12.31 0.03 mm (0.4846 0.0012 inch) X
144-5692 Plate Gasket 0.21 0.03 mm (0.008 0.001 inch) Y
Allowable projection 0.05 mm (0.002 inch) to 0.12 mm (0.005 inch) Introduction
Use this procedure to check the cylinder liner projection out of the cylinder block and installed in the cylinder block.Reference: Refer to Reuse And Salvage Guidelines, "Procedure to Salvage Top Decks of Cylinder Blocks of 3500 Engines" for additional information about reuse and/or salvage of the cylinder block.Required Tools
Table 2
Required Tools Qty
1A-0075 Bolt (3/4-16 thread, 44.45 mm (1.750 inch) long) 4
1U-9895 Crossblock 1
3B-1925 Washer (COPPER) 4
3H-0465 Push-Puller Plate 2
6V-7059 Micrometer 1
8F-6123 Bolt (3/4-16 thread, 139.7 mm (5.5.50 inch) long) 2
8T-0455 Liner Projection Tool Group 1 Preparation
For checking the cylinder liner projection with the liner out of the cylinder block, ensure that the following surfaces are clean prior to measuring:
Cylinder liner flanges
Spacer plate
Spacer plate gasketFor checking the installed cylinder liner projection, ensure that the following surfaces are clean prior to measuring:
Top surface of the cylinder block
Cylinder liner bores
Cylinder liner flanges
Spacer plates
Spacer plate gasketCylinder Liner out of the Cylinder Block - Check
Illustration 1 g02247495
Use the 6V-7059 Micrometer to measure the thickness of the following items:
(X) Spacer Plate
(Y) Spacer Plate Gasket
(Z) Cylinder Liner FlangeThe cylinder liner projection depends on which spacer plate is used. Refer to Table 1.Note: To determine the cylinder liner projection, subtract the thickness of the spacer plate and gasket from the thickness of the cylinder liner flange.
Refer to Table 1 for the correct value of your cylinder liner projection based on your spacer plate.Cylinder Liner Installed in the Cylinder Block - Check
Illustration 2 g01192749
Measuring the cylinder liner projection
(1) 3H-0465 Push-Puller Plate
(2) 1P-2403 Dial Indicator
(3) 1P-2402 Gauge Body
(4) 1A-0075 Bolt and 3B-1925 Washer (COPPER)
(5) Spacer plate
(6) 1U-9895 Crossblock
Install a new gasket and spacer plate (5) on the cylinder block.
Install the cylinder liner in the cylinder block without seals or bands.
Hold spacer plate (5) and the cylinder liner in position according to the following procedure:
Install four 3B-1925 Washers (COPPER) and four 1A-0075 Bolts (4) around spacer plate (5). Tighten the bolts evenly to a torque of 95 N m (70 lb ft).
Install the following components: 1U-9895 Crossblock (6), two 3H-0465 Push-Puller Plates (1) and two 8F-6123 Bolts. Ensure that 1U-9895 Crossblock (6) is in position at the center of the cylinder liner. Ensure that the surface of the cylinder liner is clean. Tighten the bolts evenly to a torque of 70 N m (50 lb ft).
Check the distance from the bottom edge of 1U-9895 Crossblock (6) to the top edge of spacer plate (5). The vertical distance from both ends of the 1U-9895 Crossblock must be equal.
Use 8T-0455 Liner Projection Tool Group (6) to measure the cylinder liner projection.
Mount 1P-2403 Dial Indicator (2) in 1P-2402 Gauge Body (3). Use the back of the 1P-5507 Gauge Block to zero dial indicator (2).
Refer to Table 1 for the correct value of the cylinder liner projection based on the part number of the spacer plate.
Read the measurement on the outer flange of the cylinder liner at four equally distant positions. Do not read the measurement on the inner flange. The maximum allowable difference between the high measurements and the low measurements at four positions around each cylinder liner is 0.05 mm (0.002 inch). The maximum allowable difference between the four measurements must not exceed 0.05 mm (0.002 inch) on the same cylinder liner.Note: If the cylinder liner projection is not within specifications, turn the cylinder liner to a different position within the bore. Measure the projection again. If the cylinder liner projection is not within specifications, move the cylinder liner to a different bore. Inspect the top face of the cylinder block.Note: When the cylinder liner projection is correct, put a temporary mark on the cylinder liner and the spacer plate. Be sure to identify the particular cylinder liner with the corresponding cylinder. When the seals and the filler band are installed, install the cylinder liner in the marked position.