09180-08203 Suzuki SPACER (8.2x14x16.5)

1. Fasten a hoist to elbow assembly (1). Remove bolts (2) and the elbow assembly. The weight of the elbow assembly is 26 kg (57 lb.). 2. Remove tube assemblies (3) and (4) from the cylinder head and air compressor. 3. Put identification on wires (5) and disconnect them.4. Remove bolts (6) that hold the water inlet elbow to the cylinder head. 5. Fasten a hoist to cylinder head (7). Remove the bolts that hold the cylinder head in place.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
6. Remove cylinder head (7) from the engine. The weight of the cylinder head is 84 kg (185 lb.). Always install a new gasket between the spacer plate and cylinder block before the cylinder head is installed. See REMOVE SPACER PLATE.Install Cylinder Head
Be sure a new gasket has been installed between spacer plate and cylinder block. See INSTALL SPACER PLATE. 1. Thoroughly clean the spacer plate and bottom surface of the cylinder head. Install a new head gasket (2), water ferrules (1) and O-ring seal (3) on the hollow dowel.2. Install a new gasket on the water inlet elbow. 3. Fasten a hoist to the cylinder head. Put cylinder head (4) in position and make an alignment of the head and the dowels in the cylinder block.4. Install the bolts that hold the head in place except for the ones that hold the rocker shafts. Do not tighten the bolts at this time. 5. Install bolts (6) that hold the water inlet elbow to the cylinder head.6. Connect wires (5) to the sending unit. 7. Install tube assemblies (7) and (8) on the cylinder head and air compressor. 8. Install the push rods and put rocker shaft (9) in position on the cylinder head. See INSTALL ROCKER SHAFT AND PUSH RODS. 9. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head and rocker shaft bolts. Install the bolts and washers and tighten the bolts as follows: Step 1. Tighten all bolts in number sequence to a torque of 155 N m (115 lb.ft.).Step 2. Again tighten all bolts in number sequence to a torque of 250 17 N m (185 13 lb.ft.).Step 3. Again tighten all bolts in number sequence (hand torque only) to a torque of 250 17 N m (185 13 lb.ft.).Step 4. Tighten all bolts in letter sequence to a torque of 30 N m (22 lb.ft.).Step 5. Again tighten all bolts in letter sequence to a torque of 43 7 N m (32 5 lb.ft.).Step 6. Again tighten all bolts in letter sequence to a torque of 43 7 N m (32 5 lb.ft.).10. Make an adjustment of the valves to have a clearance of 0.38 mm (.015 in.) for the intake and 0.64 mm (.025 in.) for the exhaust. See VALVE CLEARANCE in TESTING AND ADJUSTING. 11. Put elbow assembly (10) in position on the head and install the bolts.end by:a) install exhaust manifoldb) install fan drivec) install air cleaner elements and housingd) install mufflere) install valve cover