09160-30038 Suzuki THRUST WASHER

2. Remove bolts (4) and (3), then remove heat shield (2) and oil filter base bracket (1). 3. Remove aftercooler to engine oil cooler water line (5).4. Remove valve covers (6). 5. Remove fuel lines (7) with tool (A). Put caps or plugs on all fuel openings. 6. Disconnect glow plug wires (9) from the valve cover bases. Remove valve cover bases (8) and seal. 7. Loosen bolt (13) in automatic timing advance unit enough so it is free of bracket (12). Remove two bolts (11) and bracket (12).8. Remove one bolt (10) from fuel injection pump housing. Remove two bolts (14) and bracket (15). 9. Remove push rods (18) from the cylinder head with tool (B).10. Remove six bolts (16) and rocker arm shaft assemblies (17).11. Remove valve bridges (19) from the bridge dowels. 12. Fasten straps and a hoist to the air cleaner. Remove bolts (21) that hold air cleaner to the bracket. Remove air cleaner (20). Weight of the air cleaner is 100 lb. (45 kg).13. Remove bolt (22), then remove fuel filter bracket (23). 14. Loosen clamps (26) and slide hose (24) up on tube. Remove bolt (25) that holds fuel lines to bonnet.15. Remove four bolts (28), then remove elbow (27) and gasket. 16. Remove three bolts (30), then remove water temperature regulator (29) and housing. 17. Remove two bolts (32), then remove two plates (31). Remove seal. 18. Disconnect glow plug wires (34) from the glow plugs. Remove bolts (33), then remove glow plug wiring harness (35). Remove cylinder head bolts (36) and remainder of twelve bolts on back side of the cylinder head. 19. Fasten tooling (C) and a hoist to the cylinder head. Remove cylinder head (37) and gasket. Weight of the cylinder head is 300 lb. (135 kg).Install Cylinder Heads
1. Thoroughly clean the spacer plate and bottom surface of the cylinder head. Install a new cylinder head gasket (1). Do not use any adhesives. 2. Fasten tooling (A) and a hoist to the cylinder head (2). Put the cylinder head in position over the spacer plate and make an alignment of the holes in cylinder head with the dowel pins. Lower the cylinder head on to the spacer. Be careful not to cause damage to water seals and cylinder head gasket.3. Put engine oil on all bolt threads and tighten the bolts in the following sequence. a) Tighten bolts from A to T in letter sequence to 200 20 lb.ft. (270 25 N m).b) Tighten bolts from A to T in letter sequence to 330 15 lb.ft. (450 20 N m).c) Tighten bolts from A to T in letter sequence again to 330 15 lb.ft. (450 20 N m). 4. Install glow plug wiring harness (3), then connect wires (4) to the glow plugs. 5. Install valve bridges (5) in their respective positions. Install push rods.6. Put rocker arm shaft assemblies in position on the cylinder head. Put clean engine oil on bolts (U) through (Z). Install the bolts and washers. Tighten the bolts in the following sequence. a) Tighten the bolts from U to Z in letter sequence to 200 20 lb.ft. (270 25 N m).b) Tighten the bolts from U to Z in letter sequence to 330 15 lb.ft. (450 20 N m).c) Tighten the bolts from U to Z in letter sequence to 330 15 lb.ft. (450 20 N m).7. Check bridge adjustment. See BRIDGE ADJUSTMENT in TESTING AND ADJUSTING.8. Make an adjustment of the valves to have a clearance of .015 in. (0.38 mm) for intake and .030 in. (0.76 mm) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 9. Install two brackets (8) and (9) and thirteen bolts (6). Tighten bolts (6) to a torque of 32 5 lb.ft. (43 7 N m). Install bolt (7) that holds bracket (8) to the fuel injection pump housing. Install the bolt that holds bracket (9) to the automatic timing advance housing. 10. Install a new O-ring seal (11) on bracket (10). Put bracket (10) in position on the cylinder head and install the bolts that hold it. 11. Install a new gasket (13) on water temperature regulator housing (12). Install water temperature regulator housing (12) on bracket (10) with the three bolts that hold it. 12. Slide hose (14) down on regulator tube and tighten two clamps (16). Install two new gaskets on elbow (17). Put elbow (17) in position on regulator housing and water line. Install the four bolts that hold it. Install bolt (15) that holds fuel lines to the regulator bonnet. 13. Fasten straps and a hoist to the air cleaner (18). Put the air cleaner in position on support (19) and bracket (10). Install the bolts that hold it. 14. Install fuel filter housing bracket (22) on air cleaner bracket. Install hoses (20) with bolt (21) that holds them to bracket (22). Remove straps and hoist from air cleaner. 15. Install new seals on valve cover bases (23) if necessary. Install valve cover bases (23) on cylynder head with the bolts that hold them. Tighten the bolts in number sequence to a torque of 18 5 lb.ft. (24 7 N m). 16. Connect fuel lines (25) to the fuel line adapters and precombustion chambers. Tighten fuel line nuts (24) with tool (C) to a torque of 30 5 lb.ft. (40 7 N m). 17. Install engine oil cooler and aftercooler water line (26).18. Install valve covers (27). 19. Install the bolts that hold the valve covers to the valve cover bases. Tighten the bolts in number sequence to a torque of 18 5 lb.ft. (24 7 N m). 20. Install oil filter base bracket (31) on the cylinder head with the four bolts (30) that hold it.21. Install heat shield (28) on oil filter base bracket with the bolts (29) that hold it.22. Fill the cooling system with coolant to