09116-06094 Suzuki BOLT (6X16)

3. Remove bolts (1) and main bearing caps (2). Remove the lower halves of the main bearings from the caps. 4. Install two of the bolts that hold the flywheel in place in the end of crankshaft.5. Fasten a hoist and remove crankshaft (3) from the engine. The weight of the crankshaft is 54 kg (120 lb.).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
6. Remove the upper halves of the main bearings from the cylinder block.7. Install tooling (B) and remove the gear from the crankshaft.Install Crankshaft And Gear
1. Install the key for the crankshaft gear on the crankshaft.2. Heat the gear for the crankshaft to a maximum temperature of 260°C (500°F). Install the gear on the crankshaft with the timing mark on the crankshaft gear toward the crankshaft pulley end of the crankshaft.3. Thoroughly clean the area where the upper halves of the main bearings fit. Install the upper halves of the main bearings in the cylinder block. The main bearing half with a hole in it is the upper bearing.4. Install the thrust bearing for the No. 4 main.5. Do not put oil on the bearings and journals of the crankshaft.6. Install two of the bolts that hold the flywheel in place in the end of the crankshaft. Fasten a hoist and put the crankshaft in position in the block. Make sure the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear.7. Clean the main bearing caps and install the lower halves of the main bearings in the caps.
When bearing caps are installed, make sure the number on the side of the cap is next to and respective with the number on the engine block.
8. Check the bearing clearance with Plastigage (B). Put the caps in position and install the bolts. Tighten the bolts in number sequence as follows: a) Tighten bolts 1 through 10 to a torque of 41 4 N m (30 3 lb.ft.). b) Put a mark on each bolt head and bearing cap. Tighten bolts 1 through 10 120 5° more.9. Remove the bearing caps and measure the thickness of the Plastigage. The main bearing clearance must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance is 0.18 mm (.007 in.).10. Put clean engine oil on the bolt threads, washer faces and lower halves of the main bearings. Put the bearing caps in position and install the bolts. Tighten the bolts in number sequence as follows: a) Tighten bolts 1 through 10 to a torque of 41 4 N m (30 3 lb.ft.). b) Put a mark on each bolt and bearing cap. Tighten bolts 1 through 10 120 5° more.11. Install indicator group (A) and check the end play of the crankshaft. The end play is controlled by the thrust bearing on No. 4 main bearing. The end play with new bearings must be 0.08 to 0.25 mm (.003 to .010 in.). The maximum permissible end play with used bearings is 0.36 mm (.014 in.).end by:a) install timing gear cover and oil pumpb) install pistonsc) install valve liftersd) install flywheel housing