09116-08128 Suzuki BOLT

1. Loosen the bolts (2) that hold main bearing caps (1) to cylinder block. 2. Install one of the bolts for flywheel in each end of the crankshaft.3. Fasten a hoist and remove the main bearing caps. Remove bearings from bearing caps.4. Remove crankshaft from engine. Weight is 350 lb. (159 kg).5. Remove crankshaft main bearings from cylinder block. If new main bearings are not to be installed, keep old bearings with identification as to their location in cylinder block. 6. Use tooling (A) to remove crankshaft outer gear. Use a hammer and a chisel to remove spacer. 7. Use tooling (B) to remove dowel.8. Use tooling (A) to remove crankshaft inner gear.Install Crankshaft
1. Heat the crankshaft gears to a maximum temperature of 400°F (204°C). 2. Install crankshaft inner gear (2) on crankshaft.3. Install spacer on crankshaft.4. Install the pin in end of crankshaft. The pin must be extended no more than .19 in. (4.82 mm) from surface of crankshaft.5. Install the crankshaft outer gear (1) on crankshaft. the pin in crankshaft must be in alignment with notch in crankshaft gear (1).6. Clean the cylinder block and main bearing caps thoroughly. 7. Install upper half of main bearings (3) in the block. Put clean engine oil on the bearings and journals of crankshaft.8. Install one bolt for flywheel on each end of crankshaft.9. Fasten a hoist and put crankshaft in position in block. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear. The "K" marks on the camshaft gear can be seen at the outer edges of the idler gear when the timing gears are in the correct position.10. Install main bearings in bearing caps. Be sure the tabs (4) on back of bearings fit in the grooves of caps and cylinder block.11. Use wire (B) to check bearing clearance.12. Put wire (B) on the bearing. Be sure main bearing caps (5) are installed so the numbers on the side of the cylinder block are the same as the numbers on the bearing caps, and the arrows on the caps are toward the front of the cylinder block.13. Install the main bearing caps. Install the bolts (6) and tighten the bolts, at end with tab first, to a torque of 190 10 lb.ft. (260 14 N m). Put a mark on the bolts and caps. Turn the bolts at opposite end of tab first an extra 120° 5° from the mark.14. Remove the main bearing caps. Remove wire (B) from the caps. Check the thickness of wire (B) to find the bearing clearance. The bearing clearance must be .0036 to .0073 in. (0.091 to 0.185 mm) with new bearings. Maximum clearance with used bearings is .010 in. (0.35 mm).15. Install the thrust bearings for No. 4 main bearing. Install the thrust bearings with the side marked "BLOCK SIDE" toward the cylinder block.16. Put clean engine oil on the threads of the bolts. Install the main bearing caps. Install the bolts and the bolts, at the end with the tab first, to a torque of 190 10 lb.ft. (260 14 N m). Put a mark on the bolts and caps. Turn the bolts, opposite end of tab first, an extra 120° 5° from the mark. 17. Check the end play of the crankshaft with tool group (A). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings of No. 4 (center) main. The end play with new bearings must be .006 to .020 in. (0.152 to 0.508 mm). The maximum permissible end play with used bearings is .035 in. (0.89 mm).end by: a) install pistonsb) install flywheel housingc) install timing gear coverd) install crankshaft front seal wear sleevee) install crankshaft rear seal wear sleevef) install fuel injection pump housing and governor