09408-0003 Suzuki Clamp

Start By:a. remove oil pump1. Check the main bearing caps for identification for their location and direction in the block. The caps must be installed in the same location and direction from which they were removed. 2. Remove number 2 through number 6 bearing caps (1). Remove thrust plates from the number 4 main bearing.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either the crankshaft or cylinder block or both.
3. Remove the upper halves of the main bearings by putting Tool (A) in oil hole (2) in the crankshaft. Turn the crankshaft in the direction which will push the end of the bearing with a tab out first.4. Remove the lower halves of the bearings from the caps. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.5. Install the new bearings in the caps.6. Install the upper halves of the bearings in the cylinder with Tool (A).
Be sure tabs (3) on the back of the bearings fit in the tab slots of the caps and cylinder block. The serviceman must be very careful to use Plastigage, Tool (B) correctly. The following points must be remembered.
Make sure that the backs of the bearings and the bores are clean and dry.Make sure that the bearing locking tabs are properly seated in their slots.The crankshaft must be free of oil where the Plastigage touches it.If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.Do not turn the crankshaft with the Plastigage installed.Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider that the other.For complete details concerning measuring bearing clearance, see Engine Bearings & Crankshafts, SEBD0531.7. Check the bearing clearance with Plastigage (B). Put Plastigage (B) on the bearings.
Typical Example
Be sure the main bearing caps 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 (4) on the bearing caps are toward the front of the cylinder block.
8. Install the bearing caps for No. 2 through No. 6 main bearings. Put 2P2506 Thread Lubricant on the bolts. Install the bolts, and tighten bolts at end with tab first to a torque of 260 14 N m (190 10 lb ft). Turn the bolts an extra 120 5 degrees first at the end opposite of the tab. Remove the bearing caps for No. 2 through No. 6 main bearings. Remove Plastigage (B) from the caps. Check the thickness of Plastigage (B) to find the bearing clearance. The bearing clearance must be 0.091 to 0.185 mm (.0036 to .0073 in) with new bearings. Maximum clearance with used bearings is 0.25 mm (.010 in).9. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the bearing caps for No. 2 through No. 6 main bearings. Install the bolts, and tighten the bolts at the end with the tab first to a torque of 260 14 N m (190 10 lb ft). Put a mark on the bolts and caps. Turn the bolts at the opposite end of the tab first an extra 120 5 degrees from the mark.10. Remove the No. 1 and No. 7 main bearing caps. Do Steps 3 through 9 for the No. 1 and No. 7 caps.11. Install the thrust plates for the No. 4 main bearing. Install the thrust plates with the identification "BLOCK SIDE" toward the cylinder block.12. Check the end play of the crankshaft with Tool (C). Be sure the dial indicator is against a machined surface. The end play is control by the thrust plates of No. 4 (center) main bearing. The end play with new thrust plates must be 0.15 to 0.51 mm (.006 to .020 in). The maximum permissible end play used thrust plates is 0.89 mm (.035 in).End By:a. install oil pump