11300-98400-01J Suzuki Cylinder/Crankcase Assembly

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     2P-5518     Bearing Tool     1    
B     8T-5096     Dial Indicator     1    
C     8T-3052     Degree Wheel     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Install the main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the main bearings for final assembly.Note: Ensure that the main bearings are installed so that bearing tabs fit into the notch in the cylinder block. The upper halves of the main bearings have the oil groove and the oil hole.
Illustration 1 g01020300
Position the new upper main bearing (3) on the crankshaft. Insert the end of the upper main bearing that does not have the tab into the cylinder block. Install Tooling (A) in the oil hole of the crankshaft. Carefully rotate the crankshaft in order to push the upper main bearing into the cylinder block.Note: Push the upper main bearing from the side of the bearing tab with Tooling (A). If the crankshaft is turned in the wrong direction, the tab on the bearing will be pushed between the crankshaft and the bearing area of the cylinder block. This can result in damage to the cylinder block and/or the crankshaft.
Illustration 2 g01134355
Install thrust plates (4) on each side of the No. 4 main bearing.Note: Install the thrust plates with the words "Block Side" toward the cylinder block.
Install the lower halves of the crankshaft main bearings in the main bearing caps.Note: Ensure that the main bearings are installed so that bearing tabs fit into the notch in the main bearing caps.
Illustration 3 g01018383
Position main bearing caps (2) on the crankshaft.Note: Ensure that the numbers on the main bearing caps match the numbers on the cylinder block. Also ensure that the "FRONT" on the main bearing cap is installed toward the front of the cylinder block.
Lubricate the threads of bolts (1) with clean engine oil. Install the bolts.
Tighten bolts (1) for the main bearing caps, as follows:
Tighten Bolt (A) to a torque of 258 14 N m (190 10 lb ft).Note: Bolt (A) is on the bearing tab side of the main bearing cap.
Tighten Bolt (B) to a torque of 258 14 N m (190 10 lb ft).Note: Bolt (B) is on the opposite side of the bearing tab of the main bearing cap.
Tighten Bolt (B) for an additional 120 5 degrees (2 flats).Note: If Tooling (C) is not used, place an index mark on the bolt and the main bearing cap.
Tighten Bolt (A) for an additional 120 5 degrees (2 flats).Note: If Tooling (C) is not used, place an index mark on the bolt and the main bearing cap.
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Use Tooling (B) to check the crankshaft end play. Ensure that Tooling (B) is against a machined surface. The end play is controlled by the thrust plates of No. 4 main bearing (center). Refer to Specifications, "Crankshaft" for the crankshaft end play.End By: Install the engine oil pump.