61440-96E10 Suzuki ENGINE COVER STRIPE SET

Table 1
Required Tools
Tool Part Number Part Description Qty
A 2P-5518 Bearing Tool 1
B - Plastigage -
C 8T-5096 Dial Indicator Group 1
D - SAE 30 Clean Engine Oil -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.Note: Ensure that the upper halves and the lower halves of the main bearings are installed so that the bearing tabs fit into the notch in the cylinder block and in the main bearing caps.
Illustration 1 g00479169
Illustration 2 g00479171
Use Tooling (A) and install the new upper halves of main bearings (1) in the cylinder block. Install new lower halves of main bearings (1) in main bearing caps (2).Note: When the bearing clearance is checked and the engine is in an upright position or on the engine's side, the crankshaft must be supported against the upper halves of the main bearings. This is done in order to get a correct measurement with Tooling (B). If the crankshaft is not supported, the weight of the crankshaft will cause an incorrect reading. If the engine is not in an upright position or on the engine's side, it is not necessary to support the crankshaft. Do not rotate the crankshaft when Tooling (B) is positioned.Note: Refer to Guideline For Reusable Parts, SEBV0544, "Engine Bearings and Crankshafts" for complete details concerning the measurement of bearing clearances.
Check the main bearing clearance with Tooling (B), as follows:
Put a piece of Tooling (B) on the crankshaft journals, as shown.Note: Make sure that the part number on the main bearing cap is facing toward the front of the engine. Also, make sure that the number on the main bearing cap matches the number on the cylinder block on the left side of each main bearing cap.
Put main bearing caps (2) in position in the engine. Apply Tooling (D) on the bolt threads and the face of the washers. Install the bolts and tighten the bolts to torque of 40 4 N m (30 3 lb ft).
Put a mark on each bolt and main bearing cap. Tighten the bolts for an additional 90 degrees (1/4 turn).
Remove the main bearing caps and measure Tooling (B) in order to find the bearing clearance. The main bearing clearance for new bearings must be 0.076 to 0.165 mm (0.0030 to 0.0065 inch). The maximum permissible clearance with used bearings is 0.25 mm (0.010 inch).
Illustration 3 g00479203
Put clean oil on thrust plate (4) and install a new thrust plate for the rear main bearing. Install the new thrust plate so that the mark that is identified as the "BLOCK SIDE" faces toward the cylinder block and toward the tabs on the thrust plates in the machined area on the cylinder block. Tabs (3) on thrust plate (4) will not allow the thrust plate to be installed backward.
Illustration 4 g00479205
Install main bearing caps (2). Use the same procedure that is described in Step 2b and Step 2c.
Remove the remainder of the main bearing caps. Perform Steps 1, 2and 4 again.
Illustration 5 g00479212
Use Tooling (C) in order to check the crankshaft end play. The end play is controlled by the thrust plates on the rear main bearing. End play with new bearings must be 0.122 to 0.579 mm (0.0048 to 0.0228 inch).End By:
Install the oil pan plate. Refer to Disassembly and Assembly, "Engine Oil Pan Plate - remove and install".
Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".