25141-92J00 Suzuki HOUSING, SHIFT ROD GUIDE

Table 1
Required Tools
Tool Part Number Part Description Qty
A 198-9113 Seal Installer 1
B 8T-9022 Silicon Gasket -
C 8H-8581 Feeler Gauge 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00986838
Clean upper main bearing (7) and lubricate the bearing surface with clean engine oil. Note: Ensure that the upper halves of the main bearings are installed so that the bearing tabs fit into the notch in the cylinder block.
Only the upper half of the main bearing has lubrication holes. Make sure the upper half of the main bearing is installed correctly in the cylinder block to ensure proper lubrication.
Slide upper main bearing (7) into position between the crankshaft journal and the cylinder block.
Illustration 2 g00986837
Clean main bearing cap (5) and lower main bearing (6). Lubricate the bearing surface of lower main bearing (6) with clean engine oil. Note: Ensure that the lower halves of the main bearings are installed so that the bearing tabs fit into the notch in the main bearing caps.
Install lower main bearing (6) in main bearing cap (5). Note: Ensure that the dowels for the main bearing caps are in the correct position in the main bearing caps or in the cylinder block. Install the main bearing caps in the position that is marked during the removal process. All of the bearing tabs on the main bearings should be on the same side.
Illustration 3 g00986836
Install main bearing caps (5). Lubricate the threads of bolts (4) with clean engine oil. Note: Make sure that the bearing tabs on both halves of the main bearings are located on the same side.
Install bolts (4). Tighten the bolts to a torque of 147 N m (108 lb ft).
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Repeat Step 1 through Step 7 for the remaining main bearings.
Illustration 4 g00986882
Clean upper thrust washers and lubricate upper thrust washers . Place upper thrust washers (9) in the cylinder block on both sides of the number four crankshaft journal. The grooves on the thrust washer must be located against the crankshaft.
Illustration 5 g00986839
Install the upper half of thrust washer (8) on each side of the number four main bearing cap. The grooves on the thrust washer must be located against the crankshaft.
Install the bolts in order to secure the number four main bearing cap. Tighten the bolts to a torque of 147 N m (108 lb ft).
Illustration 6 g00986891
Check the crankshaft end play. Use a prybar to move the crankshaft toward the front of the engine. Use Tooling (C) to measure the end play between rear thrust washer (5) and the crankshaft. The maximum permissible crankshaft end play is 0.405 mm (0.0159 inch).
Install the upper main bearings in the cylinder block for the front and the rear main bearing journal. Install the lower main bearings in the front main bearing cap and for the rear main bearing cap. Note: Ensure that the dowels for the main bearing caps are in the correct position in the main bearing caps or in the cylinder block.
Illustration 7 g00740436
Position the front main bearing cap and the rear main bearing cap on the cylinder block. Install the seals in the front and the rear main bearing cap. Note: The seals for the front main bearing cap and for the rear main bearing caps have a curve at one end. The curved side must be installed toward the side of the engine. The curved end is inserted first into the hole.Note: Before installing the seals, inject a small quantity of Tooling (B) in the holes for the seals.
Illustration 8 g00740478
Start the seals into the holes by hand. Use Tooling (A) to push the seal into position. Use a small punch to push the seal below the surface of the main bearing cap until resistance is felt. Remove excess sealant from the holes. Note: The seals have a soft metal insert. Do not ben