99011-87J00-03A Suzuki MANUAL, OWNER'S

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     2P-5518     Bearing Tool     1    Start By:
Remove the engine oil pump.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Check the main bearing caps for identification of the location and check the direction of the main bearing caps in relation to the cylinder block. The main bearing caps must be installed in the original location and the original direction.
Illustration 1 g01149949
Remove bolts (1) and bolts (3) from No. 2 through No. 6 main bearing caps (2) .Note: Remove No. 1 and No. 7 main bearing caps (2) after No. 2 through No. 6 main bearing caps have been installed.
Illustration 2 g01149952
Install Tooling (A) in the oil hole of the crankshaft. Carefully rotate the crankshaft in order to remove upper main bearing (4) from the cylinder block.Note: Push the upper main bearing from the opposite 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 of the cylinder block. The result will damage the cylinder block and/or the crankshaft.
Remove the thrust plates from each side of the No. 4 main bearing.
Remove the lower halves of the main bearings from the main bearing caps.Installation Procedure
Table 2
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 3 g01149952
Position new upper main bearing (4) 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 of the cylinder block. The result will damage the cylinder block and/or the crankshaft.
Install the thrust plates 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 4 g01149987
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) and bolts (3) with clean engine oil. Install the bolts.
Tighten bolts (1) and bolts (3) 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.
Tighten Bolt (D) to a torque of 80 10 N m (59 7 lb ft).Note: Bolt (D) is on the opposite side of the bearing tab of the main bearing cap.
Tighten Bolt (C) to a torque of 80 10 N m (59 7 lb ft).Note: Bolt (C) is on the bearing tab side of 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).Crankshaft end play (new thrust plates) ... 0.10 to 0.60 mm (0.004 to 0.024 inch)End By: Install