21151-96003 Suzuki Mark, Clutch Shifting

Illustration 1 g06487363
Rear view of engine
Table 1
Item Qty Part Specification Description
1 12 197-7008 Dowel Extension of the dowel from the top face of the cylinder block is 21.0 0.5 mm (0.83 0.02 inch).
2 24 8T-0099 Dowel Extension of the dowel from the top face of the cylinder block is 21.0 0.5 mm (0.83 0.02 inch).
3 14 116-1359 Camshaft Bearing All centerlines through oil holes in the camshaft bearings and the camshaft bearing junctions must be positioned as shown in Illustration 1 on each side of cylinder block.
Oil holes must be positioned from horizontal at an angle (D2) of 20 5 degrees as shown in Illustration 1.
Bore in the cylinder block for camshaft bearing (D1) is 86.06 0.06 mm (3.388 0.002 inch).
4 8 6V-3348 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
5 7 223-1696 Crankshaft Bearing Cap Width of the crankshaft bearing cap (D4) is 340.030 0.015 mm (13.3870 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 0.015 mm (13.3852 0.0006 inch).
D3 - - New dimension from centerline of crankshaft bearing bore to the top of the cylinder block is 586 mm (23.1 inch).
D5 - - Bore in the cylinder block for the main bearings is 169.742 0.020 mm (6.6827 0.0008 inch).
D6 - - New dimension from centerline of crankshaft bearing bore to bottom of cylinder block (pan rails) is 230 mm (9.1 inch).
Illustration 2 g06487375
Table 2
Item Qty Part Specification Description
6 4 5F-9657 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
D7 1 7N-2047 Dowel Extension of the dowel from the rear face of the cylinder block is 6.0 0.5 mm (0.24 0.02 inch).
D8 2 7N-2047 Dowel Extension of the dowel from the front face of the cylinder block is 6.0 0.5 mm (0.24 0.02 inch).
D9 2 4N-0683 Dowel Extension of the dowel from the rear face of the cylinder block is 19.0 0.5 mm (0.75 0.02 inch).
D10 2 7N-2044 Dowel Extension of the dowel from the front face of the cylinder block is 40.0 0.5 mm (1.57 0.02 inch).
Illustration 3 g06487383
Table 3
Item Qty Part Specification Description
7 3 4W-4813 Plug Torque to 100 15 N m (74 11 lb ft).
8 3 8T-2929 O-Ring Seal During assembly, apply Krytox® GPL 205 to secure O-rings.
9 3 8T-2928 O-Ring Seal Lightly lubricate the bore with Bonderite S-OT 40, Rubber lubricant.
10 28 7X-7925 Bolt Use the following procedure to tighten the crankshaft bearing cap bolts:
1. Before assembly, lubricate the threads completely with clean engine oil.
2. Hand tighten the bolts in the tapped holes.
3. Tighten the bolts in the numerical sequence as shown in Illustration 3 to 190 14 N m (140 10 lb ft).
4. Again, tighten the bolts for an extra angle of 180 5 degrees.