61435-96J00 Suzuki MARK, EMBLEM REAR (150)

Illustration 1 g06411817
Front view of the engine
Table 1
Specification for 349-2528 Cylinder Block Gp
Item Qty Part Specification Description
The top face of the cylinder block, bottom surface of spacer plate (1) and both sides of plate gasket (2) must be free of fuel, oil, water, gasket adhesives, assembly compounds and any other contaminants during assembly.
1 2 225-3100 Spacer Plate Thickness is 8.585 0.025 mm (0.3380 0.0010 inch).
2 2 354-8484 Plate Gasket Thickness of plate gasket that is between cylinder block and spacer plate is 0.20 0.02 mm (0.008 0.001 inch).
3 4 7C-9614 Taperlock Plug Before assembly, apply white Loctite Low Breakloose PST to the threads.
Torque to 80 15 N m (60 11 lb ft).
D1 4 4N-1650 Dowel Protrusion is 18.5 0.5 mm (0.73 0.02 inch).
4 7 232-7607 Crankshaft Cap The crankshaft caps must be installed with the identifying marks toward the front of the engine. The number of the main bearing cap must also match the cast number on the left side of each main bearing saddle.
Width in the cylinder block for the crankshaft cap is 236.00 0.05 mm (9.291 0.002 inch).
Width (D2) is 235.500 0.025 mm (9.2716 0.0010 inch).
5 14 234-6902 Bolt Use the following procedure to install the crankshaft cap:
1. Install bolt (6).
2. Lubricate the threads of side bolt (5) and seal washers with clean engine oil. Install side bolt (5) and seal washers.
3. Tighten bolt (6) on the tab end of the crankshaft cap to 258 14 N m (190 10 lb ft).
4. Tighten bolt (6) on the opposite end to the tab end bolt of the crankshaft cap to 258 14 N m (190 10 lb ft).
5. Turn bolt (6) on the opposite end to the tab end bolt of the crankshaft cap to an angle of 120 5 degrees.
6. Turn bolt (6) on the tab end of the crankshaft cap to an angle of 120 5 degrees.
7. Tighten side bolt (5) on the opposite end to the tab end bolt of the crankshaft cap to 80 10 N m (59 7 lb ft).
8. Tighten side bolt (5) on the tab end of the crankshaft cap to 80 10 N m (59 7 lb ft).
9. Repeat Step 7 and Step 8.
6 14 3P-1323 Bearing Cap Bolt
Illustration 2 g06411823
Table 2
Item Qty Part Specification Description
7 12 142-7072 Liner Seal Immediately before inserting liners, cover the liner bore surfaces and seals with 5P-3975 Rubber Lubricant
8 12 110-2220 Liner Seal Immediately before inserting liners, cover the liner bore surfaces and seals with 5P-3975 Rubber Lubricant
9 12 142-6217 O-Ring Seal Immediately before inserting liners, cover the liner bore surfaces and seals with 5P-3975 Rubber Lubricant
D3 - - The distance from the centerline of the crankshaft bearing bore to the top of the cylinder block is 419.10 mm (16.500 inch).
D4 - - The distance from the centerline of the crankshaft bearing bore to the bottom of the cylinder block is 165.10 mm (6.500 inch).
D5 - - Bore in cylinder block for main bearing is 129.891 0.013 mm (5.1138 0.0005 inch).
Illustration 3 g06411827
Right side of the engine
Table 3
Item Qty Part Specification Description
10 1 214-1728 Stud Before assembly, apply blue Loctite 540 to the pipe threads of stud.
11 3 6L-4428 Taperlock Stud Torque to 35 5 N m (26 4 lb ft).
D6 4 4N-0683 Dowel Protrusion is 19.0 0.5 mm (0.75 0.02 inch).