09248-26001 Suzuki PLUG

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     -     Loctite 5900     -    
B     8H-8581     Feeler Gauge     1    
C     8T-3052     Degree Wheel     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The upper bearing for the No. 1 crankshaft journal has a lubricating oil slot. The remaining upper bearings have an oil hole for lubrication. All new upper bearings will have the slot for lubrication.
If necessary, install the pistons and connecting rods. Refer to Disassembly and Assembly Manual, "Pistons and Connecting Rods - Install".
Remove the setscrews (5) from the connecting rods and then remove the connecting rod caps (6) from the connecting rods. Discard the setscrews (5) .
Ensure that all of the lubrication passages are clean and free of debris.
Illustration 1 g01154512
Install upper main bearings (8) . The bearing tabs for the upper main bearings must be located in the correct position in the cylinder block. Lubricate upper main bearings (8) with clean engine oil.
Clean the upper half of the thrust washers and lubricate the upper half of thrust washers. Place the upper half of the thrust washer in both sides in the recess in the cylinder block of the center main bearing. The grooves on the thrust washer must be located against the crankshaft.
Ensure that the main bearing journals and the connecting rod bearing journals of the crankshaft are clean. Attach lifting straps and a suitable lifting device in order to position the crankshaft in the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb). Do not scratch any of the finished surfaces on the crankshaft.
Illustration 2 g01154515
Clean the lower main bearings. Install the lower main bearings (9) in the main bearing caps (4) with the bearing tabs in the correct position. Lubricate the lower main bearing caps with clean engine oil.
Ensure that the locating dowels (10) for the main bearing caps (4) are in the correct position in the main bearing caps or in the cylinder block.
Illustration 3 g01154511
Clean the lower half of the thrust washers (7) and lubricate the lower half of thrust washers . Place the lower half of the thrust washers (7) in both sides of the center main bearing cap (4) . The grooves on the thrust washer must be located against the crankshaft.
Illustration 4 g00975374
Install the main bearing caps (4) in the position that was marked during the removal process. All of the bearing tabs for the main bearings should be on the same side. Install the main bearing cap bolts (3) . Tighten the bolts to a torque of 245 20 N m (180 14 lb ft).
Ensure that the upper connecting rod bearings are centered in the connecting rod. Install the lower connecting rod bearings in the connecting rod cap. Lubricate the bearing faces with clean engine oil.Note: Do not reuse the old setscrews (5) in order to secure the connecting rod cap (6) .Note: Ensure that the etched number on the connecting rod bearing cap matches the etched number on the connecting rod . Ensure that the etched numbers are on the same side.
Install the connecting rod caps (6) . Install new setscrews (5) in the connecting rod. Tighten the setscrews evenly to a torque of 18 N m (13 lb ft).
Tighten the setscrews evenly to a torque of 70 N m (52 lb ft).
Use Tooling (C) to achieve the correct final torque.Note: If Tooling (C) is not used, place an index mark on each bolt.
Turn the setscrews for an additional 120 degrees.
Rotate the crankshaft in order to ensure that there is no binding.
Illustration 5 g00975426
Illustration 6 g00541498
Clean the bridge and the face of the cylinder block. Apply a thin bead of Tooling (A) on the corners of the seat for the bridge. Also apply Tooling (A) around the thread holes in the seat for the bridge. Use the following steps when you apply Tooling (A) to the cylinder block and the bridge.
Apply a 3.0 mm (0.12 inch) bead of Tooling (A) along the corner of the top recess in the cylinder block.Note: The maximum protrusion for the bridge (2) from the outside of the cylinder block is 0.075 mm (0.0029 inch).
Install the bridge (2) and the rubber seals, if equipped. The rubber seals will sit higher than the bridge when the seals are correctly installed. Use a straight edge to line up the bridge with the face of the cylinder block. Tighten the socket head screws (1) to a torque of 16 N m (12 lb ft). Tighten the socket head screws evenly.
When the bridge is positioned and the socket head screws have been tightened, inject Tooling (A) in the groove that is at each end of the bridge. The groove must be completely filled.
When the gasket for the oil pan is removed, damage may occur to the existing seal in the grooves of the bridge. If the seal is damaged, apply a sufficient amount of Tooling (A) in order to fill the grooves.