61653-94502 Suzuki ROD, LATCH RELEASE

1. Put the engine in position on tooling (A).If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances. Plastigage, tool (C) is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.The serviceman must be very careful to use Plastigage, tool (C) correctly. The following points must be remembered:... Make sure that the backs of the bearings and the bores are clean and dry.... Make sure that the bearing locking tabs are properly seated in their slots.... The crankshaft must be free of oil where the Plastigage touches it.... If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.... Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.... Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.... Do not turn the crankshaft with the Plastigage installed.... Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.... Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531. Install the bearings dry when the clearance checks are made. Put clean engine oil on all the bearings for final assembly.
Install the bearings dry when the clearance checks are made. Put clean engine oil on all the bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.
2. If the bearings were removed from the engine, clean the bearing surfaces in the cylinder block and the connecting rods. Install the upper halves of connecting rod bearings (1) and main bearings (2). 3. Heat crankshaft gear (3) to a maximum temperature of 316° C (600° F). Install the gear on the crankshaft. 4. Install tooling (B) on the ends of the crankshaft and fasten a hoist to it.5. Make an alignment of the connecting rods with the crankshaft. Make an alignment of the "C" marks on crankshaft gear (3) and camshaft gear (4). When the connecting rods and the "C" marks are in alignment, lower the crankshaft on to the main bearings and remove tooling (B).6. Check the main bearing clearances with Plastigage (C) as follows: a. Put a piece of Plastigage (C) in position as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
Do not turn the crankshaft when Plastigage (C) is in position.b. Install main bearing cap (5). Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers and install the bolts. Tighten the bolts to a torque of 41 4 N m (30 3 lb. ft.).c. Put a mark on each bolt and main bearing cap; then tighten the bolts 90° 1.5° more.d. Remove the main bearing caps. Remove Plastigage (C), and measure the thickness of the Plastigage. The main bearing clearance must be 0.076 to 0.165 mm (.0030 to .0065 in.). The maximum permissible clearance with used bearings is 0.25 mm (.010 in.). 7. Put clean engine oil on thrust bearing (7) for the rear main bearing. Install the thrust bearing with the identification "BLOCK SIDE" toward the cylinder block and the tabs on the thrust bearings in the machined area in the cylinder block. Tabs (6) will not let the thrust bearings be installed backward. 8. Install main bearing caps (5), and tighten the bolts as in Steps 6b and 6c. 9. Check the crankshaft end play with tooling (D) as shown. The end play is controlled by the thrust bearings on the rear main bearing. End Play with new bearings is 0.064 to 0.368 mm (.0025 to .0145 in.). The maximum permissible end play with used bearings is 0.64 mm) .025 in.). 10. Pull the connecting rod and piston assemblies into position against the crankshaft. Install the connecting rod bearings dry when the clearance checks are made. Put clean engine oil on the connecting rod bearings for final assembly.11. Install lower half of the rod bearing (8) in the connecting rod cap with the tab in the back of the connecting rod bearing in the tab groove of the connecting rod and cap. Do not turn the crankshaft when Plastigage (C) is in position.12. Put Plastigage (C) in position on the crankshaft as shown to check the connecting rod bearing clearance.13. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
When connecting rod caps are installed, make sure the number on the side of the cap