03112-04109 Suzuki Screw

Illustration 1 g06412450
Front view of the engine
Typical example
Illustration 2 g06412457
Typical example
Illustration 3 g06412460
Marks for tightening main bearings
Typical example
Table 1
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 Apply adhesive to block side of gasket-plate only, no adhesive should be on opposing side of gasket-plate. Adhesive to be applied as an even, minimal coat(Skim coat). Minimal to zero material should squeeze out of joint after assembly has been torqued. No adhesive should contact water ferrule or liner lip.
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 Loctite low breakloose PST on the threads.
Torque to 80 15 N m (60 11 lb ft).
D1 4 4N-1650 Dowel Extension of the dowels on the left bank and right bank from the cylinder block 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.
D2 - - The distance from the centerline of the crankshaft bearing bore to the bottom of the cylinder block is 165.10 0.10 mm (6.500 0.004 inch).
D3 - - The width of the slot for the crankshaft cap (4) is 236.00 0.05 mm (9.291 0.002 inch).
Width of crankshaft cap (4) is 235.500 0.025 mm (9.2716 0.0010 inch).
5 14 365-4307 Bolt Use the following procedure to install the crankshaft cap:
6 14 3P-1323 Bearing Cap Bolt
1. Apply clean engine oil on the threads of the bolts (6). Loosely install the bolts (6).
2. Apply clean engine oil on the threads of the side bearing cap bolts (5) and the washers. Loosely install the side bearing cap bolts (5) and the washers.
3. Tighten tab end of the main bearing cap bolt (6) to 258 14 N m (190 10 lb ft).
4. Tighten opposite end of the main bearing cap bolt (6) to 258 14 N m (190 10 lb ft).
5. Put a mark on each bolt (6) and each crankshaft cap (4). See Illustration 3.
6. Again, tighten opposite end of the main bearing cap bolt from the mark to an additional angle (D6) of 120 5 degrees.
7. Again, tighten tab end of the main bearing cap bolt from the mark to an additional angle (D6) of 120 5 degrees.
8. Tighten the side bearing cap bolts (5) that are at the opposite end of the main bearing cap to 80 10 N m (60 7 lb ft).
9. Tighten the side bearing cap bolts (5) that are at the tab end of the main bearing cap to 80 10 N m (60 7 lb ft).
10. Again, tighten the side bearing cap bolts (5) that are at the opposite end of the main bearing cap to 80 10 N m (60 7 lb ft).
11. Again, tighten the side bearing cap bolts (5) that are at the tab end of the main bearing cap to 80 10 N m (60 7 lb ft).
D4 - - Bore in cylinder block for main bearing is 129.891 0.013 mm (5.1138 0.0005 inch).
D5 - - The distance from the centerline of the crankshaft bearing bore to the top of the cylinder block is 419.10 0.15 mm (16.500 0.006 inch).
7 12 9L-5854 Filler Band Apply clean engine oil to the bore of the cylinder block and to the filler band. Install the cylinder liner immediately into the cylinder block.
8 12 155-0809 Liner Seal Before assembly, cover the seals with Bonderite S-OT 40, Rubber lubricant.
9 12 155-2793 Liner Seal
10 12 155-0810 Liner Seal
Illustration 4 g06412471
Right side of the engine
Typical example