09100-10253 Suzuki BOLT

1. Remove cover (1).
The cover has a spring under compression behind it.
2. Remove the spring and plunger.Install Turbocharger Lubrication Valve
1. Install plunger (1), spring (2) and cover (3) in the housing. Remove Turbocharger
1. Disconnect hose (3).2. Remove elbow (1).3. Remove tube (2). 4. Remove tube (4).5. Remove the turbocharger from the exhaust manifold elbow. Fasten a hoist and remove turbocharger.Install Turbocharger
1. Put the gasket and turbocharger in position on the exhaust manifold elbow. Put 9M3710 Anti-Seize Compound on the threads of the bolts that hold the turbocharger. Install the bolts and nuts. Tighten the nuts to a torque of 40 4 lb.ft. (54.2 5.4 N m).2. Install both tubes.3. Install the elbow.4. Connect the hose to the turbocharger.Disassemble Turbocharger
start by: a) remove turbocharger 1. Put the turbocharger in position on tool (A).2. Put a mark on the compressor cover and housings for installation purpose.3. Remove bolts (1) and plates from compressor housing.4. Remove the compressor housing. 5. Remove bolts (2) and locks from turbine housing.6. Remove cartridge (3) from turbine housing. 7. Install tool (B) in tool (C). Install cartridge in tool (C).8. Remove nut (4) from the compressor wheel.
When loosening the nut, do not put a side force on the shaft.
9. Install tool (D) on an oil heater. Heat the oil to 350°F (177°C). Install the cartridge on tool (D) with only the compressor wheel in the hot oil. Keep the compressor wheel in the hot oil for ten minutes. 10. Put tool (D) and cartridge on tool (E) under a press. Install driver (F) and push the shaft out of the compressor wheel. Step 10 must be done before the compressor wheel gets cold.11. Remove compressor wheel and shroud. Remove turbine wheel and shaft. 12. Remove the four bolts (5) and locks from plate (6). 13. Remove plate (6), spacer, collar and thrust bearing from cartridge.14. Remove seal from plate and ring from spacer. 15. Remove bearing (7), washer (11) and snap ring (8) from compressor side of cartridge.16. Remove snap ring (13), washer (10), bearing (12) and snap ring (9) from turbine side of cartridge.17. Inspect all parts and install new parts as needed.Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 2. Install snap ring (6), bearing (3), washer (7) and snap ring (4) in turbine side of cartridge. Install the two snap rings with tool (A). Install the snap rings with the rounded edge toward the bearing.3. Install snap ring (2), washer (5) and bearing (1) in compressor side of cartridge. 4. Install seal (12) on plate (8).5. Install collar (10) in the plate.6. Install rings (9) with the openings 180° apart on spacer (11). Install spacer (11) in the plate. 7. Install bearing (13).8. Install plate (8), bolts and locks. Tighten the bolts to a torque of 35 5 lb.in. (4.0 0.6 N m). 9. Install ring (14) on turbine wheel. Install turbine wheel and shaft in cartridge. Be careful not to break ring (14) when shaft is installed. 10. Put cartridge on tool (C) and tool (C) on tool (B).11. Install the compressor wheel as follows: a) Heat the compressor wheel (15) in oil to 350°F (176°C) for ten minutes.b) Install the compressor wheel on the shaft and install the nut. Tighten the nut to a torque of 150 lb.in. (16.9 N m). c) Let the compressor wheel cool and then remove the nut (16).d) Put clean engine oil on the threads of shaft. Install the nut and tighten to a torque of 30 lb.in. (3.4 N m). Turn the nut 90° more. When nut is tightened, do not put a side force on shaft. 12. Install the cartridge on the turbine housing. Put 9M3710 Anti-Seize Compound on the bolts. Install the locks and bolts (17) in the turbine housing. Tighten the bolts to a torque of 175 15 lb.in. (19.8 1.7 N m). 13. Install the compressor housing on the cartridge. Put 8S6747 Gasket Sealer on threads of bolts (18). Install the bolts in the compressor housing. Tighten bolt to a torque of 105 5 lb.in. (11.9 0.6 N m). end by:a) install turbocharger