09118-10050 Suzuki BOLT

1. Remove two bolts (2) from tube assembly (3).2. Remove bolts (4) and the washers from tube assembly (5).3. Remove nuts (8), the washers and the bolts and muffler support (7). Remove extension (6) from turbocharger (1). 4. Disconnect tube assembly (3), and set aside.5. Remove two bolts (9). Position ground wire assembly (10) out of the way. Remove tube assembly (5), and position out of the way. 6. Attach lifting sling to the turbocharger.7. Remove the four nuts and bolts (11). Remove the bolt and retainer (12). 8. Use a pry bar at point (A) to separate turbocharger (1) from air transfer pipe extension (15). Remove turbocharger (1) and elbow (13) as a unit.9. Remove the bolt and retainer (14) and elbow (13) from the turbocharger. The following steps are for the installation of the turbocharger. If gaskets on tube assembly (3), gaskets on tube assembly (5), gasket at the manifold and O-rings on air transfer pipe extension (15) and elbow (13) are worn or damaged replace with new parts. 10. Position turbocharger (1) and elbow (13). Put 5P-3931 Anti-Seize Compound on the threads, of bolts (11) when installing turbocharger (11) to the manifold. Install a new turbocharger gasket. Tighten bolts (11) to a torque of 55% 5 N m (41% 4 lb ft).11. Put elbow (13) in position on turbocharger (1), and install the bolt and retainer (14). 12. Put 5P-3931 Anti-Seize Compound on the threads of bolt, and install retainer (12), and the four nuts and bolts (11). 13. Connect tube assembly (3).14. Position ground wire assembly (10). Install tube assembly (5). Install two bolts (9). 15. Install extension (6) to turbocharger (1).16. Install nuts (8), the washers and the bolts to muffler support (7).17. Install bolts (4) and the washers to tube assembly (5).18. Install two bolts (2) to tube assembly (3).End By:a. install mufflerDisassemble & Assemble Turbocharger
Start By:a. remove turbocharger 1. Install the turbocharger on Tool (A).2. Put alignment marks on the three housings of the turbocharger for correct alignment during assembly. Loosen the two clamps, and separate the center section (cartridge) from the two outside housings.
When the nut is loosened, do not put side force on the shaft. This can result in a bent shaft
3. Put the cartridge group (shown in the illustration) with nut (1) up in Tool (B). Use a 5S-9566 Sliding T-Wrench and a universal socket to remove nut (1) that holds the compressor wheel (2) to the wheel assembly (11).4. Remove compressor wheel (2), shims (3), and housing assembly (20) from wheel assembly (11). Remove piston ring (12) and backplate (10) from wheel assembly (11).5. Use Tool (C), and remove snap ring (4) from housing assembly (20). Remove insert (5) and sleeve (22) from housing assembly (20). Remove ring (21) from sleeve (22).6. Remove two screws (7), deflector (19), ring (24), bearing assembly (8), sleeve (9), and ring (18) from housing assembly (20).7. Remove O-ring seal (6). Use Tool (D), and remove snap ring (23) from the housing assembly. Remove bearing (17). Use Tool (D), and remove snap ring (16) behind the bearing.8. Use Tool (D), and remove snap ring (13) from the housing assembly. Remove bearing (14). Remove snap ring (15) behind the bearing with Tool (D).9. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 For Turbocharger Reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.10. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (14) and (17) in position in housing assembly (20) are installed with the round edge of the outside diameter toward the bearing.
11. Install snap ring (15) with Tool (D). Install bearing (14). Install snap ring (13) with Tool (D).12. Install snap ring (16) behind bearing (17) with Tool (D). Install bearing (17). Install snap ring (23) with Tool (D).13. Install O-ring seal (6) in the housing assembly.14. Put wheel assembly (11) in position on Tool (B) with the threaded portion end up. Put backplate (10) in position on the wheel assembly. Put 6V-2055 High Vacuum Grease in the groove for ring (12) at assembly to one half or more of the depth of the groove all the way around.15. Install piston ring (12) in the groove in wheel assembly (11).16. Put housing assembly (20) in position on wheel assembly (11). Install ring (18) and sleeve (9) on the wheel assembly.17. Make sure the screen is in place in bearing assembly (8). Install bearing assembly (8) over the sleeve. Make sure the screen in the bearing assembly is facing down when it is installed.18. Put ring (24) in position on bearing assembly (8). Install deflector (19) with two screws (7). Put 6V-2055 High Vacuum Grease in the groove of sleeve (22) to one half or more of the depth of the grooves all the way around.19. Install ring (21), in the groove, in sleeve (22). Put sleeve (22) in position in insert (5). Install the insert and the sleeve as an assembly.20. Use Tool (C), and install snap ring (4) to hold insert (5) on the housing assembly. 21. Put compressor wheel (2) in position in the compressor housing (25). Center the wheel in the compressor housing.22. Use a straight edge and a depth