09128-06072 Suzuki BOLT

3. Remove supply line (1) from the turbocharger. 4. Remove the oil drain line (2) from the turbocharger. 5. Remove the air pipe (3) to the aftercooler. Remove the air inlet elbow (4) from the air cleaner. 6. Fasten a hoist to the turbocharger. Remove the bolts (5) that hold the turbocharger to the exhaust manifold. Remove the turbocharger (6). Weight of the turbocharger is 54 lb. (24.5 kg).Install Turbocharger
1. Fasten a hoist to the turbocharger (1). Put the turbocharger in position on the exhaust manifold. Put 9M3710 Anti-Seize Compound on the threads of the bolts that hold the turbocharger in position. Install the bolts that hold it to the exhaust manifold. Tighten the nuts to a torque of 40 4 lb.ft. (54.2 5.4 N m). 2. Install the air inlet elbow (2) from the air cleaner. 3. Install the air pipe (3) to the aftercooler. Install the bolts that hold the air pipe to the engine. 4. Install the oil supply line at the oil filter base and connect the oil supply line (4) to the top of the turbocharger.5. Install the front oil filter on the oil filter base.6. Connect the oil drain line to the bottom of the turbocharger.7. Connect the air line to the exhaust bypass regulator.8. Fill the engine with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE for the correct level.end by:a) install hoodDisassemble 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 positions.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.
Do not put a side force on the shaft, when the nut is loosened.
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) and ring (9) on spacer.5. Install collar (10) in plate and spacer (11) in collar. 6. Install thrust bearing (13) with the three radial grooves toward the outside.7. Install plate (8), bolts and locks. Tighten bolts to a torque of 35 5 lb. in. (3.95 0.56 N m). 8. Install ring (14) on turbine wheel.9. Install turbine wheel and shaft in cartridge. Be careful not to break ring (14) when the 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 (177°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 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. Do not put a side force on the shaft. 12. Install the cartridge in 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