11301-94625-0ED Suzuki CYLINDER/CRANKCASE ASSY

2. Remove exhaust pipe (1) and precleaner (2) from engine.3. Remove panel assemblies (3), (4) and (5). The weight of panel assembly (3) is 41 kg (90 lb.) and panel assembly (4) weighs 34 kg (75 lb.). 4. Remove air cleaner (7) and loosen hose clamps (9) on elbow.5. Remove four bolts (6) and pipe assembly (8) from crossbeam. 6. Fasten a hoist to and remove dirt ejector tube (11), muffler (10) and elbow (12) as a unit. Weight of the assembly is 39 kg (85 lb.). 7. Remove elbow (13) and pipe (14) from the turbocharger. 8. Remove four seals (15) from pipe (14). 9. Remove bracket mounting bolts (19) from the exhaust manifold. Remove elbows (16), (17) and (18). Remove coupling between elbow (18) and the turbocharger. If assembly is removed as a unit the weight is 50 kg (110 lb.). 10. Remove supply (20) and drain line (21) and gaskets from the turbocharger. 11. Install a strap and hoist on the turbocharger. Remove four bolts (23), turbocharger (22) and gasket (24). Weight of the turbocharger is 27 kg (60 lb.).12. Remove the pipe between the aftercooler elbow and turbocharger. 13. Remove four seals (25) from pipe (26).Install Turbocharger
Put engine oil on all seals and their respective bores. 1. Install four seals (1) on pipe (2). 2. Install new exhaust manifold gasket (5). Put turbocharger (3) in position with pipe (2) between turbocharger and the aftercooler elbow.3. Put 5P3931 Anti-Seize Compound on threads and install four bolts that hold the turbocharger to the manifold. Tighten bolts (4) to a torque of 55 5 N m (40 4 lb.ft.). 4. Install gaskets and the supply (6) and drain lines (7). 5. Install coupling between elbow (10) and turbocharger. Install elbows (9) and (8).6. Put 5P3931 Anti-Seize Compound on bolt threads and install bolts (12) to fasten bracket (11) to the exhaust manifold. 7. Install four seals (13) on pipe (14). 8. Install pipe (14) and elbow (15) on turbocharger. 9. Put muffler assembly (16) in position. Put 5P3931 Anti-Seize Compound on the threads and install four bolts (17).10. Install clamp on the opposite end of the muffler. Both clamps (18) must be 2.5 to 0.8 mm (.098 .031 in.) from the edge of muffler. Tighten clamps (18) to a torque of 25 7 N m (18 5 lb.ft.). 11. Install hose (21) on elbow and pipe (19) on crossmember. The hump in hose must be centered between elbow and pipe. Install air cleaner (20). 12. Install three panel assemblies (24), (25) and (26). Install precleaner assembly (23) and exhaust pipe (22). The clamp on the exhaust pipe (22) is 2.54 mm (.100 in.) from the edge of the pipe.13. Fill radiator to the correct coolant level. See Maintenance Guide.Disassemble Turbocharger (Schwitzer)
START BY:a) remove turbocharger 1. Install turbocharger in tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4). 3. Put the cartridge assembly in tool (B) as shown.4. Use tool (C) and remove the nut that holds compressor wheel (6). Remove compressor wheel (6).
When the nut is loosened, do not put a side force on the shaft.
5. Remove the turbine shaft (7) from the cartridge housing. 6. Remove seal ring (9) and shroud (8) from turbine shaft (7). 7. Use tool (D) and remove ring (11) that holds insert (10) in the cartridge housing. 8. Remove insert (10) with tooling (E). 9. Remove O-ring seal (13) and sleeve (12) from insert (10). Remove the seal ring from sleeve (12). 10. Remove deflector (14) and the ring from the cartridge housing. 11. Remove bearing (15), sleeve (16) and the ring from the cartridge housing. The oil hole in bearing (15) must be open or a bearing failure will be the result. 12. Use tool (F) and remove the ring that holds bearing (17) in position. Remove bearing (17) and put a long dye mark on the top of the bearing. 13. Turn the cartridge assembly over. Use tool (F) and remove the ring that holds bearing (18) in position. Remove bearing (18) from the cartridge housing. Put a short dye mark on the top face of bearing (18). The dye marks are used for identification of the bearings when they are installed.14. If necessary, remove the two rings that hold the bearings in position from the cartridge housing with tool (F).15. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See SPECIAL INSTRUCTION FORM NO. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS Form No. SEBF8018 and ANALYZING TURBOCHARGER FAILURE Form No. FEG45138.Assemble Turbocharger (Schwitzer)
1. Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.3. Make a replacement of the two inside rings that hold the bearings in position in the cartridge housing if necessary. Install the rings that hold the bearings in position with the round edges of the rings toward the bearings. 4. Install bearing (2) in the cartridge housing with the short dye mark up.5. Use tool (A) to install ring (1) in the cartridge housing. 6. Turn the cartridge assembly over and install bearing (4) with the long dye mark up. Use tool (A) and install ring (3) to hold the bearing in position. 7. Install ring (7), sleeve (6) and bearing (5) in the cartridge housing. Make sure the oil hole in bearing (5) is open and clean to prevent a bearing failure. 8. Install ring (9) and deflector (8) in the cartridge housing. 9. Install O-ring seal (12) around insert (11).10. Install the seal ring on sleeve (10).11. Install sleeve (10) in insert (11) from the bottom side. 12. Install insert