11301-96313-02M Suzuki Cylinder Assembly

start by:a) remove turbocharger 1. Put the turbocharger in position on tool (A) as shown.2. Put marks on the housings for the correct installation at assembly.3. Loosen clamp (1). Remove housing (2) from the cartridge. Remove the clamp. 4. Loosen clamp (3). Remove cartridge (4) from housing (5). Remove the clamp from the housing. 5. Install tool (C) in tool (B). Put the cartridge in position in tool (C) as shown.
Do not put a bending force on the shaft and wheel assembly when the nut is loosened.
6. Remove the nut from the shaft and wheel assembly. 7. Install tool (D) on tool (E). Put the cartridge in position in tool (D) as shown. Use tool (F) and a press to remove wheel (6) from the shaft and wheel assembly. 8. Remove shaft and wheel assembly (8) and shroud (7) from the cartridge. 9. Remove seal ring (9) from the wheel and shaft assembly. 10. Remove locks and bolts (10). Remove back plate assembly (12) from the housing assembly.11. Remove spacer (11) from the backplate assembly. 12. Remove seal ring (13) from the spacer. 13. Remove collar (14) from the housing assembly. 14. Remove thrust bearing (15), bearing (16) and washer from the housing assembly. 15. Use tool (G) to remove snap rings (17) and (18) from the housing assembly. Remove bearing (19) and washer. Remove the snap ring from under the bearing.Assemble Turbocharger (Direct Injection)
1. Clean all parts thoroughly before they are assembled. 2. Use tool (A) to install snap ring (7) in the housing assembly. Install washer (6), bearing (5), snap rings (4), washer (3), bearing (2) and thrust bearing (1) in the housing assembly (8). 3. Put collar (9) in position on the housing assembly. 4. Install the back plate assembly (12) on the housing assembly. Install the bolts and locks that hold it. Tighten the bolts to a torque of 90 10 lb.in. (10.2 1.1 N m).5. Install seal rings (11) on the spacer. Install spacer (10) in the backplate assembly.6. Put 4L7464 Silicone Grease in the seal ring groove of the shaft and wheel assembly. Make sure it fills approximately one half or more of the groove depth for the complete circumference of the groove. 7. Install seal ring (15) on the shaft and wheel assembly.
Do not cause damage to the seal ring when the shaft and wheel assembly are installed.
8. Install shroud (14) and shaft and wheel assembly (13) in the cartridge. 9. Put wheel (16) in position on the shaft and wheel assembly. 10. Install tool (C) in tool (B). Put the cartridge in position in tool (C) as shown. Put a small amoung of SAE 30 oil on the threads of the shaft and wheel assembly and on the face of the wheel that makes contact with the nut.11. Install the nut on the shaft and wheel assembly. Tighten the nut to a torque of 120 lb.in. (13.6 N m). Loosen the nut. Tighten the nut again to a torque of 30 lb.in. (3.4 N m). Put a mark on the nut and wheel. Tighten the nut 120° past the mark.12. Put housing (18) in position on tool (D) as shown. 13. Put cartridge (17) in position on the housing. Make sure the cartridge is installed in its original position in the housing. Install clamp (19). Tighten the nut to a torque of 120 10 lb.in. (13.6 1.1 N m). 14. Put housing (20) in position on the cartridge. Make sure the cartridge is installed in its original position on the cartridge. Install clamp (21). Tighten the nut to a torque of 120 10 lb.in. (13.6 1.1 N m).15. Put clean SAE 30 oil in the cartridge and turn the shaft and wheel assembly.end by:a) install turbocharger