25212-94401 Suzuki GUIDE, SHIFT ROD LOWER

1. Open the engine compartment hood and doors. 2. Remove eight bolts (2) and washers. Remove turbocharger guard (3).3. Loosen two bolts (1).4. Slide clamp assembly (5) off tube assembly (6) (not shown).5. Loosen clamp (7). Remove tube assembly (6) (not shown).6. Remove two bolts (8).7. Disconnect pipe assembly (4). Check the O-ring seal on the pipe assembly for wear or damage. Replace if necessary. 8. Loosen hose clamp (11).9. Disconnect hose (9) from turbocharger (10). Plug the opening in the turbocharger. 10. Remove two bolts (12), loosen the connector on oil tube (13) and remove oil tube. Remove the gasket. Check gasket for wear or damage. Replace if necessary.11. Remove two bolts (15). Remove oil tube (14). Remove the gasket and the seal. Check gasket and seal for wear or damage. Replace if necessary. 12. Remove two bolts and washers. Remove adapter (21).13. Remove two bolts (16) and washers to disconnect tube assembly (17). Remove the gasket. Check for wear or damage. Replace if necessary.14. Remove two bolts (18) and washers to disconnect tube assembly (19). Remove the gasket. Check for wear or damage. Replace if necessary.15. Remove four bolts (20). Remove turbocharger (10) and gasket. Check for wear or damage. Replace if necessary. The weight of the turbocharger is 20 kg (45 lb). For installation of the turbocharger, reverse the removal steps.Disassemble & Assemble Turbocharger
Start By:a. remove turbocharger 1. Install turbocharger on Tool (A). Place alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Remove "V" clamp (2) and compressor housing (1). 3. Remove "V" clamp (4).4. Remove cartridge housing (3) from turbine housing (5). 5. Install Tool (C) in Tool (B). Put the cartridge assembly in Tool (C) as shown. Use Tool (D) to remove the nut that holds compressor wheel (6).
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
When assembling, put a small amount of clean engine oil on the turbine shaft threads and compressor wheel face that makes contact with the nut. Install the nut. Tighten the nut to a torque of 17 N m (13 lb ft) to push compressor wheel (6) on the shaft. Loosen the nut and tighten again to a torque of 3.5 N m (30 lb in). Tighten the nut an additional 120 degrees of a turn.Remove the nut from the turbine shaft. Put 6V-1542 Quick Cure Primer on the threads of the turbine shaft and nut.Put 9S-3265 Retaining Compound on the threads of the shaft and nut. Install the nut. Tighten the nut to a torque of 3.5 N m (30 lb in). Tighten the nut an additional 120 degrees of a turn. 6. Remove compressor wheel (6). 7. Remove backplate assembly (8) from shaft assembly (7). 8. Inspect shaft assembly (7) for wear or damage. Replace if necessary. 9. Remove retaining ring (8), bushing (9), two retaining rings (10) and bushing (11) (not shown). 10. Turn backplate assembly (12) 180 degrees.11. Remove retaining ring (13). 12. Put backplate assembly (12) in a press as shown.13. Press out spacer (13) (not shown), collar (14) (not shown) and hub (15) (not shown). When installing, place spacer (13) and collar (14) in position inside backplate (12). Lower the temperature of hub (15). Install the hub. For assembly of the turbocharger, reverse the disassembly steps.14. When backplate assembly (12) and compressor wheel (6) have been assembled on shaft assembly (7) and the nut has been installed to the proper torque, place Tool (E) in position on backplate (12). Check the shaft end play. The shaft end play must be 0.08 mm (.003 in). The shaft end play must not exceed 0.25 mm (.010 in).End By:a. install turbocharger