67241-92E00 Suzuki FREE ACCEL ROD

3. Use a hoist to lift the rear of the engine off tool (A). Install a piece of 1/4" (6.4 mm) thick metal spacer (1) approximately 1" (25.4 mm) wide and 3" (76.2 mm) long between the oil pan and the cylinder block on each side of the engine. Put the weight of the engine back on tool (A). Make sure the metal spacers are directly above the surface of the oil pan that makes contact with tool (A). 4. Remove turbocharger elbows (2) and (3) from the plate. 5. Remove bolts (5). Remove lifting eye assembly (4). The weight of the lifting eye assembly is 50 lb. (23 kg). 6. Remove O-ring seal (6) from the back of the lifting eye assembly. 7. Remove plate (7) from the flywheel housing. 8. Remove bolts (8). Remove cage (9).9. Remove O-ring seal (12) from the cage. 10. Remove lip seal (11).11. Remove bearing cup (10). 12. Remove gear assembly (13) from the flywheel housing. 13. Use tooling (B) to remove bearing cones (14) from each side of gear (15). 14. Remove bearing cup (16) from the flywheel housing. 15. Install two of the bolts (18) that hold the flywheel to the crankshaft in the gear as shown. The bolts will hold the gear in place when the flywheel housing is removed.16. Install two 3/8"-16 NC forged eyebolts (17) in the top of the flywheel housing as shown. Fasten a hoist to the flywheel housing.17. Remove bolts (20) that hold the flywheel housing to the cylinder block. Remove flywheel housing (19) and gasket from the cylinder block. The weight of the flywheel housing is 380 lb. (171 kg).18. Put the flywheel housing in position on the floor and keep the hoist fastened to the flywheel housing so it can not fall. 19. Remove washer (21) from the back of the flywheel housing. 20. Remove shaft (22) from the flywheel housing. Remove gear (23). Remove bearing cones and spacer from the gear. 21. Remove bearing cups (24) and retainer ring and spacer (25) from the gear. 22. Remove O-ring seal (26) from the shaft. 23. Remove bolts (18). Remove gear (27) from the crankshaft. 24. Remove O-ring seal (28) from the back of the gear.Install Flywheel Housing
1. Install O-ring seal (1) on the gear. Put a small amount of clean SAE 30 oil on the seal. 2. Put gear (2) in position on the end of the crankshaft. Use two bolts that hold the flywheel to the crankshaft to hold the gear in place until the flywheel housing is installed. 3. Install retainer ring and spacer (4) in gear (5).4. Lower the temperature of the bearing cups. Install bearing cups (3) in the gear. 5. Install bearing cones (7) and (8) in gear (5) with spacer (6) between the bearing cones.6. Install the O-ring seal on the shaft. Put a small amount of clean SAE 30 oil on the O-ring seal.7. Put the gear assembly in position in the flywheel housing. Install shaft (9). 8. Install two 3/8"-16 NC forged eyebolts (10) in the top of the flywheel housing. Fasten a hoist to the flywheel housing. Put the flywheel housing in position on the floor as shown. Install washer (11) on the shaft.9. Install a new gasket on the flywheel housing. Cut the gasket between the flywheel housing and the block even with the bottom of the flywheel housing after assembly. 10. Put flywheel housing (12) in position on the cylinder block. Install the bolts that hold it. 11. Tighten the flywheel housing bolts as follows: a) Tighten bolts 1 through 7 in number sequence to a torque of 100 10 lb.ft. (135 14 N m).b) Tighten bolts 8 through 18 in number sequence to a torque of 40 5 lb.ft. (55 7 N m).c) Do Steps a and b again. 12. Lower the temperature of the bearing cup. Install bearing cup (13) in the flywheel housing. 13. Heat the bearing cones to a maximum temperature of 275°F (135°C). Install bearing cones (14) on each side of gear (15). 14. Install gear assembly (16) in the flywheel housing. 15. Use tooling (B) to install the lip seal in the cage. Install the seal with the lip toward the inside of the cage. Put a small amount of clean SAE 30 oil on the lip of the seal. 16. Lower the temperature of the bearing cup. Install bearing cup (17) in the cage.17. Install O-ring seal (18). Put a small amount of clean SAE 30 oil on the O-ring seal. 18. Put cage (19) in position on the flywheel housing. Install the bolts that hold it. 19. Install plate (20) on the top of the flywheel housing. 20. Install O-ring seal (21) on the lifting eye assembly. 21. Install lifting eye assembly (22) on the flywheel housing. 22. Install turbocharger elbows (23) and (24). 23. Fasten a hoist to the back of the engine. Lift the engine from tooling (A) until spacers (25) can be removed. Put the weight of the engine back on tooling (A). Install the bolts that hold the oil pan to the flywheel housing. Tighten all the oil pan bolts. end by:a) install torque converter *b) install crankshaft rear and seal wear sleevec) install air compressord) install turbochargerse) install engine and torque converter*This operation is in the POWER TRAIN, DISASSEMBLY AND ASSEMBLY section.