61112-94502 Suzuki SEAL, LOWER COVER UPPER

1. Fasten a hoist and remove the hood from over the engine. Weight is 24 kg (53 lb.).2. Remove turbocharger oil supply line (6) and turbocharger oil return line (7) to the turbocharger.3. Loosen clamp (3) and remove muffler (2).4. Remove bolts (9) and nuts and then remove elbow (5) from the turbocharger.5. Loosen clamp (4). Remove bolts (8) and then remove turbocharger (1). Check the O-ring seals on the turbocharger.6. Upon installation, use the following procedures.7. Put clean oil on the O-ring seals on the turbocharger.8. Put 5P3931 Anti-Seize Compound on the threads of the bolts (8) that hold the turbocharger to the exhaust manifold. Install the bolts and nuts and tighten to a torque of 55 5 N m (40 4 lb.ft.).Disassemble And Assemble Turbocharger
Start By:a. remove turbocharger 1. Install the turbocharger on tool (A).2. Put alignment marks on the three housings of the turbocharger for correct alignment during assembly. Loosen the two clamps and separate the center section (cartridge) from the two outside housings.3. Put the cartridge group (shown in the illustration) with nut (1) up in tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (1) that holds the compressor wheel (2) to the wheel assembly (11).4. Remove compressor wheel (2), shims (3), and housing assembly (20) from wheel assembly (11). Remove piston ring (12) and backplate (10) from the wheel assembly.5. Use tool (C), and remove snap ring (4) from housing assembly (20). Remove insert (5) and sleeve (22) from the housing assembly. Remove ring (21) from sleeve (22).6. Remove two screws (7), deflector (19), ring (24), bearing assembly (8), sleeve (9), and ring (18) from the housing assembly.7. Remove O-ring seal (6). Use tool (D) and remove snap ring (23) from the housing assembly. Remove bearing (17). Use tool (D) and remove snap ring (16) behind the bearing.8. Use tool (D) and remove snap ring (13) from the housing assembly. Remove bearing (14). Remove snap ring (15) behind the bearing with tool (D).9. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 For Turbocharger Reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.10. Make sure that all the oil passages in the turbocharger catridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (14) and (17) in position in housing assembly (20) are installed with the round edge of the outside diameter toward the bearing.
11. Install snap ring (15) with tool (D). Install bearing (14). Install snap ring (13) with tool (D).12. Install snap ring (16) behind bearing (17) with tool (D). Install bearing (17). Install snap ring (23) with tool (D).13. Install O-ring seal (6) in the housing assembly.14. Put wheel assembly (11) in position on tool (B) with the threaded portion end up. Put backplate (10) in position on the wheel assembly. Put 6V2055 High Vacuum Grease in the groove for ring (12) at assembly to one half or more of the depth of the groove all the way around.15. Install piston ring (12) in the groove in wheel assembly (11).16. Put housing assembly (20) in position on wheel assembly (11). Install ring (18) and sleeve (9) on the wheel assembly.17. Make sure the screen is in place in bearing assembly (8). Install bearing assembly (8) over the sleeve. Make sure the screen in the bearing assembly is facing down when it is installed.18. Put ring (24) in position on bearing assembly (8). Install deflector (19) with two screws (7). Put 6V2055 High Vacuum Grease in the groove of sleeve (22) to one half or more of the depth of the grooves all the way around.19. Install ring (21), in the groove, in sleeve (22). Put sleeve (22) in position in insert (5). Install the insert and sleeve as an assembly.20. Use tool (C) and install snap ring (4) to hold insert (5) on the housing assembly. 21. Put compressor wheel (2) in position in the compressor housing (25). Center the wheel in the compressor housing.22. Use a straight edge and a depth micrometer (26) and measure the distance between the wheel seating face and the compressor housing mounting face (dimension X) in four places. Find the average of the measurements. 23. Use a depth micrometer (26) to measure the distance between the face of housing assembly (20) and the surface of sleeve (22) [dimension Y].24. Use a depth micrometer (26) and measure the distance between the surface of housing assembly (20) and the compressor housing mounting face (dimension Z).25. Calculate the necessary shim thickness as follows: The shims must be of uniform thickness and free of burrs and other imperfections. The total shim thickness should be 0.13 mm to 0.41 mm (.005 to .016 in.) and consist of one or two shims.26. Install compressor wheel (2) at room temperature as follows:a. With the correct amount of shims, position wheel assembly (11) and housing assembly (20).b. Put a small amount of clean engine oil on the threads of the wheel assembly.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
c. Install the nut that holds wheel (2) in place. Tighten the nut to a torque of 14 to 17 N m (125 to 150 lb.in.).d. Remove the nut and put 6V1541 Quick Cure Primer on the threads of the wheel assembly.e. Put 9S3265 Retaining Compound on the threads of the wheel assembly and install the nut. Tighten the nut to a torque of 4 N m (35 lb.in.).f. Tighten the nut an additional 90°.27. Install the two outside housings on the