67221-92E00 Suzuki SHIFT ASSEMBLY

1. Remove bolts and nuts (3). Remove support (2) and coupling (1) from the turbocharger. 2. Remove clamp (6) from the oil lines.3. Remove oil supply line (4) and return line (5) from the turbocharger and the engine. 4. Remove bolts (8) from elbow (7). Remove elbow and pipe (9) from the engine as a unit. 5. Remove bolts and nuts (11) that hold the turbocharger to the exhaust manifold. Remove turbocharger (10).Install Turbocharger
1. Check O-ring seals (1) for wear or damage. If necessary, make a replacement. Put a small amount of SAE 30 oil on the O-ring seals.2. Install a new gasket on the exhaust manifold. Put turbocharger (2) in position on the coupling and exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Install the bolts and nuts and tighten to a torque of 55 7 lb.ft. (75 10 N m).3. Check O-ring seals (4) for wear or damage. If necessary, make a replacement. Put a small amount of SAE 30 oil on the O-ring seals. 4. Install a new gasket on elbow (3). Install elbow and pipe (5) on the engine. 5. Install oil return line (7) and oil supply line (6) on the turbocharger and the engine. 6. Install clamp (11) on the oil lines.7. Check seal (8) for wear or damage. If necessary make a replacement.8. Install coupling (10) and support (9). Install the bolts that hold the support to the exhaust manifold.end by:a) install mufflerDisassemble Turbocharger
start by:a) remove turbocharger1. Install the turbocharger on tool (A).2. Put marks on the housings for correct installation at assembly. 3. Loosen clamp (1). Remove compressor housing (2). Remove the clamp. 4. Remove bolts (3), locks (6) and plates (5).5. Remove the center section from turbine housing (4). 6. Install tool (C) in tool (B). Install the center section in tool (C) as shown.7. Remove nut (7) that holds the impeller to the shaft and wheel assembly. 8. Install tool (E) on tool (D). Heat tool (D) to 350°F (177°C). Install the impeller on tool (E).
Make sure only the impeller is in the hot oil.
9. Install tool (E) with the center section on tool (F). Remove impeller (9) with an arbor press (8) and tool (G). Step 9 must be done before the impeller gets cold. 10. Remove shaft and wheel assembly (10), shroud (11) and spacer (13) from center housing (12). 11. Remove bolts (14), locks (15) and plate (16) from the center housing. 12. Remove collar (17). 13. Remove two bearings (18) and three snap rings (19) from the center housing.Assemble Turbocharger
1. Clean all parts thoroughly before assembly.2. Install snap ring (15), bearing (12) and snap ring (11) in center housing (10). Install snap ring (9) and bearing (8).3. Install shroud (13). Put 6V2055 High Vacuum Grease in the turbine end ring seal groove. Make sure it fills approximately one half or more of the groove depth for the complete circumference of the groove. Install ring seal (14) on the shaft. Install shaft and wheel assembly (16) in the center housing.
Use caution not to cause damage to ring seal (14) when the shaft and wheel assembly is installed.
4. Install spacer (7) and collar (6).5. Put plate (5) in position on the center housing. Install bolts (4). Tighten the bolts to a torque of 35 5 lb.in. (4.0 0.6 N m).6. Install spacer (3). Make sure the small inside diameter of the spacer is toward the impeller end of the shaft and wheel assembly.
Install spacer (3) with the small inside diameter away from center housing (10) or it will cause a restriction of oil flow to the chamber and rings. This will cause a failure of the turbocharger.
7. Heat impeller (1) in oil to a maximum temperature of 350°F (177°C). Install the impeller on the shaft and wheel assembly. 8. Install tool (C) in tool (B). Install the center section in tool (C). Install nut (2). Tighten the nut to a torque of 120 lb.in. (13.6 N m). Let the temperature of the impeller get below 150°F (65°C). Loosen the nut. Put a light amount of oil on the threads of the shaft and wheel assembly. Tighten the nut again to a torque of 30 lb.in. (3.4 N m). Put a mark on the nut and impeller. Tighten the nut 120° Past the mark.
Do not put a bending force on the shaft and wheel assembly when nut (2) is tightened.
9. Install turbine housing (17) on tool (A). Install the center section in the turbine housing. Put the marks that were made at disassembly in alignment to make sure the housings are in their original position.10. Put 5P3931 Anti-Seize Compound on the threads of bolts (21). Install plates (20), locks (19) and the bolts. Tighten the bolts to a torque of 175 5 lb.in. (19.8 1.7 N m). 11. Install a new O-ring seal (18) on the center housing. 12. Put clamp (23) over the center section. Put compressor housing (22) in alignment with the marks made at disassembly. Put the clamp in position over the housing. Tighten the clamp to a torque of 120 10 lb.in. (13.6 1.1 N m).13. Put oil in the center section and turn the shaft and wheel assembly.end by:a) install turbocharger