09181-28020 Suzuki TURUST WASHER (T:1.6)

1. Remove the inlet, exhaust, and aftercooler tubes (1). See "Remove & Install Muffler & Air Cleaner Assembly" in this module.2. Remove oil supply line (2) and oil drain line (3). 3. Remove four nuts and washers (4) and turbocharger (5). Check the condition of the gasket located beneath the base of turbocharger (5), and replace if needed. The following steps are for the installation of the turbocharger.4. Apply 5P3931 Anti-Seize to the turbocharger mounting studs. Position turbocharger (5) and turbocharger gasket, and secure with four nuts and washers (4). Tighten nuts and washers (4) to a torque of 55 5 N m (40 4 lb ft).5. Install oil supply line (2) and oil drain line (3).6. Install the inlet, exhaust, and aftercooler tubes (1). See the topic "Remove & Install Muffler & Air Cleaner Assembly" in this module.Disassemble & Assemble Turbocharger
Start By:a. remove turbocharger 1. Place turbocharger in tooling (A). Put alignment marks on all the housings. Loosen clamp (1), and remove housing (2). 2. Loosen clamp (3), and remove cartridge assembly (4). 3. Place cartridge assembly (4) in tooling (B).
Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (5). Do not bend or add stress to the shaft when nut (5) is loosened or tightened.
4. Remove nut (5), and remove compressor wheel (6).5. Remove snap ring (7); then use two screw drivers, and remove adapter plate (8). Remove o-ring (9), and inspect for wear or damage.6. Remove and inspect bushing and seal (10).7. Remove oil deflector (11) and thrust ring (12).8. Remove bearing (13), sleeve (14) and thrust ring (15).9. Lift housing assembly (17) off of shaft and wheel (18).10. Remove seal ring (19) and backplate (16).11. Check all parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instructions, Form No. SMHS6854 for turbocharger reconditioning. Also, see Guideline For Reusable Parts - Turbochargers, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.12. Be sure that all of the oil passages in the turbocharger cartridge 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 assembled. Put clean engine oil into the oil inlet of the turbocharger.13. With shaft and wheel (18) in tooling (B), install seal (19) and backplate (16).14. Position housing assembly (17) onto shaft and wheel (18).15. Install thrust ring (15), bearing (13), sleeve (14) and thrust ring (12). Install oil deflector (11), then bushing and seal (10).16. With oil seal (9) in place, position adapter plate (8), and install snap ring (7).
Do not bend or add stress to the shaft when nut (5) is tightened.
17. Install compressor wheel (6) on the shaft. Put one drop of 9S3263 Thread Lock on the threads of the shaft. Install nut (5), and tighten it to a torque of 24 1 N m (216 12 lb in).18. Remove cartridge assembly (4) from tooling (B), and install it into the housing on tooling (A). Align the marks, and tighten clamp (3).19. Install housing (2). Align the marks, and tighten clamp (1).End By:a. install turbocharger