09160-30041 Suzuki THRUST WASHER

1. Put engine in position on tool (A). Disconnect tube assembly (1) from the flywheel housing. 2. Remove bolt (4) and lock (2), then remove tube (5). Remove O-ring seals (3) from the tube. 3. Remove bolts and nuts (6), then remove lifting bracket (7). 4. Remove nuts (9) and cover (8). Remove O-ring seal from the cover. 5. Remove two bolts (13) and lock (12). Remove washer (11) and seal behind retainer. Remove yoke (10). 6. Remove bolts (14). Remove gear and cage assembly (15) from the flywheel housing. 7. Remove bearings (16) from the gear. 8. Remove bearing cup (17) from cage.9. Remove lip type seal (18) from cage. 10. Remove bearing cup (19) from the flywheel housing. 11. Install two 3/8"-16 NC forged eyebolts in the flywheel housing. Fasten a hoist to the eyebolts. Remove the bolts (20) that hold the flywheel housing to the cylinder block. Remove flywheel housing (2). Weight of the flywheel housing is 430 lb. (580 kg). 12. Remove three bolts (23), shaft (22) and seal. Remove gear (24), two bearings and spacer. 13. Remove two bearing cups (25) from gear (24).Install Flywheel Housing
1. Lower the temperature of the bearing cups (1), then install them in gear (2). 2. Install gear (2), two bearings and spacer in the flywheel housing. Install O-ring seal on shaft (3). Install shaft (3) with the three bolts that hold it.3. Put 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. 4. Install two 3/8"-16 NC forged eyebolts in the flywheel housing. Fasten a hoist to the eyebolts. Put flywheel housing (4) in position on the cylinder block. Install all the bolts that hold housing to cylinder block.5. Tighten flywheel housing bolts with this procedure: a) Tighten bolts 5 through 11 in number sequence to a torque of 100 10 lb.ft. (135 14 N m).b) Tighten bolts 12 through 22 in number sequence to a torque of 40 5 lb.ft. (55 7 N m).c) Tighten bolts 5 through 11 again in number sequence to a torque of 100 10 lb.ft. (135 14 N m).d) Tighten bolts 12 through 22 again in number sequence to a torque of 40 5 lb.ft. (55 7 N m). 6. Lower the temperature of bearing cup and install it in cage (23).7. Install lip type seal in cage (23) with tool group (B). Install the seal until it makes contact with the counterbore in the cage and with the lip of the seal toward the bearing. 8. Heat bearings (24) to a maximum temperature of 275°F (135°C). Install these bearings on gear (25) with asbestos gloves. 9. Lower the temperature of bearing cup (26), then install it in the flywheel housing. 10. Install gear assembly in flywheel housing. Install cage (23) on housing with the bolts (27) that hold it.11. Install yoke (28). Install O-ring seal, washer, lock and two bolts. 12. Install a new O-ring seal (29) on cover (30). Install cover (30) on the flywheel housing with the nuts that hold it. 13. Install lifting bracket (31) on the flywheel housing with the bolts and nuts that hold it. 14. Install two new O-ring seals (33) on tube (32). Install tube (32) in the flywheel housing with the lock and bolt that hold it. 15. Connect tube assembly (34) to the flywheel housing.end by:a) install rear seal and wear sleeveb) install starterc) install oil pand) install engine