09169-28003 Suzuki WASHER

start by:a) remove turbocharger 1. Put the turbocharger in position on tooling (A). Put a mark on cover (1), cartridge (2) and housing (3) for correct alignment and installation at assembly. 2. Loosen V-clamp (4). Remove cover (1) and the V-clamp from the cartridge.3. Loosen V-clamp (5). Remove cartridge (2) and the V-clamp from the housing.4. Put the cartridge in position in tool (B).
When the nut is loosened, do not put a side force on the shaft.
5. Use tool (C) to remove the nut that holds compressor wheel (6) in position. Remove the compressor wheel. 6. Remove cartridge (2) from the shaft. 7. Remove seal ring (7) from the shaft. 8. Use tool (D) to remove ring (8). 9. Remove insert (9) from the cartridge.10. Remove sleeve (10) from insert (9).11. Remove the piston ring (not shown) from the sleeve. 12. Remove deflector (11) and ring (12) from the cartridge. 13. Remove thrust bearing (13), sleeve (14) and ring (15). 14. Use tool (E) to remove ring (16).15. Remove bearing (17).16. Use tool (E) to remove the other ring (not shown) from the cartridge. 17. Use tool (E) to remove ring (18).18. Remove sleeve (19) and the bearing (not shown).19. Use tool (E) to remove the other ring (not shown) from the cartridge.Assemble Turbocharger
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. See SPECIAL INSTRUCTION FORM NO. SMHS 6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSEABLE PARTS FORM NO. SEBF8018. Install the rings that hold the bearings in position with the round edges of the rings toward the bearings. 2. Use tool (A) to install the ring in the cartridge.3. Put bearing (1) and sleeve (2) in position in the cartridge. 4. Use tool (A) to install the ring in the cartridge.5. Use tool (A) to install ring (3) in the cartridge.6. Put bearing (4) in position in the cartridge.7. Use tool (A) to install the ring in the cartridge. 8. Put ring (7), sleeve (6) and thrust bearing (5) in position in the cartridge. 9. Put ring (9) and deflector (8) in position in the cartridge. 10. Install piston ring (11) on sleeve (10). Install the sleeve in insert (12). Make sure the O-ring seal is in position on the insert. 11. Install insert (12) in the cartridge. 12. Use tool (B) to install ring (13) to hold the insert in position.13. Install the O-ring seal on the cartridge. Put 6V2055 High Vacuum Grease in the groove for seal ring (14) at assembly to one half or more of the depth of the groove all the way around. 14. Install seal ring (14) on the shaft.15. Install the shaft on tool (C).16. Put the cartridge in position on the shaft.
Do not put a side force on the shaft when the nut is tightened.
17. Install compressor wheel (15) on the shaft. Put clean engine oil on the threads of the turbine shaft. Install the nut that holds the compressor wheel on the turbine shaft. Use a torque wrench and a universal socket of the correct size and tighten the bolt to a torque of 22 2 lb.ft. (28 3 N m).18. Make sure the compressor wheel is clean and dry.
TYPICAL EXAMPLE19. Put the cartridge in a vise as shown. Check the shaft end play with tool (D). The end play must be .0045 .0015 in. (0.114 0.038 mm) (new). If the shaft end play is not the correct dimension, the inside parts of the cartridge housing must be checked for too much wear. See TURBOCHARGER (SCHWITZER FC452 in SPECIFICATIONS). 20. Install housing (16) on tool (E). Put V-clamp (17) and the cartridge in the correct position on the housing. Put 5P3931 Anti-Seize Compound on the threads of the V-clamp. Tighten the V-clamp to a torque of 10 2 lb.ft. (14 3 N m). Use a soft hammer to tap the V-clamp with light pressure to make sure it is in its correct position. Tighten the V-clamp to a torque of 10 2 lb.ft. (14 3 N m). 21. Make sure O-ring seal (18) is in its correct position on the cartridge. Put V-clamp (20) and cover (19) in the correct position on the cartridge. Put 5P3931 Anti-Seize Compound on the threads of the V-clamp. Tighten the V-clamp to a torque of 10 2 lb.ft. (14 3 N m). Use a soft hammer to tap the V-clamp with light pressure to make sure it is in its correct position. Tighten the V- clamp to a torque of 10 2 lb.ft. (14 3 N m).end by:a) install turbocharger