36610-92E20 Suzuki WIRE HARNESS ASSEMBLY

START BY:a. remove turbocharger (4MF and 4MFW) 1. Install the turbocharger in tool group (A). Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4). 3. Put the cartridge assembly in tool (B) a shown.
When the nut is loosened, do not put a side force on the shaft.
4. Use tool (C), and remove the nut that holds compressor wheel (6). Remove compressor wheel (6). 5. Remove turbine shaft (7) from the cartridge housing. 6. Remove seal ring (9) and shroud (8) from turbine shaft (7). 7. Use tool (D), and remove ring (11) that holds insert (10) in the cartridge housing. 8. Remove insert (10) with tooling (E). 9. Remove O-ring seal (13) and sleeve (12) from insert (10). Remove the seal rings from sleeve (12). 10. Remove deflector (14) and the ring from the cartridge housing. 11. Remove bearing (15), sleeve (16) and the ring from the cartridge housing. The oil hole in bearing (15) must be open or a bearing failure will result. 12. Use tool (F), and remove the ring that holds bearings (17) in position. Remove bearing (17), and put a long dye mark on the top face of the bearing. 13. Turn the cartridge assembly over. Use tool (F), and remove the ring that holds bearing (18) in position. Remove bearing (18) from the cartridge housing. Put a short dye mark on the top face of bearing (18). The dye marks are used for identification of the bearings when they are installed.14. If necessary, remove the two rings that hold the bearings in position from the cartridge housing with tool (F).15. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See Special Instruction, Form No. SMHS6854, for Turbocharger Reconditioning. Also see Guideline For Reusable Parts, Form No. SEBF8018-01.Assemble Turbocharger (4MF And 4MFW)
1. Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.3. Make a replacement of the two inside rings that hold the bearings in position in the cartridge housing if necessary. Install the rings that hold the bearings in position with the round edges of the rings toward the bearings.4. Install bearing (2) in the cartridge housing with the short dye mark up.5. Use tool (A) to install ring (1) in the cartridge housing. 6. Turn the cartridge assembly over, and install bearing (4) with the long dye mark up. Use tool (A), and install ring (3) to hold the bearing in position. 7. Install ring (7), sleeve (6) and bearing (5) in the cartridge housing. Make sure the oil hole in bearing (5) is open and clean to prevent a bearing failure. 8. Install ring (9) and deflector (8) in the cartridge housing. 9. Install O-ring seal (12) around insert (11).10. Install the seal rings on sleeve (10).11. Install sleeve (10) in insert (11) from the bottom side. 12. Install insert (11) in the cartridge housing. Use tool (B), and install the ring to hold the insert in position. Put 4L7464 Silicone Grease in the groove for seal ring (15) at assembly to one half or more of the depth of the groove all the way around.13. Install seal ring (15) and shroud (13) on turbine shaft (14). 14. Put the turbine shaft in tool (C), and install the cartridge housing on turbine shaft (14). Make sure seal ring (15) is fitted correctly in the cartridge housing. 15. Use the following procedure to install compressor wheel (16) on the turbine shaft.a. Put 6V1541 Quick Cure Primer on the nut and the shaft threads to clean them if necessary.b. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
Do not let the retaining compound get into the compressor wheel bore or on the shaft, because it can make removal of the compressor wheel difficult during future turbocharger disassembly.
c. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put lubricant on the threads.
Do not bend or add stress to the shaft when the nut is tightened.
d. Tighten the compressor wheel retainer nut to a torque of 60 3 N m (44 2 lb.ft.). 16. Put the cartridge housing in a vise as shown. Check the shaft end play with tool (D). The end play must be 0.114 0.038 mm (.0045 .0015 in.). If the shaft end play is not the correct dimension, the inside parts of the cartridge housing must be checked for excessive wear. See Turbocharger (4MF And 4MFW) in the Specifications section. 17. Install the turbine housing on tool group (E). Put the cartridge assembly in position in the turbine housing. Make sure the marks on the housings are in alignment with each other. Put 5P3931 Anti-Seize Compound on the threads of the "V" clamp that hold the cartridge assembly to the turbine housing. Install the "V" clamp, and tighten the bolt to a torque of 14 1 N m (10 1 lb.ft.). 18. Install the compressor housing to the cartridge assembly. Install the "V" clamp that holds the compressor housing to the cartridge housing, and tighten the bolt to a torque of 14 1 N m (10 1 lb.ft.).END BY:a. install turbocharger (4MF and 4MFW)