38500-87000 Suzuki Buzzer

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g06168060
Typical example
Used ball clamp should be discarded and new ball clamps should be installed.
Note: If the V-band clamp (9) remains tight on the flanges, apply releasing fluid on the V-band clamps to assist removal. Lightly tap the bolts on the V-band clamps with a soft faced hammer to assist removal. Do not use a pry bar to remove V-band clamps.
Sufficiently loosen ball clamp (5) to allow removal.
Position ball clamp (5) onto tube assembly (4).
Make temporary marks on turbo charger (1), exhaust adaptor, (6), and tube assembly (4) for installation purposes.
Remove bolts (3) from exhaust adaptor (6).
Illustration 2 g06168061
Used V-band clamp should be discarded and new V-band clamps should be installed.
Sufficiently loosen the V-band clamp assembly (9), to allow V-band clamp assembly (9) to be positioned onto tube assembly (4).
Make temporary marks on tube assembly (4) and stub pipe (10) for installation purposes.
Remove tube assembly (4) from stub pipe (10) and turbocharger (1).
Remove ring (7) and seal (8) from tube assembly (4).
Remove gasket (2) (not shown).Installation of Exhaust Clamps
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Molyslip Ferroslip Anti-seize compound 1
Ensure that all components are clean and free from damage and wear. Replace any components that are worn or damaged.
Illustration 3 g06168060
Typical example
Illustration 4 g06168065
Ball clamp not shown for clarity
Position (W) is acceptable
Position (X) is not acceptable
Illustration 5 g06168132
Slide Ball clamp over Ball joint, ensuring that the edges of the clamp are equidistant and centered between the radices of the ball joint. Loose fit the ball clamp over ball joint.
Install new ball clamp (5) to tube assembly (4) ensure that the ball and the cup are correctly positioned. Refer to Illustration 4.
Install tube assembly (4) to exhaust adaptor (6), ensuring temporary marks are aligned. Tighten ball clamp finger tight.
Illustration 6 g06168061
Ensure that stub pipe (10) on the Clean Emissions Module (CEM) is clean, free from wear and damage.
Install new ring (7) onto tube assembly (4). Ensure that the ring is correctly orientated.
Install new seal (8) to ring (7).
Illustration 7 g06442302
Apply 20 mm (0.78740 inch) of Tooling (A) on the internal circumference in Positions (X) on the V-band clamp prior to installation.
Install new V-band clamp (9) onto stub pipe (10). Ensure that the V-band clamp is sufficiently loosened to allow installation. Ensure that the V-band clamp is correctly orientated.
Install tube assembly (4) into stub pipe (10) on the CEM.
Position V-band clamp (9) onto ring (7) and seal (6). Ensure that the V-band clamp is correctly seated onto the ring and the seal. Tighten V-band clamp finger tight.
Install gasket (2) (not shown) between turbocharger (1) and exhaust adapter (6), Install bolts (3) to exhaust adapter (3) finger tight.
Ensure that tube assembly (4) is correctly aligned with CEM. Use the temporary marks to align tube assembly (4) and stub pipe (10).
Tighten bolts (3) to a torque of 44 N m (389 lb in)
Ensure ball clamp (5) is correctly positioned. Refer to Illustration 5.
Tighten ball clamp (5) to a torque of 35 N m (310 lb in)