38100-88L11 Suzuki MOTOR ASSY, PTT

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     4C-5597     Anti-Seize Compound     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02682436
Illustration 2 g02682676
Torque sequence
Ensure that second stage turbocharger (22) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
If necessary, install studs (28) in second stage turbocharger (22). Tighten studs (28) to a torque of 18 N m (159 lb in).
Position bracket (23) on second stage turbo (22).
Loosely install nuts (27) .Note: Bracket (23) must be able to move freely to allow correct positioning.
Apply sufficient pressure to second stage turbocharger (22) in th direction of arrow. Do not release the pressure on the turbocharger in the direction shown until nuts (27) have been tightened securely.
Tighten nuts ( 27) to a torque of 44 N m (32 lb ft) in the sequence shown.
Illustration 3 g02680157
Position the second stage turbocharger and bracket in order to attach clip (26) .
Illustration 4 g02682837
Illustration 5 g02682917
second stage turbo removed for clarity
Position second stage turbocharger (22) and bracket (23) on studs (24) .
Loosely install nuts (25) on studs (24) .Note: Bracket (23) must be able to move freely to allow correct positioning.
Apply sufficient pressure to second stage turbo (22) and bracket (23) in the direction shown in illustration 5. Ensure second stage turbo (22) and bracket (23) are at the lowest point on studs (24). Do not release the pressure on second stage turbocharger (22) and bracket (23) in the direction shown until nuts (25) have been tightened securely.
Tighten nuts (25) to a torque of 44 N m (33 lb ft) in the sequence shown in Illustration 5.
Illustration 6 g02680137
Position a new gasket (19) and tube assembly (21). Install bolts (20). Tighten bolts (20) to a torque of 22 N m (195 lb in).
Position a new gasket (18) and tube assembly (17) on second stage turbocharger (22). Install bolts (16). Tighten bolts (16) to a torque of 22 N m (195 lb in).
Illustration 7 g02679977
Position tube assembly (10) Use Tooling (A) to lubricate the allen head bolt for clamp (9). Position clamp (9) on tube assembly (10). Tighten the allen head bolt for clamp (9) to a torque of.
Tighten hose clamps (11) to a torque of 6 N m (53 lb in).
Connect hose (8) and tube (15).
Use Tooling (A) to lubricate the allen head bolt for clamp (7) and clamp (14) .
Position elbow (13) .
Tighten allen head bolt for clamp (7) and clamp (14) finger tight. Ensure that the clamps are seated correctly onto the turbochargers.
Tighten allen head bolts for clamp (7) and clamp (14) to a torque of 12 N m (106 lb in).
Position tube assembly (6) and install clamp (5). Use Tooling (A) to lubricate the allen head bolt for clamp (12). Tighten allen head bolt for clamp (12) to a torque of 22 N m (195 lb in).
Illustration 8 g02679900
Install tube assembly (2) and hose (4). Connect hose assembly (3) and install bracket (1) .
Install the engine panels on the left-hand side of the engine.
Turn the disconnect switch to the ON position.
Lower the hood.