38410-93J12 Suzuki RELAY ASSY, PTT

START BY:a) remove turbochargers 1. Put the turbocharger in position on tool group (A) as shown. Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Loosen clamp (2) and remove compressor housing (1) and the clamp from the cartridge assembly. 3. Bend the tabs on locks (4) from the bolts. Remove the bolts, locks (4) and the clamps that hold cartridge housing (3) in turbine housing (5).4. Remove cartridge housing (3) from turbine housing (5).
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
5. Put the end of the turbine shaft in tool (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (6) on the turbine shaft. 6. Use a press and push the turbine shaft out of compressor wheel (6) and the cartridge housing. Remove compressor wheel (6) from the cartridge housing. 7. Remove seal ring (8) and shroud (9) from turbine shaft (7). 8. Bend the tabs of the locks from bolts (10) and remove the bolts.9. Remove backplate assembly (11) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly. 10. From the opposite side of backplate (11) that is shown, push spacer (12) out of its bore. 11. Remove seal rings (13) from spacer (12). 12. Remove thrust collar (14) and seal ring (15) from the cartridge housing. 13. Remove thrust bearing (16) from the cartridge housing. If the bearings are to be used again, put identification on them as to their location for correct assembly. 14. Remove bearing (17) from the cartridge housing. 15. Remove washer (18) from the cartridge housing. 16. Use tool (C) and remove snap rings (19) and (20) from the cartridge housing. 17. Remove bearing (21) and washer (22) from the cartridge housing. 18. If necessary, use tool (C) and compress the end snap ring and push it out of the bearing bore toward the compressor end of the cartridge housing to remove it.Assemble Turbochargers (Airesearch TV91)
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge at assembly. Make sure the round edge of the snap rings are toward the bearings when the snap rings are installed.3. Use tool (A) and install snap ring (1) in the turbine end of the cartridge housing.4. Install washer (2) and bearing (3). Use tool (A) to install snap ring (4) to hold the washer and bearing in position. 5. Use tool (A) and install snap ring (5) in the cartridge housing. 6. Install washer (7) and bearing (6) in the cartridge housing until washer (7) makes contact with snap ring (5). 7. Install thrust bearing (8) over the dowels in the cartridge housing. Make sure the grooves in bearing (8) are toward the outside as shown. 8. Install seal ring (9) in the groove of the cartridge housing. 9. Put thrust collar (10) in position on the thrust bearing with the counterbore for the spacer up. 10. Install seal ring (11) on spacer (12) so the gaps in the rings are 180° apart. 11. Install spacer (12) in backplate assembly (13). 12. Make sure oil passage (14) in the cartridge housing and oil passage (15) in the backplate assembly are in alignment. Put backplate assembly (13) in position on the cartridge housing. Make sure the spacer fits correctly in the counterbore of the thrust collar. 13. Install the locks and bolts to hold backplate assembly (13) to the cartridge housing. Tighten the bolts to a torque of 10 1 N m (7 1 lb.ft.) and bend the tabs of the locks on the bolts. 14. Put the turbine shaft in position in tooling (B). Put 6V2055 High Vacuum Grease in the groove for seal ring (16). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring (16) and shroud (17) on the turbine shaft. 15. Install the cartridge housing on the turbine shaft while spacer (12) is held in position. Make sure the seal ring on the turbine shaft is fitted correctly in the cartridge housing. 16. Use the following procedure to install impeller (18) on the shaft.a) Put impeller on shaft.b) Put a small amount of 2P2506 Thread Lubricant on the threads and impeller face that will be under the nut. Do not bend or add stress to the shaft when the nut is loosened or tightened.c) Tighten the nut to a torque of 31 N m (23 lb.ft.).d) Loosen the nut on the shaft.e) Tighten the nut to a torque of 5 N m (4 lb.ft.).f) Tighten the nut 120° more. 17. Put the cartridge housing in a vise as shown. Check the shaft end play with tool group (C). The shaft end play must be 0.165 0.063 mm (.0065 .0025 in.). 18. Install turbine housing (19) on tool group (D) as shown. Put the cartridge in position in housing (19). Make sure the marks on the housing and cartridge are in alignment. 19. Put 5P3931 Anti-Seize Compound on the threads of the bolts and install clamps (21), locks (20) and the bolts to hold the cartridge in position. Tighten the bolts to a torque of 20 2 N m (15 1 lb.ft.) and bend the tabs of the locks on the bolts. 20. Install clamp (23) and compressor housing (22) on the cartridge in the correct position. Move clamp (23) into position and tighten the nut to a torque of 14 1 N m (10 1 lb.ft.). Lightly hit all around the clamp with