38410-94551 Suzuki RELAY ASSY, PTT (UP & DN)

3. Remove four nuts (5) that hold the turbocharger to the exhaust manifold.4. Remove turbocharger (4) and the gasket from the exhaust manifold.Install Turbocharger
1. Put 5P3931 Anti-Seize Compound on the threads of the studs that hold the turbocharger in place.2. Put the gasket and turbocharger (1) in position on the exhaust manifold. Install the four nuts that hold the turbocharger in place. Tighten them to a torque of 54 5.5 N m (40 4 lb.ft.). 3. Install oil inlet line (3) and oil outlet line (4) on the engine and turbocharger. Install the clamp that holds lines (3) and (4) together.4. Tighten hose clamp (2).Disassemble Turbocharger
START BY:a. remove turbocharger 1. Put the turbocharger in position on tooling (A). Put alignment marks on the compressor and exhaust housings as to their location on the cartridge so they can be installed in the same position.2. Bend the tabs on the locks away from the bolts.3. Remove bolts (2), locks (1) and compressor housing (3). 4. Bend the tabs on the locks away from the bolts. Remove bolts (5), the locks and cartridge assembly (4) from exhaust housing (6). 5. Put the cartridge assembly in position on tooling (B).
Do not put a bending force on the shaft and wheel assembly when the nut is loosened.
6. Remove nut (7) from the shaft.
Do not let shaft assembly (9) fall when it is pushed out of the cartridge assembly.
7. Use a press to push shaft assembly (9) out of the cartridge assembly.8. Remove wheel (8) from the cartridge. 9. Remove seal ring (11) from shaft assembly (9).10. Remove shroud (10) from the shaft. Put alignment marks on the cartridge and backplate assembly (14) as to the location of the backplate on the cartridge so it can be installed in its original position.11. Bend the tabs on the locks away from the bolts.12. Remove bolts (13) and locks (12).13. Remove the cartridge from backplate assembly (14). 14. Remove bearing (15) and collar (16) as a unit from the backplate assembly. 15. Remove bearing (15) from collar (16). 16. Remove seal ring (17) from collar (16). 17. Remove spring (18) from the backplate assembly. 18. Remove seal ring (19) from the cartridge housing. 19. Remove snap ring (21), bearing (20) and snap ring (22) from the cartridge housing. 20. Turn the cartridge housing over, and remove snap ring (24), bearing (23) and snap ring (25). For more information on turbochargers, see Analyzing Turbocharger Failures, Form No. FEG45138, Guideline For Reusable Parts-Turbochargers, Form No. SEBF8018 and Guideline For Reusable Parts-Specifications For Reusable Turbocharger Components, Form No. SEBF8019.Assemble Turbocharger
1. Clean all parts of the turbocharger thoroughly before they are assembled. Put clean engine oil on all parts. 2. Install snap ring (2), bearing (3) and snap ring (1) in the cartridge housing. 3. Turn the cartridge housing over, and install snap ring (5), bearing (6) and snap ring (4). 4. Put seal ring (7) in position on the cartridge housing. 5. Put seal ring (8) in position on collar (9).
Bearing (10) must be installed on the collar with the side that has a groove up as shown.
6. Put bearing (10) in position on collar (9). 7. Put bearing (10) and the collar in position on the cartridge housing as a unit. Make an alignment of the holes in the bearing with dowels (11). 8. Put spring (12) in position in backplate (13). 9. Put shaft assembly (14) in position on tooling (A).10. Fill the groove in the shaft with 6V2055 High Vacuum Grease.11. Put seal ring (16) in position on the shaft assembly.12. Install shroud (15) as shown.13. Put the cartridge housing in position on shaft assembly (14). 14. Put the backplate in its original position. Install locks (18) and bolts (17). Tighten the bolts to a torque of 8.5 to 10.2 N m (75 to 90 lb.in.).15. Bend the tabs on locks (18) up against the bolts. 16. Put compressor wheel (19) in position on shaft assembly (14).17. Use the procedure which follows to install and tighten the nut which holds the compressor wheel in position.
Do not put a bending force on the shaft and wheel assembly when the nut is loosened or tightened.
a. Put a small amount of clean engine oil on the threads and impeller face surface that makes contact with the nut. Install the nut.b. Tighten the nut to a torque of 2.25 N m (20 lb.in.) plus 100° more.c. Remove the nut from the shaft.d. Put 6V1541 Quick Cure Primer on the threads of the shaft and nut.e. Put 9S3265 Retaining Compound on the threads of the shaft and nut.f. Install the nut on the shaft, and tighten the nut to a torque of 2.25 N m (20 lb.in.) plus 100° more. 18. Put cartridge assembly (20) in a vise as shown. Make sure soft (brass) jaws are used.19. Install tooling (C) on the cartridge assembly to check end play. The end play must be 0.03 to 0.10 mm (.001 to .004 in.). 20. Put cartridge assembly (20) in its original position in turbine housing (21). 21. Put 5P3931 Anti-Seize Compound on bolts (23).22. Put locks (22) in position, and install the bolts. Tighten the bolts to a torque of 13 1.7 N m (115 15 lb.in.). Bend the tabs on the locks against the bolts. 23. Put compressor housing (24) in its original position on the cartridge assembly. 24. Put locks (25) in position, an