01104-05108 Suzuki Bolt

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Illustration 1 g02464417
If necessary, follow Step 1.a thought Step 1.d in order to install clamps (2) to bracket (11).
Position clamp (2) onto bracket (11). Ensure clamp (2) is correctly orientated. Install pins (23) to clamp (2).
Install new retaining pins (21) to pins (23).
Position clamp (2) to bracket (11). Ensure clamp (2) is correctly orientated. Install pins (24) to clamp (2).
Install new retaining pins (22) to pins (24).
Illustration 2 g02464396
Illustration 3 g02464317
If necessary, follow Step 2.a thought Step 2.f in order to install bracket (11) to valve mechanism cover (20).
Position bracket (11) onto valve mechanism cover (20).
Install nuts (19) from bracket (11). Tighten the nuts to a torque of 22 N m (195 lb in).
Position bracket (14) onto bracket (11). Install bolts (13). Tighten the bolts to a torque of 55 N m (41 lb ft).
Connect harness assembly (18). Slide locking tab (15) into the lock position.
Connect harness assembly (17). Slide locking tab (16) into the lock position.
Install new cable straps (12) to the harness assembly for the temperature sensor. Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specification.
Illustration 4 g02313333
Position a new ball clamp (8) onto flexible exhaust pipe (9).
Attach a suitable lifting device to the assembly of the Diesel Particulate Filter (DPF) (6). The weight of the DPF is approximately 43 kg (95 lb).
Use the suitable lifting device in order to install the DPF to the mounting bracket for the clean emissions module. Procedure for Reinstalling the Original Diesel Particulate Filter
Illustration 5 g02520577
If the original DPF (6) will be reinstalled, follow Step 2 through Step 12 for the correct procedure.
Ensure that the exhaust gases flow in the direction of temporary mark (5).
Loosely install clamps (2).
Align temporary marks in Position (A), Position (B), Position (C), and Position (D) that were made on clamps (2) and DPF (6).
Tighten the nuts on clamps (2) to a torque of 17 N m (151 lb in).
Loosely assemble the flexible exhaust pipe assembly (9) to inlet (10).
Loosely install the Original Equipment Manufacturer's (OEM) exhaust pipe assembly to outlet section (3) of the DPF.
Tighten the flexible exhaust pipe ball clamp (8) to a torque of 35 N m (26 lb ft). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Tighten the OEM exhaust pipe assembly to the outlet section of the DPF. Refer to the OEM for the correct procedure.
Remove the suitable lifting device from the assembly of the DPF.
Install soot antenna (4) and soot antenna (7). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Install temperature sensor (1) into the DPF. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure. Procedure for Installing a Replacement Diesel Particulate Filter
Illustration 6 g02520522
Illustration 7 g02520520
Illustration 8 g02520521
If a replacement DPF (6) is being installed, follow Step 2 through Step 10 for the correct procedure.
Loosely assemble the flexible exhaust pipe (9) to inlet (10).
Loosely install the Original Equipment Manufacturer's (OEM) exhaust pipe assembly to outlet section (3) of the DPF.
Using Dimension (E) and Dimension (F) that was recorded during the DPF removal procedure, position the DPF in the correc