01107-08458 Suzuki Bolt

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 g06456616
A high proportion of engine oil will be removed from the blow-by gas by the oil separator in the valve mechanism cover. In a closed breather system, the presence of some oil in the breather connection to the air induction systems and downstream of the compressor in air to air charge cooler connections after service is to be expected.
Loosen the Original Equipment Manufacturers (OEM) hose clamps and disconnect the hose assembly from inlet tube assembly (5) and from turbocharger outlet (3).
Remove connector (1) and disconnect breather hose assembly (2) from inlet tube assembly (5).
Loosen hose clamp (4) and remove inlet tube assembly (5) from the turbocharger.
Illustration 2 g06474630
Remove banjo bolt (7) from the tube assembly (8). Remove O-ring seal (9) (not shown) and O-ring seal (10) (not shown) from the tube assembly.
Position tube assembly (8) away from turbocharger (6).
Illustration 3 g06456625
Loosen bolts (18) and remove heat shield (17).
Remove bolts (18) from the cylinder head.
Remove Allen head bolts (15) from the oil drain pipe (16).
Illustration 4 g06456640
Sufficiently loosen V-band clamp (22), position the V-band clamp away from adaptor (21).
Loosen bolts (20) from turbocharger (6).
Remove nuts (12) from turbocharger (6).
Support adapter (21) and remove bolts (20). Remove gasket (19) (not shown).
Remove turbocharger (6) from exhaust manifold (11).
Remove adapter (21) from clean emissions module (23).
Remove gasket (14) (not shown) from tube assembly (16).
Illustration 5 g06456647
Remove seal (25) and ring (24) from adaptor (21).
Remove gasket (13) (not shown) from turbocharger (6).
Illustration 6 g06456650
If necessary remove stud (26) and studs (27) from turbocharger (6).
Illustration 7 g06456654
If necessary, follow Step 19a through Step 19b to remove tube assembly (16).
Remove bolts (30) and remove tube assembly (16) from the cylinder block.
Remove gasket (29) (not shown) from tube assembly (16).
If necessary, follow step 20a through 20d to disassemble tube assembly (16) and tube assembly (31) from hose (28).
Make temporary marks on tube assembly (16), tube assembly (31), and hose (28) for installation purposes.
Use a suitable tool to reposition hose clamp (33) away from hose assembly (28).
Use a suitable tool to reposition hose clamps (32) away from tube assembly (28).
Remove tube assembly (16) and tube assembly (31) from hose (28).
If necessary, remove fuel pressure regulator. Refer to , "Fuel Pressure Regulator - Remove and install" for the correct procedure.
If necessary, remove throttle valve. Refer to , "Throttle Valve (Intake Air) - Remove and Install" for the correct procedure.
If necessary, remove the pump to rail fuel injection line. Refer to , "Fuel Injection Lines - Remove" for the correct procedure.
Illustration 8 g06457544
If necessary, follow Step 24a through Step 24d to remove engine harness to allow turbo oil feed line removal.
Cut cable strap (34), cable strap (37), cable strap (38), cable strap (39), and cable strap (44).
Disconnect engine harness (35) from Diesel Particulate Filter (DPF) pressure sensor (36).
Disconnect engine harness (42) from fuel temperature sensor (43).
Disconnect engine harness (40) from flow control valve (41).
Illustration 9 g06456659
If necessary, follow step 25a through 25c to remove tube assembly (8)
Remove bolt (49) and bolt (48) from the clamps on the tube assembly (8).
Loosen tube nut (47) and remove tube assembly (8).