09100-12039 Suzuki Bolt

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1
B - P-80 Emulsion Rubber
Assembly Lubricant 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06463172
Illustration 2 g06463175
Ensure that turbocharger (3) 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.
Clean the gasket surface of exhaust manifold (15).
If necessary, install studs (21) (not shown) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (20) (not shown) onto exhaust manifold (15).
Position turbocharger (3) onto exhaust manifold (15). Install nuts (22) finger tight.
Illustration 3 g06463466
Apply sufficient pressure in Position (A) to ensure that the turbocharger is at the lowest point on studs (21). Do not release the pressure on the turbocharger in Position (A) until nuts (22) have been tightened securely.
Tighten nuts (22) to a torque of 22 N m (195 lb in).
Remove plugs from tube assembly (16). Ensure that tube assembly (16) is clean and free from restriction. Replace any damaged components.
Position a new gasket (17)(not shown) onto tube assembly (16).
Remove the plugs from turbocharger (3).
Position tube assembly (16) onto turbocharger (3).
Install bolts (18) to tube assembly (16). Tighten the bolts to a torque of 9 N m (80 lb in).
Illustration 4 g06463450
Illustration 5 g06463154
Illustration 6 g06463175
Remove the plug from oil inlet port (25). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times to lubricate the bearings.
Position a new O-ring seal (4) (not shown) onto banjo bolt (5).
Ensure that tube assembly (6) is clean and free from restriction. Replace any damaged components.
Install banjo bolt (5) to tube assembly (6) and position the remaining new O-ring seal (4) (not shown) onto the banjo bolt.
Tighten banjo bolt (5) to a torque of 15 N m (133 lb in).Note: Ensure that the hose assembly does not come into contact with the turbine housing as the banjo bolt is tightened.
Use Tooling (B) to lubricate the new O-ring seal (23) and new O-ring seal (24).
Install O-ring seal (23) and O-ring seal (24) to adaptor (10). Install adaptor (10) to turbocharger (3).Note: Seal has an external visibility tab.
Install new seal (13) (not shown) to air duct (11). Install the air duct to turbocharger (19) and turbocharger (3).
Install bolts (12) to air duct (11). Tighten the bolts to a torque of 22 N m (195 lb in)
Ensure that elbow (1) is free from wear and damage. If necessary, replace the elbow.
Use Tooling (A) to lubricate the Allen head bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Use Tooling (A) to lubricate the Allen head bolt for V-band clamp (14). Position V-band clamp (14) onto turbocharger (19).
Position elbow (1) onto turbocharger (19) and turbocharger (3).
Tighten the Allen head bolt for V-band clamp (2) and the Allen head bolt for V-band clamp (14) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten the Allen head bolt for V-band clamp (2) and the Allen head bolt for V-band clamp (14) to a torque of 12 N m (106 lb in).
Connect harness assembly (8) to actuator (9).
Install new cable strap (7) to harness assembly (8).
Test wastegate actuator for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.End By:
Run an air systems motor valve verification test. Refer to Troubleshooting, "Air Systems Motor Valve Verification Test" for the correct procedure.