17681-96J00 Suzuki COVER, THERMOSTAT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-4653 Counterweight Tool 1
B 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02176197
Ensure that turbocharger (4) 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.
Test wastegate actuator (24) 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.
Illustration 2 g02175963
Clean the gasket surface of exhaust manifold (20). If necessary, install studs (23) to turbocharger (4). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (22) to turbocharger (4).
Position turbocharger (4) onto the exhaust manifold and install nuts (21) finger tight. The nuts (21) should not constrain the turbocharger and prevent Tooling (A) from correctly positioning the turbocharger onto the exhaust manifold.
Use Tooling (A) to align turbocharger (4). Note: Ensure that the turbocharger is correctly oriented.
Tighten nuts (21) to a torque of 44 N m (32 lb ft).
Remove Tooling (A) from turbocharger (4).
Illustration 3 g02176198
Illustration 4 g02175962
Remove plugs and caps from tube assemblies. Ensure that tube assembly (19) and tube assembly (15) are clean and free from damage. Replace any damaged components.
Position a new gasket (17) (not shown) onto tube assembly (19).
Install bolts (18) to tube assembly (19). Tighten the bolt to a torque of 9 N m (80 lb in).
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 in order to lubricate the bearings.
Install a new sealing washer (16) to banjo bolt (14). Install banjo bolt (14) to tube assembly (15) and install remaining sealing washers (16) to banjo bolt (14).
Tighten banjo bolt (14) to a torque of 20 N m (177 lb in).
Illustration 5 g02175961
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (6). Position V-band clamp (6) onto air duct (13).
Position hose assembly (12) and air duct (13) onto the outlet of turbocharger (10) and turbocharger (4). Ensure that the V-band clamp (6) is seated correctly onto the turbochargers.
Tighten the allen head bolt for V-band clamp (6) to a torque of 12 N m (106 lb in).
Tighten hose clamps (11) to a torque of 6 N m (53 lb in).
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (9). Position V-band clamp (9) onto turbocharger (10).
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (3). Position V-band clamp (3) onto elbow (1).
Position elbow (1) onto turbocharger (10) and turbocharger (4).
Tighten allen head bolt for V-band clamp (3) and V-band clamp (9) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten allen head bolt for V-band clamp (3) and V-band clamp (9) to a torque of 12 N m (106 lb in).
Connect hose assembly (2) to the wastegate actuator. Note: Ensure that the clip for hose assembly is correctly positioned.
Connect hose assembly (7) to the connection in outlet of turbocharger (4). Note: Ensure that the clip for hose assembly is correctly positioned.
Install bolt (8) to clip for tube assembly. Tighten the bolt to a torque of 22 N m (195 lb in).
Connect hose assembly to air outlet (5) of turbocharger (4). Tighten the hose clamps securely.