61142-95200 Suzuki Grommet

Table 1
Required Tools
Tool Part Number Part Description Qty
B 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03459376
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.
Test wastegate actuator (25) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.
Illustration 2 g03459363
Clean the gasket surface of exhaust manifold (21). If necessary, install studs (24) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (23) to studs (24).
Position turbocharger (3) onto the exhaust manifold and loosely install nuts (22). Note: Ensure that the turbocharger is correctly oriented.
Illustration 3 g03459362
Illustration 4 g03459359
Turbocharger tightening sequence viewed from the exhaust manifold.
Apply sufficient pressure in Position (A) to ensure that the studs (24) are in the lowest position on manifold (21) and horizontal. Do not release the pressure from the turbocharger in Position (A) until nuts (22) have been tightened securely.
Tighten nuts (22) in the sequence shown in Illustration 4 to a torque of 44 N m (32 lb ft).
Illustration 5 g03459358
Illustration 6 g03459357
Remove plugs and caps from tube assemblies. Ensure that tube assembly (20) and tube assembly (16) are clean and free from damage. Replace any damaged components.
Position a new gasket (18) (not shown) onto tube assembly (20). Install bolts (19) to tube assembly (20). Tighten bolt (19) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (26). 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 (17) to banjo bolt (15). Install the banjo bolt to tube assembly (16). Install the remaining new sealing washer (17) to banjo bolt (15).
Position tube assembly (16) onto turbocharger (3). Tighten the banjo bolt to a torque of 20 N m (177 lb in).
Illustration 7 g03459356
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (4). Position V-band clamp (4) onto air duct (14).
Position hose assembly (10) and air duct (14) onto the outlet of (3) turbocharger and the turbocharger. Ensure that V-band clamp (4) is correctly seated on the air duct (14) and turbocharger (3).
Tighten allen head bolt for V-band clamp (4) to a torque of 12 N m (106 lb in)
Tighten hose clamps (9) to a torque of 6 N m (53 lb in).
Ensure that elbow (1) is free from wear and damage. If necessary, replace the elbow that is worn or damaged.
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (2) and the allen head bolt for V-band clamp (8).
Position V-band clamp (8) onto the turbocharger.
Position V-band clamp (2) onto elbow (1).
Position elbow (1) onto turbocharger (3) and the turbocharger. Install V-band clamp (2) and V-band clamp (8).
Tighten the allen head bolt for V-band clamp (2) and the allen head bolt for V-band clamp (8) 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 V-band clamp (8) to a torque of 12 N m (106 lb in).
Connect hose assembly (6) (not shown) to the wastegate actuator. Slide clip (3) along the hose assembly ensure that the clip is correctly positioned.
Connect hose assembly (14) to turbocharger (3). Slide clip (13) along the hose assembly ensure that the clip is correctly positioned.
Install bolt (7) (not shown) to the clip for the tube assembly. Tighten the bolt to a torque of 22 N m (195 lb in).
Connect hose assembly to air outlet (11) to turbocharger (3). Tighten the hose clamps securely.