61435-90J81 Suzuki MARK, EMBLEM REAR (115)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite Nickel Anti-Seize - Note: If reusing the exhaust elbow, refer to Special Instruction, REHS5014, "Reuse Guideline for the Lines Group - Flexpipe on Tier 4 Engines".
Illustration 1 g03423737
Remove step (1) and panel (2).
Illustration 2 g02306375
Illustration 3 g03423463
Remove sensor (10 ). Loosen clamp assemblies (3), (5), and (7). Note: Mark the orientation of clamp assembly (5) prior to removal.
Slide elbow (4) into bellows (6) in order to gain clearance. Remove the bellows assembly. Note: Mark the orientation of tube assembly (8) prior to removal.
Loosen clamp assembly (9) and remove tube assembly (8). Installation Procedure
Note: If reusing the exhaust elbow, refer to Special Instruction, REHS5014, "Reuse Guideline for the Lines Group - Flexpipe on Tier 4 Engines".
Illustration 4 g02340277
Illustration 5 g02340280
Alignment Wrap (A) is not shown for photographic purposes.
Note: Alignment Wrap (A) will be included with the new bellows assembly. The Tooling will be pre-installed on the bellows. Note: The Alignment Wrap (A) should not be removed until Step 11. Bellows (6) should never be flexed during installation.
Place Mark (B) onto elbow (4). Mark (B) should be a distance of Dimension (X) from the end of elbow (3). Dimension (X) is 40 mm (1.6 inch).
Insert elbow (4) into bellows (6). Elbow (4) should be inserted as far as possible without using force. The action will minimize the overall length of the bellows assembly and will help with installation.
Illustration 6 g02306375
Alignment wrap (A) is not shown for photographic purposes.
Illustration 7 g02340356
The photo is a cutaway view of the ball clamp assembly which is located near the combustion head group.
Illustration 8 g02340357
Cutaway view of the ball clamp assembly.
Position tube assembly (8) and tighten clamp assembly (9).
Prior to installation, position both ball clamp assemblies (3) and (7) onto the bellows assembly.
Position the bellows assembly between the Clean Emissions Module and the turbocharger adapter. Adjust the length of elbow (4) in the slip joint at clamp assembly (5) in order to position the bellows assembly.
Verify that the cup of the Ball Joint (E) does not touch the radius of the Ball (D). Position ball clamp (3) and hand tighten ball clamp (3). Measure Dimension (Y) and Dimension (Z). Dimension (Y) and Dimension (Z) should be equal to each other. Repeat the measurements every 90° around ball clamp (3). If necessary, adjust ball clamp (3).
Repeat Step 6 for ball clamp (7) which is located near the turbocharger.
Verify that Mark (B) is not visible at the slip joint that is positioned near clamp assembly (5). Note: Do not use power tools in order to torque clamp assemblies (3), (5), and (7).
Torque ball clamp (3) to a torque of 35 2 N m (26 1 lb ft).
Torque ball clamp (7) to a torque of 35 2 N m (26 1 lb ft).
Remove alignment wrap (A) from bellows (6).
Torque clamp assembly (5) to a torque of 55 8 N m (41 6 lb ft).
Apply Tooling (A) to the threads of sensor (10). Tighten sensor (10) to a torque of 50 10 N m (37 7 lb ft).
Illustration 9 g03423737
Install step (1) and panel (2).