12100-87J02 Suzuki PISTON SET

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02570377
Ensure that turbocharger (15) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test wastegate actuator (28) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 2 g02570158
If necessary, follow Step 3.a through Step 3.i in order to install tube assembly (8) and tube assembly (14).
Ensure that tube assembly (8) and tube assembly (14) are clean and free from restriction. Clean the gasket surface of the cylinder block.
Position a new gasket (27) (not shown) onto tube assembly (14).
Position tube assembly (14) onto cylinder block. Install bolts (26) finger tight.
Install bolt (21) and spacer (22) (not shown) finger tight.
Tighten bolts (26) to a torque of 22 N m (195 lb in). Tighten bolt (21) to a torque of 18 N m (159 lb in).
Position a new sealing washer (24) (not shown) onto banjo bolt (23). Install banjo bolt (23) to tube assembly (8) and install remaining new sealing washer (24) (not shown) onto banjo bolt (23).
Position tube assembly (8) onto cylinder block. Tighten banjo bolt (23) finger tight.
Install clip (25) to tube assembly (8) and tube assembly (14). Note: Ensure that the clip is correctly positioned onto tube assemblies.
Tighten banjo bolt (23) to a torque of 40 N m (30 lb ft). Ensure tube assembly (8) is not strained as banjo bolts (23) is tightened. Note: Ensure that the tube assembly does not come into contact with any other engine component.
Illustration 3 g02568359
Clean the gasket surfaces of the exhaust manifold (20). If necessary, install studs (17) (not shown) to the turbocharger (15). Tighten the studs to a torque of 18 N m (13 lb ft).
Position a new gasket (16) (not shown) onto tube assembly (14).
Position a new gasket (16) (not shown) onto exhaust manifold (20).
Position turbocharger (15) on exhaust manifold (20). Note: Do not use the actuator rod to lift the turbocharger.
Install nuts (18). Tighten the nuts to a torque of 44 N m (32 lb ft).
Illustration 4 g02568360
Illustration 5 g02572637
Install bolts (13) to tube assembly (14).
Tighten bolts (13) to a torque of 9 N m (80 lb in).
Lubricate the bearings of turbocharger (15) with clean engine oil through oil inlet port (29). Rotate the shaft of the turbocharger in order to distribute the lubricant.
Position a new sealing washer (4) (not shown) onto banjo bolt (5). Install banjo bolt (5) onto tube assembly (8) and install remaining new sealing washer (4) (not shown) to banjo bolt (5).
Tighten banjo bolt (5) to a torque of 15 N m (133 lb in).
Install clip (9) from tube assembly (8) and tube assembly (14).
Position tube assembly (10) onto turbocharger. Install bolt (3) and bolt (11) finger tight.
Connect hose assembly (2) to the wastegate actuator. Slide hose clamp (12) along the hose assembly. Note: Ensure that hose clamp is correctly position onto the hose assembly.
Install the hose assembly to tube assembly (10). Slide hose clamp (12) along the hose assembly. Note: Ensure that hose clamp is correctly position onto the hose assembly.
Tighten bolt (3) and bolt (11) to a torque of 22 N m (195 lb in).
Connect the hose assemblies to turbocharger inlet (7) and to turbocharger outlet (6) (not shown). Tighten hose clamps securely End By:
Install the exhaust elbow from the turbocharger. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.