09160-35002 Suzuki WASHER (35X46X1.00)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02529479
Ensure that turbocharger (8) 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.
If necessary, follow Step 2.a through Step 2.b in order to install bracket (23) onto cylinder block (24).
Position bracket (23) onto cylinder block (24). Install bolts (25). Note: Ensure that the camshaft position sensor is not damaged during the installation of the bracket.
Tighten bolts (25) to a torque of 44 N m (32 lb ft).
If necessary, install studs (22) to turbocharger (8). Tighten the studs to a torque of 18 N m (159 lb in).
Install turbocharger (6) onto bracket (23).
Install nuts (26) and hand tighten the nuts.
Tighten the nuts to a torque of 44 N m (32 lb ft).
Illustration 2 g02529478
Illustration 3 g02529636
Position a new gasket (13) (not shown) and a new gasket (20) (not shown) onto tube assembly (17).
Position tube assembly (17) onto turbocharger (8) and the cylinder block.
Install bolts (15) and bolts (19).
Tighten bolts (15) and bolts (19) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (27). 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.
Remove plugs from tube assembly (14). Ensure that tube assembly (14) is clean and free from restriction. Replace any damaged components.
Position a new gasket (10) (not shown) onto turbocharger (8).
Position tube assembly (14) onto turbocharger (8) and the cylinder block. Loosely install bolts (11) to the tube assembly.
Position a new sealing washer (18) (not shown) onto banjo bolt (16).
Install banjo bolt (16) to hose assembly (14). Install the remaining new sealing washer (18) (not shown) to banjo bolt (16).
Install bolt (21) to clamp for hose assembly (14).
Tighten banjo bolt (16) to a torque of 40 N m (29 lb ft). Tighten bolts (11) to a torque of 22 N m (195 lb in).Tighten bolts (21) to a torque of 22 N m (195 lb in).
Remove plug from hose assembly (12) and connection on turbocharger (8). Ensure that hose assembly (12) and connection are clean and free from restriction. Replace any damaged components.
Connect hose assembly (12) from the connection on turbocharger (8). Tighten tube nut for hose assembly (12) on turbocharger (8) to a torque of 30 N m (265 lb in).
Illustration 4 g02529457
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (4). Position V-band clamp (4) onto air duct (5).
Position hose assembly (6) and air duct (5) onto the outlet of turbocharger (8) and turbocharger (3). Tighten the allen head volt V-band clamp to a torque of 12 N m (106 lb in).
Tighten hose clamps (9) securely.
Ensure that elbow (1) is free from wear and damage. If necessary, replace the elbow that is worn or damaged.
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 (7). Position V-band clamp (7) onto turbocharger (8).
Position elbow (1) onto turbocharger (3) and turbocharger (8).
Tighten V-band clamp (2) and V-band clamp (7) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten allen head bolt for V-band clamp (2) and allen head bolt for V-band clamp (7) to a torque of 12 N m (106 lb in).
Connect the air inlet hose to the turbocharger and tighten the hose clamp securely. End By:
Install the exhaust elbow to the second stage turbocharger. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.