09160-35003 Suzuki WASHER (35X46X1.10)

Illustration 1 g02522557
If the Diesel Particulate Filter (DPF) assembly is mounted on the valve mechanism cover, removal of the DPF assembly will be necessary in order to access the wastegate solenoid. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" for the correct procedure.
Loosen hose clamps and remove hose assembly from connection (12).
Remove plastic tube assembly (2) from the valve mechanism cover and the crankcase breather canister.
Slide locking tab (13) into the unlocked position. Disconnect harness assembly (5) from the harness assembly for wastegate solenoid (3).
Slide the harness assembly for wastegate solenoid (3) from bracket (4).
Remove bolts (9) from tube assembly (1).
Remove banjo bolt (11) and remove sealing washers (10) (not shown).
Cut cable straps (8) from harness assembly (5). Position harness assembly (5) away from NRS induction mixer.
Remove nut (7) and bolts (14).
Remove the assembly of inlet connection (12) from the NRS induction mixer assembly.
Remove gasket (6) (not shown) and gasket (15) (not shown).
Illustration 2 g02522558
Remove allen head bolts (15) from wastegate solenoid (3). Remove bracket (4).
Remove wastegate solenoid (3) from inlet connection (12).
Plug inlet connection (12) and cap wastegate solenoid (3) with new plugs and caps. Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that all components of the wastegate solenoid are clean and free from wear and damage. If necessary, replace the wastegate solenoid as an assembly if any of the components are worn or damaged.
Illustration 3 g02522577
Ensure that O-ring seal (16), O-ring seal (17), and O-ring seal (18) on wastegate solenoid (3) are free from damage and wear.
If the O-ring seals are damaged or worn, the wastegate solenoid should be replaced as an assembly.
Ensure that the ports in Position (X) are clean and free from restriction.
Remove the cap from wastegate solenoid (3) and remove plug from inlet connection (12).
Use Tooling (A) in order to lubricate O-ring seal (16), O-ring seal (17), and O-ring seal (18) on wastegate solenoid (3).
install wastegate solenoid (3) to inlet connection (12).
Position bracket (4) onto wastegate solenoid (3). Note: Ensure that the bracket is correctly orientated.
Install allen head bolts (15) to wastegate solenoid (3). Tighten the allen head bolts to a torque of 9 N m (80 lb in).
Illustration 4 g02522557
Illustration 5 g02524456
Position a new gasket (6) and a new gasket (15) (not shown) onto the NRS induction mixer assembly. Ensure that gasket (6) and gasket (15) (not shown) is correctly located on Pins (Y).
Position the assembly on inlet connection (12) onto the NRS induction mixer assembly.
Install nut (7) and bolts (14).
Tighten nut (7) and bolts (14) to a torque 22 N m (195 lb in).
Position a new sealing washer (10) (not shown) onto banjo bolt (11). Install banjo bolt (11) to tube assembly (1) and install the remaining new sealing washer (10) (not shown) onto the banjo bolt. Tight the banjo bolt finger tight
Install bolts (9) to tube assembly (1). Tighten the bolts to a torque 22 N m (195 lb in).
Tighten banjo bolt (11) to a torque 15 N m (133 lb in).
Slide the harness assembly for wastegate solenoid (3) onto bracket (4).
Position harness assembly (5) onto NRS induction mixer. Install new cable straps (8) to harness assembly (5). Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specification.
Connect harness assembly (5) to the harness assembly for wastegate solenoid (3). Slide locking tab (13) into the locked position.
Install plastic tube assembly (2) to the valve mechanism cover and the crankcase breather canister.
Install hose assembly onto connection (12). Tighten hose clamps securely.
If the Clean Emissions Module (CEM) assembly was mounted on the valve mechanism cover, installation of the DPF assembly will be necessary after the installation of the wastegate solenoid. Refer to Disassembly and Assembly, "Clean Emissions Module - Remove and Install" for the correct procedure.