Turbocharger Removal and Installation - Suzuki Jimny Workshop Manual
1D
Turbocharger Removal and Installation
Removal
WARNING:
To avoid danger of being burned, do not service exhaust system while it is still hot. Service should be performed after system cools down.
1)
Disconnect negative (–) cable at battery.
2)
Remove air cleaner assembly referring to
Air Cleaner Assembly Removal and Installation:K9K
.
3)
Remove EGR valve body referring to
EGR Valve and Intake Pipe Removal and Installation:K9K
.
4)
Disconnect intercooler inlet hose (1).
5)
Remove exhaust pipe No.1 referring to
Exhaust System Components:K9K
.
6)
Remove lubrication pipe (1).
7)
Disconnect turbocharger oil return pipe (2) from turbocharger.
8)
Remove turbocharger assembly (3) from exhaust manifold (4), and then remove turbocharger oil return pipe (2) from cylinder block.
Installation
1)
Clean mating surfaces of turbocharger, exhaust pipe No.1 and exhaust manifold.
2)
Apply engine oil to new O-ring, and install turbocharger oil return pipe with new O-ring to cylinder block.
3)
Install turbocharger assembly (1) to exhaust manifold (2).
4)
Apply thread lock cement to thread part of lubrication pipe (3), and then install it.
Turbocharger nut (with flange) ( a ): 29 N·m ( 2.9 kg-m, 21.0 lb-ft)
Turbocharger oil return pipe bolt ( b ): 12 N·m ( 1.2 kg-m, 9.0 lb-ft)
Lubrication pipe ( c ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
Lubrication pipe union bolt (TORX® head type) ( d ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
Lubrication pipe union bolt (Hexagon head type) ( d ): 18 N·m ( 1.8 kg-m, 13.0 lb-ft)
Lubrication pipe clamp bolt ( e ): 12 N·m ( 1.2 kg-m, 9.0 lb-ft)
Tightening torque
Turbocharger nut (without flange)
(
a
):
25
N·m (
2.5
kg-m,
18.0
lb-ft)Turbocharger nut (with flange) ( a ): 29 N·m ( 2.9 kg-m, 21.0 lb-ft)
Turbocharger oil return pipe bolt ( b ): 12 N·m ( 1.2 kg-m, 9.0 lb-ft)
Lubrication pipe ( c ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
Lubrication pipe union bolt (TORX® head type) ( d ): 23 N·m ( 2.3 kg-m, 17.0 lb-ft)
Lubrication pipe union bolt (Hexagon head type) ( d ): 18 N·m ( 1.8 kg-m, 13.0 lb-ft)
Lubrication pipe clamp bolt ( e ): 12 N·m ( 1.2 kg-m, 9.0 lb-ft)
5)
Install exhaust pipe No.1 referring to
Exhaust System Components:K9K
.
6)
Connect intercooler inlet hose.
7)
Install EGR valve body referring to
EGR Valve and Intake Pipe Removal and Installation:K9K
.
8)
Install air cleaner assembly referring to
Air Cleaner Assembly Removal and Installation:K9K
.
9)
Connect negative (–) cable at battery.
10)
Using SUZUKI scan tool, cut fuel injection referring to “Operation Manual”.
11)
Crank engine for 15 seconds in order to lubricate turbocharger.
12)
Check to make sure that there is no oil leakage and exhaust gas leakage at each connection.