Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 159
1D-162 Engine Mechanical: For F9Q Engine
Installation
CAUTION
!
Before starting engine (including when
performing oil level check and air bleeding
process of cooling system) for the first time
after installing turbocharger, be sure to
lubricate turbocharger while disabling engine
to start according to the following procedure.
Otherwise, lack of lubrication will cause
turbocharger damage.
1. Disconnect fuel pressure sensor
connector.
2. Crank engine for 20 seconds to lubricate
turbocharger with engine oil.
3. Connect fuel pressure sensor connector.
4. As DTC is stored in ECM memory in Step
2), make sure to clear it.
1) Install turbocharger lubrication pipe union nut (1)
with new copper ring, turbocharger lubrication pipe
(2), turbocharger water inlet pipe (3) and
turbochanger water outlet pipe (4) to turbocharger
with new gasket and new clamp, if removed.
Tightening torque
Turbocharger lubrication pipe union nut (a): 36
N·m (3.6 kgf-m, 26.5 lb-ft)
Turbocharger lubrication pipe union bolt
(turbocharger side) (b): 16 N·m (1.6 kgf-m, 12.0
lb-ft)
Turbocharger water inlet pipe union bolt (c): 29
N·m (2.9 kgf-m, 21.0 lb-ft)
Turbocharger water outlet pipe union bolt (d):
29 N·m (2.9 kgf-m, 21.0 lb-ft)
2) Install turbocharger (1) to exhaust manifold with new
gasket.
Tightening torque
Turbocharger nut (a): 37 N·m (3.7 kgf-m, 27.0 lb-
ft)
3) Fit turbocharger inlet pipe (2) to turbocharger.
Tighten turbocharger inlet pipe bolt by hand
temporarily.
4) Tighten turbocharger inlet pipe clamp by specified
torque.
Tightening torque
Turbocharger inlet pipe clamp (i): 2.5 N·m (0.25
kgf-m, 2.0 lb-ft)
5) Tighten turbocharger inlet pipe bolt by specified
torque.
Tightening torque
Turbocharger inlet pipe (b): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Install exhaust manifold heat shield (3) to exhaust
manifold.
Tightening torque
Exhaust manifold heat shield bolt (c): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
7) Connect turbocharger lubrication pipe (4) and
lubrication pipe stiffeners to cylinder block.
Tightening torque
Turbocharger lubrication pipe union bolt
(cylinder block side) (d): 44 N·m (4.4 kgf-m, 32.0
lb-ft)
Turbocharger lubrication pipe stiffener bolt (e):
25 N·m (2.5 kgf-m, 18.0 lb-ft)
8) Install oil return pipe No.1 (5) and No.2 (6) with new
gasket and O-ring.
Tightening torque
Oil return pipe No.1 bolt (f): 12 N·m (1.2 kgf-m,
9.0 lb-ft)
Oil return pipe No.1 stiffener bolt (g): 12 N·m (
1.2 kgf-m, 9.0 lb-ft)
Oil return pipe No.2 bolt (h): 12 N·m (1.2 kgf-m,
9.0 lb-ft)
9) Connect boost pressure control actuator hose (7) to
boost pressure control actuator.
10) Connect turbocharger water inlet hose (8) and outlet
hose (9).
2
1, (a)
3
4
(b)
(c)
(d)
I5JB0B140055-04