by Bill Sutton » Sun Sep 27, 2015 21:49
OK, the good news, It is the right part, at £21 much cheaper than Suzukis offer of a new turbo £200+. The bad news.........................
This is the worst job I have ever attempted in 30years of vehicle maintenance. There is very little access to the top bolt requiring hose/manifold/heat shield removal, and the bottom bolt is virtually impossible to access being behind the water in/out pipes. I did manage to undo it, but then have no way of refitting it as my hands cant get anywhere near the hole to line the bolt up. I spent 4 hours trying and reassembled with one bolt only in the hope that it doesn't involve a lot of force to open the waste gate and that it won't matter. I did consider removing the entire turbo, but the exhaust studs are solid and would have sheared, causing much more work. This car was designed by sadists, and whilst the aesthetic of making something so small but perfectly formed counts for something, another 1/2" clearance all round would have made it a much more serviceable vehicle. even from underneath there isn't a gap wide enough for a human hand to pass through, and I even considered dropping the whole sub frame and engine for access, till I noticed that it had been welded to the body by someone at some point rendering that option null and void without angle grinding it off again and presumably re welding on completion
So, was it worth it? It doesn't reek of exhaust gas recirculation any more, Hooray!! it still makes a strange moaning noise, so it wasn't the diaphragm doing that after all. I have discovered an after market variable turbo boost also fitted. Do they moan? and to cap it all, one of the water hoses won't seal with the jubilee clip re used, it only becomes apparent when the engines warm and pressurised, then it squirts steam out like a steam engine, quite spectacular/disturbing to say the least. So it will all have to come out again to access the hose and fit another clip, or hose depending on the damage.
Would I recommend this as a DIY fix? no way, if you've got the dosh pay someone, they'll hate you for evermore and probably rob you blind for the privelege, it was ever thus.