Suzuki Grand Vitara JB416 / JB420. Manual - part 12

1-iv Table of Contents

Valve Spring Inspection ....................................1D-41
Pistons, Piston Rings, Connecting Rods and 

Cylinders Components....................................1D-42

Pistons, Piston Rings, Connecting Rods and 

Cylinders Removal and Installation.................1D-42

Pistons, Piston Rings, Connecting Rods and 

Cylinders Disassembly and Assembly ............1D-44

Cylinders, Pistons and Piston Rings 

Inspection........................................................1D-45

Piston Pins and Connecting Rods Inspection ...1D-47
Crank Pin and Connecting Rod Bearings 

Inspection........................................................1D-48

Main Bearings, Crankshaft and Cylinder 

Block Components..........................................1D-52

Main Bearings, Crankshaft and Cylinder 

Block Removal and Installation .......................1D-53

Crankshaft Inspection .......................................1D-56
Main Bearings Inspection..................................1D-57
Sensor Plate Inspection ....................................1D-61
Rear Oil Seal Inspection ...................................1D-61
Flywheel Inspection...........................................1D-62
Cylinder Block Inspection..................................1D-62

Specifications.....................................................1D-63

Tightening Torque Specifications......................1D-63

Special Tools and Equipment ...........................1D-64

Recommended Service Material .......................1D-64
Special Tool ......................................................1D-64

For J20 Engine ......................................................1D-66

General Description ...........................................1D-66

Engine Construction Description.......................1D-66
Air Cleaner Element Introduction ......................1D-68
IMT (Intake Manifold Tuning) System 

Description ......................................................1D-68

Diagnostic Information and Procedures..........1D-70

Compression Check..........................................1D-70
Engine Vacuum Check......................................1D-71
Valve Lash (Clearance) Inspection ...................1D-72

Repair Instructions ............................................1D-75

Air Cleaner Assembly Removal and 

Installation.......................................................1D-75

Air Cleaner Filter Removal and Installation.......1D-75
Air Cleaner Filter Inspection and Cleaning........1D-75
Throttle Body and Intake Manifold 

Components....................................................1D-76

Throttle Body On-Vehicle Inspection.................1D-76
Electric Throttle Body Assembly Removal and 

Installation.......................................................1D-76

Throttle Body Cleaning......................................1D-77
Intake Manifold Removal and Installation .........1D-77
Cylinder Head Cover Removal and 

Installation.......................................................1D-78

Engine Mountings Components ........................1D-80
Engine Assembly Removal and Installation ......1D-81
Timing Chain Cover Components .....................1D-84
Timing Chain Cover Removal and Installation ..1D-84
Timing Chain Cover Cleaning and Inspection...1D-87
2nd Timing Chain and Chain Tensioner 

Components....................................................1D-87

2nd Timing Chain and Chain Tensioner 

Removal and Installation.................................1D-88

2nd Timing Chain and Chain Tensioner 

Inspection........................................................1D-91

1st Timing Chain and Chain Tensioner 

Components....................................................1D-91

1st Timing Chain and Chain Tensioner 

Removal and Installation.................................1D-92

1st Timing Chain and Chain Tensioner 

Inspection........................................................1D-94

Camshafts, Tappet and Shim Components ......1D-95
Camshafts, Tappet and Shim Removal and 

Installation .......................................................1D-96

Camshaft, Tappet and Shim Inspection ............1D-97
Valves and Cylinder Head Components .........1D-100
Valves and Cylinder Head Removal and 

Installation .....................................................1D-100

Valves and Cylinder Head Disassembly and 

Assembly.......................................................1D-102

Valves and Valve Guides Inspection...............1D-105
Cylinder Head Inspection ................................1D-107
Valve Spring Inspection ..................................1D-108
Pistons, Piston Rings, Connecting Rods and 

Cylinders Components..................................1D-109

Pistons, Piston Rings, Connecting Rods and 

Cylinders Removal and Installation...............1D-109

Pistons, Piston Rings, Connecting Rods and 

Cylinders Disassembly and Assembly ..........1D-110

Pistons, Piston Rings, Connecting Rods and 

Cylinders Inspection and Cleaning................1D-113

Main Bearings, Crankshaft and Cylinder 

Block Components ........................................1D-119

Main Bearings, Crankshaft and Cylinder 

Block Removal and Installation .....................1D-120

Main Bearings, Crankshaft and Cylinder 

Block Inspection ............................................1D-123

Specifications ...................................................1D-129

Tightening Torque Specifications....................1D-129

Special Tools and Equipment .........................1D-130

Recommended Service Material .....................1D-130
Special Tool ....................................................1D-130

Engine Lubrication System .................... 1E-1

For M16A Engine with VVT.....................................1E-1

General Description .............................................1E-1

Engine Lubrication Description ...........................1E-1

Diagnostic Information and Procedures ............1E-3

Oil Pressure Check .............................................1E-3

Repair Instructions ..............................................1E-4

Oil Pan and Oil Pump Strainer Components.......1E-4
Oil Pan and Oil Pump Strainer Removal and 

Installation .........................................................1E-5

Oil Pan and Oil Pump Strainer Cleaning.............1E-6
Oil Pump Components ........................................1E-7
Oil Pump Removal and Installation .....................1E-7
Oil Pump Disassembly and Reassembly ............1E-7
Oil Pump Inspection ............................................1E-8

Specifications .....................................................1E-10

Tightening Torque Specifications......................1E-10

Table of Contents 1-v

Special Tools and Equipment ........................... 1E-10

Recommended Service Material....................... 1E-10
Special Tool ......................................................1E-10

For J20 Engine ......................................................1E-11

General Description ........................................... 1E-11

Engine Lubrication Description .........................1E-11

Diagnostic Information and Procedures.......... 1E-13

Oil Pressure Check ........................................... 1E-13

Repair Instructions ............................................1E-14

Oil Pan and Oil Pump Strainer Components.....1E-14
Oil Pan and Oil Pump Strainer Removal and 

Installation.......................................................1E-15

Oil Pan and Oil Pump Strainer Cleaning........... 1E-16
Oil Pump Components......................................1E-16
Oil Pump Removal and Installation ...................1E-17
Oil Pump Disassembly and Assembly .............. 1E-17
Oil Pump Inspection ..........................................1E-18

Specifications..................................................... 1E-19

Tightening Torque Specifications......................1E-19

Special Tools and Equipment ........................... 1E-20

Recommended Service Material....................... 1E-20
Special Tool ......................................................1E-20

Engine Cooling System ...........................1F-1

General Description ............................................. 1F-1

Cooling System Description................................ 1F-1
Coolant Description............................................. 1F-1

Schematic and Routing Diagram........................ 1F-2

Coolant Circulation.............................................. 1F-2

Diagnostic Information and Procedures............ 1F-3

Engine Cooling Symptom Diagnosis................... 1F-3

Repair Instructions .............................................. 1F-4

Cooling System Components ............................. 1F-4
Coolant Level Check........................................... 1F-6
Engine Cooling System Inspection and 

Cleaning............................................................ 1F-6

Cooling System Draining .................................... 1F-7
Cooling System Flush and Refill ......................... 1F-7
Cooling Water Pipes or Hoses Removal and 

Installation......................................................... 1F-8

Thermostat Removal and Installation (For 

M16 Engine Model)........................................... 1F-8

Thermostat Removal and Installation (For J20 

Engine Model)................................................... 1F-9

Thermostat Inspection ........................................ 1F-9
Radiator Cooling Fan Motor On-Vehicle 

Inspection........................................................ 1F-10

Radiator Cooling Fan Relay Inspection............. 1F-10
Radiator Cooling Fan Assembly Removal and 

Installation....................................................... 1F-11

Radiator On-Vehicle Inspection and Cleaning .. 1F-11
Radiator Removal and Installation .................... 1F-12
Water Pump Removal and Installation (For 

M16 Engine Model)......................................... 1F-12

Water Pump Removal and Installation (For 

J20 Engine Model) .......................................... 1F-13

Water Pump Inspection..................................... 1F-13

Specifications..................................................... 1F-14

Tightening Torque Specifications...................... 1F-14

Special Tools and Equipment ........................... 1F-14

Recommended Service Material ....................... 1F-14

Fuel System ............................................. 1G-1

Precautions.......................................................... 1G-1

Precautions on Fuel System Service ................. 1G-1

General Description ............................................ 1G-1

Fuel System Description .................................... 1G-1
Fuel Delivery System Description ...................... 1G-1
Fuel Pump Description....................................... 1G-2

Schematic and Routing Diagram....................... 1G-2

Fuel Delivery System Diagram........................... 1G-2

Diagnostic Information and Procedures........... 1G-3

Fuel Pressure Inspection ................................... 1G-3
Fuel Cut Operation Inspection ........................... 1G-4

Repair Instructions ............................................. 1G-5

Fuel System Components.................................. 1G-5
Fuel Hose Disconnecting and Reconnecting ..... 1G-8
Fuel Pressure Relief Procedure ....................... 1G-10
Fuel Leakage Check Procedure....................... 1G-10
Fuel Lines On-Vehicle Inspection .................... 1G-10
Fuel Pipe Removal and Installation.................. 1G-10
Fuel Injector On-Vehicle Inspection ................. 1G-11
Fuel Injector Removal and Installation ............. 1G-11
Fuel Injector Inspection .................................... 1G-13
Fuel Pressure Regulator Removal and 

Installation ...................................................... 1G-14

Fuel Pressure Regulator Inspection................. 1G-15
Fuel Filler Cap Inspection ................................ 1G-15
Fuel Tank Inlet Valve Removal and 

Installation ...................................................... 1G-15

Fuel Tank Inlet Valve Inspection ...................... 1G-16
Fuel Tank Removal and Installation................. 1G-16
Fuel Tank Inspection........................................ 1G-18
Fuel Tank Purging Procedure .......................... 1G-18
Fuel Pump On-Vehicle Inspection.................... 1G-19
Fuel Pump Assembly Removal and 

Installation ...................................................... 1G-19

Main Fuel Level Sensor Removal and 

Installation ...................................................... 1G-20

Fuel Pump Inspection ...................................... 1G-21
Sub Fuel Level Sensor Removal and 

Installation ...................................................... 1G-21

Sub Fuel Level Sensor Inspection ................... 1G-21

Specifications.................................................... 1G-22

Tightening Torque Specifications..................... 1G-22

Special Tools and Equipment .......................... 1G-22

Recommended Service Material ...................... 1G-22
Special Tool ..................................................... 1G-23

Ignition System........................................ 1H-1

General Description .............................................1H-1

Ignition System Construction ..............................1H-1

Schematic and Routing Diagram........................1H-2

Ignition System Wiring Circuit Diagram...............1H-2

Component Location ...........................................1H-3

Ignition System Components Location................1H-3

Diagnostic Information and Procedures............1H-4

Ignition System Symptom Diagnosis...................1H-4

1-vi Table of Contents

Reference Waveform of Ignition System.............1H-4
Ignition System Check ........................................1H-4
Ignition Spark Test ..............................................1H-6

Repair Instructions ..............................................1H-7

High-Tension Cord Removal and Installation 

(For M16 Engine) ..............................................1H-7

High-Tension Cord Inspection (For M16 

Engine)..............................................................1H-7

Spark Plug Removal and Installation ..................1H-7
Spark Plug Inspection .........................................1H-8
Ignition Coil Assembly (Including ignitor) 

Removal and Installation...................................1H-8

Ignition Coil Assembly (Including ignitor) 

Inspection..........................................................1H-9

Ignition Timing Inspection .................................1H-10

Specifications.....................................................1H-11

Tightening Torque Specifications......................1H-11

Special Tools and Equipment ...........................1H-11

Special Tool ......................................................1H-11

Starting System ......................................... 1I-1

Precautions............................................................ 1I-1

Cranking System Note ......................................... 1I-1

General Description .............................................. 1I-1

Cranking Circuit Introduction................................ 1I-1
Starting Motor Circuit Description ........................ 1I-1

Diagnostic Information and Procedures............. 1I-2

Cranking System Symptom Diagnosis................. 1I-2
Starting Motor Performance Test ......................... 1I-4

Repair Instructions ............................................... 1I-5

Starting Motor Dismounting and Remounting ...... 1I-5
Starting Motor Components ................................. 1I-6
Starting Motor Inspection ..................................... 1I-7

Specifications...................................................... 1I-10

Starting Motor Specifications ............................. 1I-10
Tightening Torque Specifications....................... 1I-10

Special Tools and Equipment ............................ 1I-10

Recommended Service Material ........................ 1I-10

Charging System...................................... 1J-1

General Description ............................................. 1J-1

Battery Description.............................................. 1J-1

Generator Description ......................................... 1J-2

Diagnostic Information and Procedures ............ 1J-3

Battery Inspection ............................................... 1J-3
Generator Symptom Diagnosis ........................... 1J-4
Generator Test (Undercharged Battery 

Check)............................................................... 1J-4

Generator Test (Overcharged Battery Check) .... 1J-5

Repair Instructions .............................................. 1J-6

Jump Starting in Case of Emergency.................. 1J-6
Battery Dismounting and Remounting ................ 1J-7
Water Pump and Generator Drive Belt 

Removal and Installation (For M16 Engine)...... 1J-7

Water Pump and Generator Drive Belt 

Tension Inspection and Adjustment (For 
M16 Engine)...................................................... 1J-8

Water Pump and Generator Drive Belt On-

Vehicle Inspection (For J20 Engine) ................. 1J-9

Water Pump and Generator Drive Belt 

Removal and Installation (For J20 Engine) ..... 1J-10

Generator Dismounting and Remounting.......... 1J-11
Generator Components..................................... 1J-12
Generator Inspection......................................... 1J-13

Specifications ..................................................... 1J-16

Charging System Specifications ....................... 1J-16
Tightening Torque Specifications...................... 1J-16

Exhaust System....................................... 1K-1

General Description .............................................1K-1

Exhaust System Description ...............................1K-1

Diagnostic Information and Procedures ............1K-1

Exhaust System Check .......................................1K-1

Repair Instructions ..............................................1K-1

Exhaust System Components.............................1K-1
Exhaust Manifold Removal and Installation 

(For M16 Engine Model) ...................................1K-4

Exhaust Manifold Removal and Installation 

(For J20 Engine Model).....................................1K-4

Exhaust Pipe and Muffler Removal and 

Installation .........................................................1K-5

Specifications .......................................................1K-6

Tightening Torque Specifications........................1K-6

Precautions: 1-1

Engine

Precautions

Precautions

Precautions for Engine

S5JB0A1000001

Air Bag Warning
Refer to “Air Bag Warning in Section 00”.

Precautions on Engine Service
Refer to “Precautions on Engine Service in Section 1A”.

Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 1A”.

Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service in Section 1G”.

Engine Cooling System Warning
Refer to “Coolant Description in Section 1F”.

Cranking System Note
Refer to “Cranking System Note in Section 1I”.

Exhaust System Caution
Refer to “Exhaust System Check in Section 1K”.

Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in Section 00”.

Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter in Section 00”.

Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service in Section 00”.

Precautions of ECM Circuit Inspection
Refer to “Precautions of ECM Circuit Inspection in Section 1A”.

Precautions of Electric Throttle Body System Calibration
Refer to “Precautions of Electric Throttle Body System Calibration in Section 1A”.

Precaution in Replacing ECM
Refer to “Precaution in Replacing ECM in Section 10C”.