Suzuki Grand Vitara JB416 / JB420. Manual - part 87

1D-16 Engine Mechanical: For M16A Engine with VVT

17) With hose connected, detach A/C compressor from 

its bracket (if equipped) referring to “Compressor 
Assembly Removal and Installation for M16 Engine 
Model in Section 7B”.

CAUTION

!

 

Suspend removed A/C compressor at a place 
where no damage will be caused during 
removal and installation of engine assembly.

 

18) Support front suspension frame and engine rear 

mounting member using jack (2).

19) Carry out Step 1) to 12) of “Removal” under “Front 

Suspension Frame, Stabilizer Bar and/or Bushings 
Removal and Installation in Section 2B” in order to 
lower engine with front suspension frame.

20) Remove front suspension frame mounting bolt (1).

21) Remove engine rear mounting member bolt (1).

22) Before lowering engine with transmission and front 

suspension frame from engine compartment, 
recheck to make sure all hoses, electric wires and 
cables are disconnected from engine.

23) Lower engine with transmission and front 

suspension frame from engine compartment.

CAUTION

!

 

Before lowering engine, in order to avoid 
damage to A/C compressor and P/S pump, 
make clearance by rising them.

 

24) Disconnect transmission from engine referring to 

“Manual Transmission Assembly Dismounting and 
Remounting in Section 5B”, if necessary.

25) Remove engine with engine front mounting bracket 

(1) from engine front mounting (2), if necessary.

26) Remove clutch cover and clutch disc referring to 

“Clutch Cover, Clutch Disc and Flywheel Removal 
and Installation in Section 5C”, if necessary.

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Engine Mechanical: For M16A Engine with VVT 1D-17

Installation

1) Install clutch cover and clutch disc referring to 

“Clutch Cover, Clutch Disc and Flywheel Removal 
and Installation in Section 5C”, if necessary.

2) Install engine with engine front mounting bracket to 

engine front mounting.
For tightening torque, refer to “Engine Mountings 
Components: For M16A Engine with VVT”, if 
necessary.

3) Connect transmission to engine referring to “Manual 

Transmission Assembly Dismounting and 
Remounting in Section 5B”, if necessary.

4) Lift engine with transmission and front suspension 

frame into engine compartment with jack.

CAUTION

!

 

Before lifting engine, in order to avoid 
damage to A/C compressor and P/S pump, 
make clearance by rising them.

 

5) Tighten engine rear mounting member bolt referring 

to “Engine Mountings Components: For M16A 
Engine with VVT”.

6) Carry out Step 5) to 19) of “Installation” under “Front 

Suspension Frame, Stabilizer Bar and/or Bushings 
Removal and Installation in Section 2B” in order to lift 
engine with front suspension frame.

7) Remove engine jack.
8) Install front and rear propeller shafts referring to 

“Propeller Shaft Removal and Installation in Section 
3D”.

9) Install exhaust No.1, No.2 and center pipes referring 

to “Exhaust System Components in Section 1K”.

10) Install A/C compressor to its bracket (if equipped) 

referring to “Compressor Assembly Removal and 
Installation for M16 Engine Model in Section 7B”.

11) Install P/S pump to its bracket (if equipped) referring 

to “P/S Pump Removal and Installation for M16 
Engine Model in Section 6C”.

12) Return disconnected hoses, cables and electric 

wires noting the followings.
• Tighten nuts to specified torque.

Tightening torque
Starting motor terminal nut:  11 N·m (1.1 kgf-m, 
8.0 lb-ft)
Generator terminal nut:  7 N·m (0.7 kgf-m, 5.0 lb-
ft)

13) Install P/S pump and A/C compressor (if equipped) 

drive belt referring to “P/S Pump and A/C 
Compressor (If Equipped) Drive Belt Removal and 
Installation for M16 Engine Model in Section 6C”.

14) Adjust P/S pump and A/C compressor (if equipped) 

drive belt tension referring to “P/S Pump and A/C 
Compressor (If Equipped) Drive Belt Inspection and 
Adjustment for M16 Engine Model in Section 6C”.

15) Install air cleaner case (2).
16) Connect MAF sensor connector (1).

17) Install air intake pipe (2).
18) Connect breather union (1) to air intake pipe (2).

19) Check all removed parts are back in place.
20) Refill cooling system with coolant referring to 

“Cooling System Flush and Refill in Section 1F”.

21) Refill engine with engine oil referring to “Engine Oil 

and Filter Change in Section 0B”.

22) Install engine hood after disconnecting windshield 

washer hose.

23) After installation, bleed air from clutch system.

Refer to “Air Bleeding of Brake System in Section 
4A” for air bleeding procedure.

24) Connect negative cable at battery.
25) With engine OFF, turn ignition switch to ON position 

and check for fuel leakage.

26) Start engine and check coolant oil and exhaust gas 

leakage at each connection.

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1D-18 Engine Mechanical: For M16A Engine with VVT

Timing Chain Cover Components

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1. Crankshaft pulley bolt

9. Oil gallery pipe No.1

17. Oil control valve

2. Crankshaft pulley

 10. Copper washer

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

3. Oil seal

: Apply engine oil to oil seal lip.

11. Oil gallery pipe No.1 bolt

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

4. Timing chain cover

: Apply sealant 99000-31140 to the mating surface 
of cylinder and cylinder head.
: Apply sealant 99000-31260 to the mating surface 
of timing chain cover referring to the figure of Step 5) 
of “Installation” under “Timing Chain Cover Removal 
and Installation: For M16A Engine with VVT”.

12. Oil gallery pipe No.2

: 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft)

5. Pin

13. Oil gallery pipe No.2 bolt

: 150 N

⋅m (15.0 kgf-m, 108.5 lb-ft)

6. Oil control valve mounting nut

14. Oil gallery pipe No.3

: Do not reuse.

7. Timing chain cover mounting bolts

15. Oil gallery pipe No.3 bolt

8. Timing chain cover mounting nut

16. O-ring

: Apply engine oil.

Engine Mechanical: For M16A Engine with VVT 1D-19

Timing Chain Cover Removal and Installation

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CAUTION

!

 

• Keep working table, tools and hands clean 

while overhauling.

• Use special care to handle aluminum parts 

so as not to damage them.

• Do not expose removed parts to dust. 

Keep them always clean.

 

Removal

1) Remove engine assembly from vehicle referring to 

“Engine Assembly Removal and Installation: For 
M16A Engine with VVT”.

2) Remove P/S pump and A/C compressor (if 

equipped) drive belt referring to “P/S Pump and A/C 
Compressor (If Equipped) Drive Belt Removal and 
Installation for M16 Engine Model in Section 6C”.

3) Remove water pump and generator drive belt 

referring to “Water Pump and Generator Drive Belt 
Removal and Installation (For M16 Engine) in 
Section 1J”.

4) Remove crankshaft pulley bolt.

To lock crankshaft pulley (1), use special tool with it 
as shown in the figure.

Special tool
(A):  09917–68221

5) Remove crankshaft pulley (1).

If it is hard to remove, use special tools as shown in 
the figure.

Special tool
(A):  09944–36011
(B):  09926–58010

6) Remove cylinder head cover referring to “Cylinder 

Head Cover Removal and Installation: For M16A 
Engine with VVT”.

7) Remove oil pan referring to “Oil Pan and Oil Pump 

Strainer Removal and Installation: For M16A Engine 
with VVT in Section 1E”.

8) Remove water pump pulley.
9) Remove A/C compressor bracket and P/S pump 

bracket from cylinder block.

10) Remove oil gallery pipes No.2 (1) and No.3 (2).

11) Remove water outlet pipe (1) from timing chain 

cover.

12) Remove timing chain cover (2).

13) Remove oil control valve from timing chain cover 

referring to “Oil Control Valve Removal and 
Installation: For M16A Engine with VVT”, if 
necessary.

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