Suzuki Grand Vitara JB416 / JB420. Manual - part 103

 

  Index      Suzuki     Suzuki Grand Vitara JB416 / JB420- service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  101  102  103  104   ..

 

 

Suzuki Grand Vitara JB416 / JB420. Manual - part 103

 

 

1D-80 Engine Mechanical: For J20 Engine

Engine Mountings Components

S5JB0A1426043

(a)

9

(a)

7

(a)

7

(a)

(a)

9

(a)

1

2

1

3

5

6

(a)

(a)

(a)

8

(a)

8

4

I5JB0A142016-01

1. Engine front mounting

6. Engine splash cover

2. Engine front mounting right bracket

7. Engine front mounting nut

3. Engine front mounting left bracket

8. Engine rear mounting member bolt

4. Engine rear mounting member

9. Engine front mounting bracket bolt

5. Engine rear mounting

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)

Engine Mechanical: For J20 Engine 1D-81

Engine Assembly Removal and Installation

S5JB0A1426019

Removal

1) Relieve fuel pressure according to “Fuel Pressure 

Relief Procedure in Section 1G”.

2) Disconnect negative cable at battery.
3) Drain engine oil referring to “Engine Oil and Filter 

Change in Section 0B”.

4) Drain transmission oil referring to “Manual 

Transmission Oil Change in Section 5B”.

5) Drain A/T fluid referring to “A/T Fluid Change in 

Section 5A”.

6) Drain coolant referring to “Cooling System Draining 

in Section 1F”.

7) Remove Air cleaner case referring to “Air Cleaner 

Assembly Removal and Installation: For J20 
Engine”.

8) Remove water pump and generator drive belt 

referring to “Water Pump and Generator Drive Belt 
Removal and Installation (For J20 Engine) in Section 
1J”.

9) Disconnect the following electric wires:

• MAP sensor (1)
• ECT sensor (2)
• EGR valve (3)
• CMP sensor (4)
• EVAP canister purge valve (5)
• Ignition coil assembly (6)
• Injectors (7)
• HO2S  (8)
• A/F sensor (9)
• Engine oil pressure switch (10)
• CKP sensor (11)
• Back up light switch (For M/T model) (12)
• Generator (13)
• Starting motor (14)
• Ground terminal
• Magnet clutch switch of A/C compressor (if 

equipped) (15)

• P/S pump (16)
• Electric throttle body (17)
• Transfer actuator (18)
• Center differential switch (19)
• 4L/N switch (20)
• Each wire harness clamps 
• Input shaft speed sensor (For A/T model) (26)
• Output shaft speed sensor (For A/T model) (27)
• Solenoid valve (For A/T model) (28)
• Transmission range sensor (For A/T model) (29)

10) Disconnect the following hoses: 

• Brake booster hose (21) from intake manifold
• Radiator inlet and outlet hoses (22) from each 

pipe

• Heater inlet and outlet hoses (23) from each pipe
• Fuel hoses (24) from fuel pipes
• Purge hose (25) from purge valve
• Clutch oil pipe from transmission front case (For 

M/T model) 

• A/T fluid cooler hoses from radiator (For A/T 

model) 

11) Disconnect A/T select cable from A/T (For A/T 

model).

21

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

19

20

18

22

23

24

25

26

27

28

29

I5JB0A142017-01

1D-82 Engine Mechanical: For J20 Engine

12) For M/T model, remove shift control lever referring to 

“Transmission Shift Control Lever Removal and 
Installation in Section 5B”.

13) Remove exhaust No.1, No.2 and center pipes 

referring to “Exhaust System Components in Section 
1K”.

14) Remove front and rear propeller shafts referring to 

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

15) With hose connected, detach P/S pump from its 

bracket (if equipped) referring to “P/S Pump 
Removal and Installation for J20 Engine Model in 
Section 6C”.

CAUTION

!

 

Suspend removed P/S pump at a place where 
no damage will be caused during removal 
and installation of engine assembly.

 

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

its bracket (if equipped) referring to “Compressor 
Assembly Removal and Installation for J20 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.

 

17) Support front suspension frame and engine rear 

mounting member using jack (2).

18) 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.

19) Remove front suspension frame mounting bolts (1).

20) Remove engine rear mounting member bolts (1).

21) Before lowering engine, recheck to make sure all 

hoses, electric wires and cables are disconnected 
from engine.

22) Lower engine with transmission, transfer, front 

suspension frame and engine rear mounting 
member 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.

 

23) Disconnect transmission from engine referring to 

“Manual Transmission Assembly Dismounting and 
Remounting in Section 5B” 
or “Automatic 
Transmission Unit Components in Section 5A”
, if 
necessary.

24) Remove engine with engine front mounting bracket 

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

25) Remove clutch cover and clutch disk referring to 

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

1

2

I5JB0A142018-01

1

1

I5JB0A142019-01

1

2

1

2

I5JB0A142020-01

Engine Mechanical: For J20 Engine 1D-83

Installation

1) Install clutch cover and clutch disk referring to 

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

2) Install engine with engine front mounting bracket to 

engine front mounting. For tightening torque, 
referring to “Engine Mountings Components: For J20 
Engine”, if 
removed.

3) Connect transmission from engine referring to 

“Manual Transmission Assembly Dismounting and 
Remounting in Section 5B”
 or “Automatic 
Transmission Unit Components in Section 5A”,
 if 
removed.

4) Lift engine with transmission, front suspension frame 

and engine rear mounting member into engine 
compartment with jack.

CAUTION

!

 

Before lifting engine, 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 J20 Engine”.

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 J20 Engine Model in Section 7B”.

11) Install P/S pump to its bracket referring to “P/S Pump 

Removal and Installation for J20 Engine Model in 
Section 6C”
.

12) Return disconnected hoses, cables and electric wire 

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 water pump and generator drive belt referring 

to “Water Pump and Generator Drive Belt Removal 
and Installation (For J20 Engine) in Section 1J”
.

14) Adjust water pump and generator drive belt tension 

referring to “Water Pump and Generator Drive Belt 
On-Vehicle Inspection (For J20 Engine) in Section 
1J”.

15) Install air cleaner assembly referring to “Air Cleaner 

Assembly Removal and Installation: For J20 
Engine”.

16) Check all removed parts are back in place.
17) For A/T model, adjust select cable referring to 

“Select Cable Adjustment in Section 5A”.

18) Refill cooling system with coolant referring to 

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

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

and Filter Change in Section 0B”.

20) Bleed air from clutch system referring to “Air 

Bleeding of Brake System in Section 4A” for air 
bleeding procedure.

21)  Install engine hood after disconnecting windshield 

washer hose.

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

and check for fuel leakage.

24) Start engine and check coolant, oil and exhaust gas 

leakage at each connection.

 

 

 

 

 

 

 

Content   ..  101  102  103  104   ..