Suzuki Grand Vitara JB416 / JB420. Manual - part 140

1K-2 Exhaust System: 

For M16 Engine Model

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[A]: Installing location of exhaust manifold bold and nut.

9. Exhaust pipe No.2

18. Exhaust pipe No.1 bracket bolt

1. Exhaust manifold gasket

10. Exhaust center pipe

19. Exhaust center pipe nut

2. Exhaust manifold

11. Muffler

20. Exhaust center pipe gasket

3. Exhaust pipe No.1 bracket

12. Mounting

: 45 N

⋅m (4.5 kgf-m, 32.5 lb-ft)

4. HO2S

13. A/F sensor

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

5. Exhaust pipe No.1 gasket

14. Exhaust manifold bolt

: 43 N

⋅m (4.3 kgf-m, 31.0 lb-ft)

6. No.1 seal ring

15. Exhaust manifold nut

: Do not reuse.

7. No.2 seal ring

16. Exhaust pipe bolt

8. Exhaust pipe No.1

17. Exhaust pipe No.1 bracket nut

Exhaust System:  1K-3

For J20 Engine Model

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[A]: Installing location of exhaust manifold bold and nut.

10. Exhaust center pipe

20. Exhaust center pipe gasket

1. Exhaust manifold gasket

11. Muffler

21. Muffler mounting

2. Exhaust manifold

12. Mounting

22. Exhaust pipe No.2 bracket

3. Exhaust pipe No.1 bracket

13. A/F sensor

23. Exhaust manifold cover

4. HO2S

14. Exhaust manifold bolt

24. Heat protector panel

5. Exhaust pipe No.1 gasket

15. Exhaust manifold nut

25. Heat protector rear panel

6. No.1 seal ring

16. Exhaust pipe bolt

: 45 N

⋅m (4.5 kgf-m, 32.5 lb-ft)

7. No.2 seal ring

17. Exhaust pipe No.1 bracket nut

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

8. Exhaust pipe No.1

18. Exhaust pipe No.1 bracket bolt

: Do not reuse.

9. Exhaust pipe No.2

19. Exhaust center pipe nut

1K-4 Exhaust System: 

Exhaust Manifold Removal and Installation (For 
M16 Engine Model)

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Removal

WARNING

!

 

To avoid danger of being burned, do not 
service exhaust system while it is still hot. 
Service should be performed after system 
cools down.

 

1) Disconnect negative cable at battery.
2) Remove exhaust pipe No.1 bracket.
3) Remove exhaust manifold (1) and its gasket from 

cylinder head.

Installation

1) Install new gasket to cylinder head and exhaust pipe 

No.1. Then install exhaust manifold.
Tighten manifold bolts (1) and nuts (2) to specified 
torque.

Tightening torque
Exhaust manifold bolt and nut (a):  50 N·m (5.0 
kgf-m, 36.5 lb-ft)

NOTE
Be sure to install exhaust manifold bolts and 
nuts to proper location referring to “Exhaust 
System Components”.

 

2) Install exhaust pipe No.1 bracket (1).

Tightening torque
Exhaust pipe No.1 bracket bolt and nut (a):  50 
N·m (5.0 kgf-m, 36.5 lb-ft)

3) Connect negative cable at battery.
4) Check exhaust system for exhaust gas leakage.

Exhaust Manifold Removal and Installation (For 
J20 Engine Model)

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Removal

WARNING

!

 

To avoid danger of being burned, do not 
service exhaust system while it is still hot. 
Service should be performed after system 
cools down.

 

1) Relieve fuel pressure in fuel feed line according to 

“Fuel Pressure Relief Procedure in Section 1G”.

2) Disconnect negative cable at battery.
3) Drain coolant referring to “Cooling System Draining 

in Section 1F”.

4) Disconnect fuel hoses (2) from fuel pipes (1).
5) Disconnect water outlet pipe (3) from radiator inlet 

hose.

6) Remove exhaust manifold cover (4).

1

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2, (a)

1, (a)

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3

2

1

4

2

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Exhaust System:  1K-5

7) Remove exhaust pipe No.1 bracket (1).
8) Remove exhaust manifold (2) and its gasket (3) from 

cylinder head.

Installation

1) Install new gasket (1) to cylinder head and exhaust 

pipe No.1. Then install exhaust manifold (2).
Tighten manifold bolts (4) and nuts (5) to specified 
torque.

Tightening torque
Exhaust manifold bolt and nut (b):  50 N·m (5.0 
kgf-m, 36.5 lb-ft)

NOTE
Be sure to install exhaust manifold bolts and 
nuts to proper location referring to “Exhaust 
System Components”.

 

2) Install exhaust pipe No.1 bracket (3) to exhaust 

manifold.
Tighten nuts to specified torque.

Tightening torque
Exhaust No.1 pipe nut (a):  50 N·m (5.0 kgf-m, 
36.5 lb-ft)

3) Install exhaust manifold cover (1).
4) Connect water outlet pipe (2) from radiator inlet 

hose.

5) Connect fuel pipe (3) from fuel hoses.

6) Refill cooling system referring to “Cooling System 

Flush and Refill in Section 1F”.

7) Connect negative cable at battery.
8) Verify that there is no fuel leakage, coolant leakage 

and exhaust gas leakage at each connection.

Exhaust Pipe and Muffler Removal and 
Installation

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For replacement of exhaust pipe, be sure to hoist vehicle 
and observe WARNING under “Exhaust System 
Components” and the following.

WARNING

!

 

To avoid danger of being burned, do not 
service exhaust system while it is still hot. 
Service should be performed after system 
cools down.

 

CAUTION

!

 

Exhaust manifold have three way catalytic 
converter in it, it should not be exposed to 
any impulse.
Be careful not to drop it or hit it against 
something.

 

• Tighten bolts and nuts to specified torque when 

reassembling. Refer to “Exhaust System 
Components”.

• After installation, start engine and check each joint of 

exhaust system for leakage.

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3

2

1

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