Suzuki Grand Vitara JB419. Service manual — part 46

Engine Mechanical: 1D-30

Installation

CAUTION

!

Before starting engine (including when
performing oil level check and air bleeding
process of cooling system) for the first time
after installing turbocharger, be sure to
lubricate turbocharger while disabling engine
to start according to the following
procedure.Otherwise, lack of lubrication will
cause turbocharger damage.
1. Disconnect fuel pressure sensor

connector.

2. Crank engine for 20 seconds to lubricate

turbocharger with engine oil.

3. Connect fuel pressure sensor connector.
4. As DTC is stored in ECM memory in Step

2), make sure to clear it.

1) Install turbocharger lubrication pipe union nut (1)

with new copper ring, turbocharger lubrication pipe
(2), turbocharger water inlet pipe (3) and
turbochanger water outlet pipe (4) to turbocharger
with new gasket and new clamp, if removed.

Tightening torque
Turbocharger lubrication pipe union nut (a): 36
N·m (3.6 kgf-m, 26.5 lb-ft)
Turbocharger lubrication pipe union bolt
(turbocharger side) (b): 16 N·m (1.6 kgf-m, 12.0
lb-ft)
Turbocharger water inlet pipe union bolt (c): 29
N·m (2.9 kgf-m, 21.0 lb-ft)
Turbocharger water outlet pipe union bolt (d):
29 N·m (2.9 kgf-m, 21.0 lb-ft)

2) Install turbocharger (1) to exhaust manifold with new

gasket.

Tightening torque
Turbocharger nut (a): 37 N·m (3.7 kgf-m, 27.0 lb-
ft)

3) Fit turbocharger inlet pipe (11) to turbocharger and

install turbocharger stiffener (2). Tighten
turbocharger stiffener bolt by hand temporarily.

4) Tighten turbocharger inlet pipe clamp by specified

torque.

Tightening torque
Turbocharger inlet pipe clamp (i): 16 N·m (1.6
kgf-m, 12.0 lb-ft)

5) Tighten turbocharger stiffener bolt by specified

torque.

Tightening torque
Turbocharger stiffener bolt (b): 21 N·m (2.1 kgf-
m, 15.5 lb-ft)

6) Install exhaust manifold heat shield (3) to exhaust

manifold.

Tightening torque
Exhaust manifold heat shield bolt (c): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)

7) Connect turbocharger lubrication pipe (4) and

lubrication pipe stiffeners to cylinder block.

Tightening torque
Turbocharger lubrication pipe union bolt
(cylinder block side) (d): 44 N·m (4.4 kgf-m, 32.0
lb-ft)
Turbocharger lubrication pipe stiffener bolt (e):
25 N·m (2.5 kgf-m, 18.0 lb-ft)

8) Install oil return pipe No.1 (5) and No.2 (6) with new

gasket and O-ring.

Tightening torque
Oil return pipe No.1 bolt (f): 12 N·m (1.2 kgf-m,
9.0 lb-ft)
Oil return pipe No.1 stiffener bolt (g): 12 N·m (
1.2 kgf-m, 9.0 lb-ft)
Oil return pipe No.2 bolt (h): 12 N·m (1.2 kgf-m,
9.0 lb-ft)

9) Connect boost pressure control actuator hose (7) to

boost pressure control actuator.

10) Connect turbocharger water inlet hose (8) and outlet

hose (9).

11) Connect turbocharger outlet hose (10) to

turbocharger (1).

Tightening torque
Turbocharger outlet hose clamp (turbocharger
side) (j): 5 N·m (0.5 kgf-m, 4.0 lb-ft)

2

1, (a)

3

4

(b)

(c)

(d)

I5JB0B140055-04

1D-31 Engine Mechanical:

12) Install catalytic converter referring to “Exhaust

System Components in Section 1K”.

13) Install thermostat assembly referring to “Thermostat

Assembly Removal and Installation in Section 1F”.

14) Install engine assembly referring to “Engine

Assembly Removal and Installation”.

Turbocharger Assembly Inspection

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Turbocharger
Rotate turbine shaft (1) by hand and verify that it turns
smoothly without any abnormal noise and excessive
runout.
If a malfunction is found, replace turbocharger.

Boost Presser Control Valve

1) Remove turbocharger referring to “Turbocharger

Assembly Removal and Installation”.

2) Set magnetic base (1) with dial gauge (2) as shown

in figure.

3) Connect special tool to boost presser control valve

(3).

Special tool
(A): 09917–47011

4) Measure stroke of boost presser control valve rod (4)

when applying specified pressure.
If measure stroke is out of specification, adjust rod
stroke referring to “Turbocharger Assembly
Adjustment” or replace turbocharger.

Boost presser control valve rod stroke
1.3 – 3.3 mm (0.052 – 0.129 in.) at 20 kPa (–0.2 kg/
cm

2

, 2.84 psi)

9.5 – 11.5 mm (0.374 – 0.452 in.) at 55 kPa (–
0.55kg/cm

2

, 7.81 psi)

Stop at 60 kPa (–0.6kg/cm

2

, 8.52 psi) or more

8

9

3

(g)

6

4

7

2

1

10

(a)

(b)

(c)

(d)

(e)

5

(f)

(h)

(e)

11

(i)

(j)

I5JB0B140056-04

1

I4RH0A140020-01

I5JB0B140139-01

Engine Mechanical: 1D-32

Turbocharger Assembly Adjustment

S5JB0B1406070

1) Loosen lock nut (1).
2) Tighten or loose adjusting wheel (2) so as to adjust

stroke of boost presser control valve rod with
applying specified pressure.
For correct stroke and specified pressure, refer to
“Boost Presser Control Valve” under “Turbocharger
Assembly Inspection”.

3) Tighten lock nut after adjusting.

Intake Manifold and Exhaust Manifold Components

S5JB0B1406058

I5JB0B140140-01

1

4

2

(a)

(b)

3

I5JB0B140057-01

1. Intake manifold

3. Intake and exhaust manifold gasket

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

2. Exhaust manifold

4. Exhaust manifold heat shield

: Do not reuse.

3. Intake and exhaust manifold gasket

: Tighten 28 N

⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure.

1D-33 Engine Mechanical:

Intake Manifold and Exhaust Manifold Removal
and Installation

S5JB0B1406059

Removal

1) Remove turbocharger assembly referring to

“Turbocharger Assembly Removal and Installation”.

2) Remove EGR pipe and cooler referring to “EGR Pipe

and EGR Cooler Removal and Installation”.

3) Remove EGR valve referring to “EGR Valve

Removal and Installation”.

4) Remove engine hanger (1).

5) Loosen intake and exhaust manifold nuts (1) from

outside to center in symmetry and evenly.

6) Remove intake and exhaust manifolds.
7) Remove exhaust gas temperature sensor-1 from

exhaust manifold referring to “Exhaust Gas
Temperature Sensor 1, 2 and 3 Removal and
Installation in Section 1B”, if necessary.

Installation

1) Install exhaust gas temperature sensor-1 to exhaust

manifold “Exhaust Gas Temperature Sensor 1, 2 and
3 Removal and Installation in Section 1B”, if
removed.

2) Install intake and exhaust manifolds as follows.

a) Fit intake and exhaust manifolds to cylinder head

with new gasket.

b) Tighten new intake and exhaust manifold nuts

from center to outside in symmetry and evenly
until specified torque is obtained.

Tightening torque
Intake and exhaust manifolds nut (a):
Tighten 28 N

⋅m (0.8 kgf-m, 6.0 lb-ft) by the

specified procedure

3) Install engine hanger (1).

Tightening torque
Engine hanger bolt (a): 25 N·m (2.5 kgf-m, 18.5
lb-ft)

4) Install EGR pipe and cooler referring to “EGR Pipe

and EGR Cooler Removal and Installation”.

5) Install EGR valve referring to “EGR Valve Removal

and Installation”.

6) Install turbocharger referring to “Turbocharger

Assembly Removal and Installation”.

1

I5JB0B140059-02

1

I5JB0B140058-01

(a)

(a)

(a)

(a)

(a)

(a)

(a)

(a)

(a)

I5JB0B140060-01

1

(a)

I5JB0B140061-01