Suzuki Grand Vitara JB627. Manual — part 119
1K-2 Exhaust System:
Repair Instructions
Exhaust System Components
S6JB0B1B06001
I6JB0B1B0001-01
[A]: Installing location of exhaust manifold bolt and nut
10. Exhaust center pipe
20. Muffler gasket
1. Exhaust manifold gasket
11. Muffler
21. Mounting No.2
2. Exhaust manifold
12. Mounting No.1
22. Exhaust manifold cover
3. Exhaust manifold stiffener
13. A/F sensor
23. Heat protector rear panel
Exhaust System: 1K-3
Exhaust Manifold Removal and Installation
S6JB0B1B06002
WARNING
!
To avoid danger of being burned, do not
service exhaust system while it is still hot.
Service should be performed after system
has cooled off.
Removal
Right side exhaust manifold
1) Remove battery and battery tray.
2) Remove air cleaner assembly and air cleaner outlet
hose.
3) Remove A/F sensor connector (1) and HO2S
connector (2) (if equipped) from bracket, then
disconnect them.
4) For RHD model, remove steering lower shaft
assembly referring to “Steering Lower Shaft
Assembly Removal and Installation in Section 6B”.
5) If equipped with EGR system, disconnect EGR pipe
(3) from exhaust manifold.
6) Remove exhaust manifold cover.
7) Remove exhaust No.1 pipe.
8) Remove exhaust manifold stiffener (1).
9) Remove exhaust manifold (1) and its gasket from
cylinder head.
Left side exhaust manifold
1) Release fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative (–) cable at battery.
3) Disconnect fuel feed hose (1) and fuel return hose
(2).
4) Disconnect brake booster hose (1), vacuum tank
hose (2) and EVAP canister purge valve hose (3)
from intake manifold and fuel No.2 pipe (4).
4. HO2S (if equipped)
14. Exhaust manifold bolt
24. Mounting No.3
5. Exhaust No.1 pipe gasket
15. Exhaust manifold nut
25. Plug (if equipped)
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 manifold stiffener bolt
: 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
8. Exhaust No.1 pipe
18. Muffler nut
: 30 N
⋅m (3.0 kgf-m, 21.5 lb-ft)
9. Exhaust No.2 pipe
19. Exhaust pipe nut
: Do not reuse.
3
1
2
I6JB011B0003-01
1
I6JB011B0004-01
1
I6JB011B0005-01
1
2
I6JB011B0006-01
1
2
4
3
I6JB011B0007-01
1K-4 Exhaust System:
5) Disconnect vacuum hose from IMT valve, and
remove vacuum tank assembly.
6) For LHD model, remove steering lower shaft
assembly referring to “Steering Lower Shaft
Assembly Removal and Installation in Section 6B”.
7) Disconnect suction hose and discharge hose from A/
C compressor referring to “Compressor Assembly
Removal and Installation in Section 7B”.
8) Remove oil filter referring to “Engine Oil and Filter
9) Remove A/F sensor connector (1) and HO2S
connector (2) (if equipped) from bracket, then
disconnect them.
10) Remove engine hook (1).
11) Remove oil level gauge (2) and oil level gauge guide
(3).
12) Remove exhaust manifold cover (4).
13) Remove exhaust No.1 pipe.
14) Remove exhaust manifold stiffener (1).
15) Remove exhaust manifold (1) and its gasket from
cylinder head.
Installation
Right side exhaust manifold
Reverse removal procedure for installation noting the
following.
• Use new gaskets and seal rings.
• Always install new exhaust manifold bolts (1) with pre-
coated adhesive.
• Tighten each bolts and nuts to specified torque.
Tightening torque
Exhaust manifold stiffener bolt (a): 30 N·m (3.0
kgf-m, 21.5 lb-ft)
Exhaust No.1 pipe bolt and nut (b): 50 N·m (5.0
kgf-m, 36.5 lb-ft)
• For RHD model, install steering lower shaft assembly
referring to “Steering Lower Shaft Assembly Removal
and Installation in Section 6B”.
• Upon completion of installation, start engine and
check that no exhaust gas leakage exists.
1
2
I6JB011B0008-01
2
1
3
4
I6JB011B0009-01
1
I6JB011B0010-01
1
I6JB011B0011-01
1, (a)
(b)
(b)
I6JB011B0012-02
Exhaust System: 1K-5
Left side exhaust manifold
Reverse removal procedure for installation noting the
following.
• Use new gaskets and seal rings.
• Always install new exhaust manifold bolts (1) with pre-
coated adhesive.
• Tighten each bolts and nuts to specified torque.
Tightening torque
Exhaust manifold stiffener bolt (a): 30 N·m (3.0
kgf-m, 21.5 lb-ft)
Exhaust No.1 pipe bolt and nut (b): 50 N·m (5.0
kgf-m, 36.5 lb-ft)
HO2S: 45 N·m (4.5 kgf-m, 32.5 lb-ft)
• Install oil filter referring to “Engine Oil and Filter
• Connect suction hose and discharge hose to A/C
compressor referring to “Compressor Assembly
Removal and Installation in Section 7B”.
• For LHD model, install steering lower shaft assembly
referring to “Steering Lower Shaft Assembly Removal
and Installation in Section 6B”.
• Upon completion of installation, turn ignition switch to
ON position and check that no fuel leakage.
• Start engine and check that no exhaust gas leakage.
Muffler Removal and Installation
S6JB0B1B06003
WARNING
!
To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.
CAUTION
!
Three way catalytic converter should not be
exposed to any impulse. Be careful not to
drop it or hit it against something.
Refer to “Exhaust System Components”.
Specifications
Tightening Torque Specifications
S6JB0B1B07001
NOTE
The specified tightening torque is also described in the following.
“Exhaust System Components”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.
1, (a)
(b)
I6JB011B0013-02
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Exhaust manifold stiffener bolt
30
3.0
21.5
Exhaust No.1 pipe bolt and nut
50
5.0
36.5
HO2S
45
4.5 32.5
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