Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 158
1D-158 Engine Mechanical: For F9Q Engine
EGR Pipe and EGR Cooler Removal and
Installation
S6JB0A1436055
Removal
1) Remove engine assembly referring to “Engine
Assembly Removal and Installation: For F9Q
Engine”.
2) Remove catalytic converter referring to “Exhaust
System Components: For Diesel Engine Model in
Section 1K”.
3) Remove thermostat assembly referring to
“Thermostat Assembly Removal and Installation: For
Diesel Engine Model in Section 1F”.
4) Disconnect water hoses (1) from EGR cooler (2).
5) Remove exhaust manifold heat shield (3) from
exhaust manifold.
6) Disconnect EGR joint (4) from exhaust manifold.
7) Disconnect EGR pipe (5) from EGR valve (6).
8) Remove EGR cooler (2) with EGR pipe (5) and EGR
joint (4) from cylinder block.
9) Remove EGR pipe as follows, if necessary.
CAUTION
!
EGR pipe clamp has two types as shown in
figure. And, Type A is disposable one and it
has not already been supplied.
Be sure to use Type B EGR pipe clamp after
removing Type A EGR pipe clamp.
• For Type A
Remove EGR pipe (1) from EGR cooler (2) after
removing EGR pipe clamp (3) with special tool.
Special tool
(A): 09910–68110
• For Type B
Remove EGR pipe (1) from EGR cooler (2) after
loosening EGR pipe clamp bolt (3).
5
1
3
5
6
2
4
I6JB0A143004-01
[A]: Type A
[B]: Type B
[A]
[B]
I5JB0B140146-01
(A)
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3
2
I5JB0B140049-04
1
2
3
I5JB0B140148-01
Engine Mechanical: For F9Q Engine 1D-159
Installation
1) Install EGR cooler (1), EGR pipe (2) and EGR joint
(3) with new gaskets.
Tightening torque
EGR cooler bolt (a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
EGR pipe bolt (b): 18 N·m (1.8 kgf-m, 13.0 lb-ft)
EGR pipe stiffener bolt (with washer) (c): 11 N·m
(1.1 kgf-m, 8.0 lb-ft)
EGR pipe stiffener bolt (without washer) (c): 9
N·m (0.9 kgf-m, 7.0 lb-ft)
EGR joint bolt (d): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
2) Install EGR pipe as follows, if necessary.
• For Type A
Type A EGR pipe clamp is disposable one, install
new Type B EGR pipe clamp as below-mentioned.
• For Type B
Install EGR pipe (1) to EGR cooler (2) by
tightening EGR pipe clamp bolt as specified
torque.
Tightening torque
Clamp bolt (a): 5 N·m (0.5 kgf-m, 4.0 lb-ft)
3) Install exhaust manifold heat shield (1) to exhaust
manifold.
Tightening torque
Exhaust manifold heat shield bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft)
4) Connect water hoses (2) to EGR cooler (3).
5) Install thermostat assembly referring to “Thermostat
Assembly Removal and Installation: For Diesel
Engine Model in Section 1F”.
6) Install catalytic converter referring to “Exhaust
System Components: For Diesel Engine Model in
Section 1K”.
7) Install engine assembly referring to “Engine
Assembly Removal and Installation: For F9Q
Engine”.
(a)
2
2
1
3
(c)
(d)
(b)
I6JB0A143005-01
1
2
(a)
I5JB0B140147-01
(a)
1
2
3
I5JB0B140051-01
1D-160 Engine Mechanical: For F9Q Engine
Turbocharger Components
S6JB0A1436056
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, referring to
“CAUTION” in “Installation” under “Turbocharger Assembly Removal and Installation”. Otherwise,
lack of lubrication will cause turbocharger damage.
4
3
5
8
7
2
6
(i)
(c)
(d)
(e)
(b)
(f)
(g)
(h)
1
7
9
(h)
(h)
7
(c)
(a)
7
(a)
I6JB0A143006-02
1. Turbocharger assembly
: Do not disassemble.
8. Turbocharger inlet pipe
: 44 N
⋅m (4.4 kgf-m, 32.0 lb-ft)
2. Turbocharger lubrication pipe
9. Copper ring
: 25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
3. Oil return pipe No.1
: 2.5 N
⋅m (0.25 kgf-m, 2.0 lb-ft)
: 12 N
⋅m (1.2 kgf-m, 9.0 lb-ft)
4. Oil return pipe No.2
: 36 N
⋅m (3.6 kgf-m, 26.5 lb-ft)
: 16 N
⋅m (1.6 kgf-m, 12.0 lb-ft)
5. Turbocharger water inlet pipe
: 29 N
⋅m (2.9 kgf-m, 21.0 lb-ft)
: Do not reuse.
6. Turbocharger water outlet pipe
: 37 N
⋅m (3.7 kgf-m, 27.0 lb-ft)
7. Boost presser control solenoid valve
: 21 N
⋅m (2.1 kgf-m, 15.5 lb-ft)
Engine Mechanical: For F9Q Engine 1D-161
Turbocharger Assembly Removal and
Installation
S6JB0A1436057
CAUTION
!
Never disassemble turbocharger assembly.
Disassembly will spoil its original function. If
faulty condition is found, replace it with new
one.
Removal
1) Remove engine assembly referring to “Engine
Assembly Removal and Installation: For F9Q
Engine”.
2) Remove thermostat assembly referring to
“Thermostat Assembly Removal and Installation: For
Diesel Engine Model in Section 1F”.
3) Remove catalytic converter referring to “Exhaust
System Components: For Diesel Engine Model in
Section 1K”.
4) Disconnect turbocharger outlet hose (1) from
turbochanger (10).
5) Disconnect turbocharger water inlet hose (2) and
outlet hose (3).
6) Remove exhaust manifold heat shield (4) from
exhaust manifold.
7) Remove oil return pipe No.1 (5) and No.2 (6).
8) Disconnect turbocharger lubrication pipe (7) and
lubrication pipe stiffeners from cylinder block.
9) Disconnect boost pressure control actuator hose (8)
from boost pressure control actuator.
10) Loosen turbocharger inlet pipe bolt (9).
11) Remove turbocharger (10) from exhaust manifold.
12) Remove turbocharger inlet pipe (5) from
turbocharger.
13) Remove turbocharger lubrication pipe (1),
turbocharger lubrication pipe union nut (2),
turbocharger water inlet pipe (3) and turbochanger
water outlet pipe (4) from turbocharger, if necessary.
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3
4
5
6
7
8
9
10
1
I6JB0A143007-01
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