Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 157

1D-154 Engine Mechanical: For F9Q Engine

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, referring to
“CAUTION” in “Installation” under “Turbocharger Assembly Removal and Installation”. Otherwise,
lack of lubrication will cause turbocharger damage.

1) Connect transmission to engine referring to “Manual Transmission Assembly Dismounting and Remounting: For

Diesel Engine Model in Section 5B”, if removed.

2) Lift engine with transmission and front suspension frame to engine compartment using engine jack.

CAUTION

!

Before lifting engine, in order to avoid damage to A/C compressor, make clearance by rising them.

3) Tighten engine rear mounting member bolt referring to “Engine Mounting Components: For F9Q Engine”.
4) Carry out Step 5) through 19) of “Installation” under “Front Suspension Frame, Stabilizer Bar and/or Bushings

Removal and Installation in Section 2B” in order to install engine with front suspension frame.

5) Remove engine jack.
6) Install relay box (1), fuse box No.1 (2) and boost pressure control solenoid valve (3) to vehicle body.

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I5JB0B140044-01

Engine Mechanical: For F9Q Engine 1D-155

7) Connect connectors and wire harness disconnected

in removal procedure.

8) Connect hoses disconnected in removal procedure.
9) Install intercooler inlet pipe (1).

Tightening torque
Intercooler inlet hose clamp (a): 4.5 N·m (0.45
kgf-m, 3.5 lb-ft)

10) Install air cleaner case (1) and turbocharger inlet

hose (2), and connect MAF sensor connector (3).

Tightening torque
Inlet hose clamp (a): 2.5 N·m (0.25 kgf-m, 2.0 lb-
ft)

11) Connect P/S suction hose and low pressure return

hose referring to “P/S Hose / Pipe Components in
Section 6C”.

12) Install A/C compressor to its bracket referring to

“Compressor Assembly Removal and Installation
(F9Q Engine Model) in Section 7B”, if removed.

13) Install front and rear propeller shafts referring to

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

14) Install exhaust No.1 pipe referring to “Exhaust

System Components: For Diesel Engine Model in
Section 1K”.

15) Install shift control lever referring to “Transmission

Shift Control Lever Removal and Installation: For
Diesel Engine Model in Section 5B”.

16) Install accessory drive belt referring to “Accessory

Drive Belt and Idler Pulley Removal and Installation:
For Diesel Engine Model in Section 1J”.

17) Check all removed parts are back in place.
18) Refill coolant referring to “Cooling System Refilling:

For Diesel Engine Model in Section 1F”.

19) Refill engine oil referring to “Engine Oil and Filter

Change (Diesel Engine Model) in Section 0B”.

20) After installation, bleed air from clutch system

referring to “Air Bleeding of Clutch System in Section
5C” for air bleeding procedure.

21) Install battery, and connect positive (+) and negative

(–) cable at battery.

22) Bleed air in fuel system referring to “Air Bleeding of

Fuel System: For Diesel Engine Model in Section
1G”.

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

leakage at each connection.

24) Check fuel leakage referring to “Fuel Leakage Check

Procedure: For Diesel Engine Model in Section 1G”.

25) Check DTC referring to “DTC Check: For Diesel

Engine Model in Section 1A”.

(a)

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(a)

(a)

I5JB0B140046-02

1D-156 Engine Mechanical: For F9Q Engine

EGR Valve Components

S6JB0A1436054

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1

2

(b)

(c)

(c)

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3-1

(d)

(e)

6-1

6-2

3-2

(a)

(c)

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I5JB0B140047-06

1. EGR valve

5. EGR cooler

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

2. Gasket

6-1. EGR pipe stiffener bolt (with washer)

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

3-1. Clamp (type A)

6-2. EGR pipe stiffener bolt (without washer)

: 9 N

⋅m (0.9 kgf-m, 7.0 lb-ft)

3-2. Clamp (type B)

: 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft)

: Do not reuse.

4. EGR pipe

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

Engine Mechanical: For F9Q Engine 1D-157

EGR Valve Removal and Installation

S6JB0A1436071

CAUTION

!

When replacing EGR valve, perform
“Initialize EGR valve data” mode of SUZUKI
scan tool referring to “EGR Valve Data
Initialization”.

Removal

1) Disconnect negative (–) cable at battery.
2) Remove engine cover.
3) Remove air intake pipe referring to “Air intake Pipe

Removal and Installation: For F9Q Engine”.

4) Disconnect EGR valve connector (1) and EGR pipe

(2) from EGR valve (3).

5) Remove EGR valve from intake manifold.

Installation

1) Install EGR valve (1) to intake manifold.

Tightening torque
EGR valve bolt (a): 25 N·m (2.5 kgf-m, 18.0 lb-ft)

2) Connect EGR valve connector (2) and EGR pipe (3)

to EGR valve.

3) Install air intake pipe referring to “Air intake Pipe

Removal and Installation: For F9Q Engine”.

4) Install engine cover.
5) Connect negative (–) cable at battery.

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I5JB0B120007-01

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(a)

I5JB0B120008-01