Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 121
1D-10 Engine Mechanical: For M16A Engine with VVT
11) Remove cylinder head cover (1) with cylinder head
cover gasket (2).
Installation
1) Install new cylinder head cover gasket (2) to cylinder
head cover (1) as shown in the figure.
2) Remove oil, old sealant, and dust from sealing
surfaces on cylinder head and cover. After cleaning,
apply sealant “A” to the following point.
• Cylinder head cover gasket (1) sealing surface
area (2) as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
• Timing chain cover (1) and cylinder head (2)
mating surface as shown.
“A”: Water tight sealant 99000–31250
(SUZUKI Bond No.1207F)
3) Install cylinder head cover to cylinder head.
NOTE
When installing cylinder head cover, use care
so that cylinder head cover gasket or spark
plug hole gaskets will not get out of place or
fall off.
4) Tightening bolts in such order as indicated in the
figure a little at a time till they are tightened to
specified torque.
Tightening torque
Cylinder head cover bolt (a): 8 N·m (0.8 kgf-m,
6.0 lb-ft)
I6RS0B141004-01
I6RS0B141005-01
I2RH0B140036-01
I2RH0B140037-01
Engine Mechanical: For M16A Engine with VVT 1D-11
5) Connect PCV hose (2) to PCV valve (3).
6) Connect breather hose (4).
7) Install oil level gauge (1).
8) Install wire harness clamp to cylinder head cover.
9) Install ignition coil assemblies with high-tension cord.
10) Connect ignition coil couplers and clamp harness
securely.
11) Install cylinder head upper cover.
12) Connect negative cable at battery.
Throttle Body and Intake Manifold Components
S6JB0A1416004
I5JB0A141007-01
I5JB0A141005-05
[A]: Installing location of intake manifold bolt and nut
7. EVAP canister purge valve
14. Intake manifold bolt (short)
1. Intake manifold
8. EVAP canister purge valve hose
15. Intake manifold bolt (long)
2. Gasket
9. MAP sensor bolt
16. To delivery pipe
3. Electrical throttle body
10. To EGR valve
: 5 N
⋅m (0.5 kgf-m, 4.0 lb-ft)
4. EGR pipe
11. To PCV valve
: Do not reuse.
5. MAP sensor
12. To brake booster
6. PCV hose
13. Intake manifold nut
1D-12 Engine Mechanical: For M16A Engine with VVT
Throttle Body On-Vehicle Inspection
S6JB0A1416005
Check electric throttle body assembly referring to “Throttle Valve Operation Check” and “Electric Throttle Body
Assembly Operation Check” under “Electric Throttle Body Assembly On-Vehicle Inspection: For Petrol Engine Model
in Section 1C”.
Electric Throttle Body Assembly Removal and
Installation
S6JB0A1416006
Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining:
For Petrol Engine Model in Section 1F”.
3) Detach breather union (1) from air intake pipe (2).
4) Disconnect air intake pipe (2).
5) Disconnect engine coolant hoses (1) from electric
throttle body assembly (3).
6) Disconnect connector (2) from electric throttle body
assembly.
7) Remove electric throttle body assembly from intake
manifold.
Installation
1) Clean mating surfaces and install new throttle body
gasket to intake manifold.
2) Install electric throttle body assembly (1) to intake
manifold.
3) Connect connector (2) to electric throttle body
assembly securely.
4) Connect engine coolant hoses (3) to electric throttle
body assembly (1).
5) Connect air intake pipe (1) and breather union (2).
6) Tighten air intake pipe bolt (3) to specified torque.
Tightening torque
Air intake pipe bolt (a): 3 N·m (0.3 kgf-m, 2.5 lb-
ft)
7) Refill coolant referring to “Cooling System Flush and
Refill: For Petrol Engine Model in Section 1F”.
8) Connect negative cable at battery.
9) Perform calibration of electric throttle body assembly
referring to “Electric Throttle Body System
Calibration: For Petrol Engine Model in Section 1C” if
replaced.
1
2
I5JB0A141008-03
3
2
1
I5JB0A141009-02
1
2
3
I5JB0A141010-02
2
1
3, (a)
I5JB0A141011-03
Engine Mechanical: For M16A Engine with VVT 1D-13
Throttle Body Cleaning
S6JB0A1416007
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection: For Petrol
Engine Model in Section 1C”.
Intake Manifold Removal and Installation
S6JB0A1416008
Removal
1) Relieve fuel pressure in fuel feed line referring to
“Fuel Pressure Relief Procedure: For Petrol Engine
Model in Section 1G”.
2) Remove throttle body referring to “Electric Throttle
Body Assembly Removal and Installation: For M16A
Engine with VVT”.
3) Disconnect the following hoses:
• Brake booster hose (2) from intake manifold
• PCV hose (3) from intake manifold
• EVAP canister purge hose (4) from intake
manifold
• Vacuum hose (5) from intake manifold
• Water No.1 hose (9) from intake manifold
• Water No.2 hose (10) from intake manifold
4) Disconnect the following electric wires:
• Injectors
• Ground terminal (6) from intake manifold
• MAP sensor (1)
5) Remove EVAP canister purge valve (7).
6) Remove intake manifold bracket (8).
7) Remove delivery pipe referring to “Fuel Injector
Removal and Installation: For Petrol Engine Model in
Section 1G”.
8) Remove intake manifold (1) and EGR pipe bolt (2)
from cylinder head, and then remove its gaskets.
Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold gasket.
• Use new EGR pipe gasket.
• Install intake manifold bolt and nut (1) as shown in
figure.
• Check to ensure that all removed parts are back in
place.
• Refill cooling system referring to “Cooling System
Flush and Refill: For Petrol Engine Model in Section
1F”.
• Upon completion of installation, turn ignition switch
ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant
leaks.
6
1
2
5
8
4
7
10
3
9
I5JB0A141012-04
2. Short bolt
3. Long bolt
1
2
I5JB0A141013-02
2
1
2
3
I5JB0A141014-02
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