Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 137
1D-74 Engine Mechanical: For J20 Engine
Repair Instructions
Air Cleaner Assembly Removal and Installation
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Removal
1) Disconnect breather hose (1) from air cleaner outlet
hose (2).
2) Remove air cleaner outlet hose (2).
3) Disconnect MAF sensor connector (3).
4) Remove air cleaner case (4).
Installation
1) Install air cleaner case (4).
2) Connect MAF sensor connector (3).
3) Install air cleaner outlet hose (2).
4) Connect breather hose (1) to air cleaner outlet hose
(2).
Air Cleaner Filter Removal and Installation
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Removal
1) Remove air cleaner upper case (1) from lower case
after hooking clamps (2) from upper case.
2) Remove air cleaner filter.
Installation
Reverse removal procedure for installation.
Air Cleaner Filter Inspection and Cleaning
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Inspection
Check air cleaner filter for dirt.
Cleaning
Blow off dust by compressed air from air outlet side of
element.
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Engine Mechanical: For J20 Engine 1D-75
Throttle Body and Intake Manifold Components
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1. Intake manifold
: Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is
found, replace it with new one.
4. Electric throttle body assembly
2. O-ring
: Do not reuse.
3. MAP sensor
1D-76 Engine Mechanical: For J20 Engine
Throttle Body On-Vehicle Inspection
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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
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Removal
1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining:
For Petrol Engine Model in Section 1F”.
3) Disconnect breather hose (1) from air cleaner outlet
hose (2).
4) Disconnect air cleaner outlet hose (2) from air
cleaner case and electric throttle body assembly.
5) Disconnect engine coolant hoses (1) from electric
throttle body assembly (2).
6) Disconnect connector (3) 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 cleaner outlet hose (1) to air cleaner
case and electric throttle body assembly.
6) Connect breather hose (2) to air cleaner outlet hose
(1).
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.
Throttle Body Cleaning
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Clean electric throttle body assembly referring to
“Throttle Valve Operation Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection: For Petrol
Engine Model in Section 1C”.
Intake Manifold Removal and Installation
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CAUTION
!
Never disassemble intake manifold.
Disassembly will spoil its original
performance. If faulty condition is found,
replace it with new one.
Removal
1) Disconnect negative cable at battery.
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Engine Mechanical: For J20 Engine 1D-77
2) Drain cooling system referring to “Cooling System
Draining: For Petrol Engine Model in Section 1F”.
3) Remove engine cover.
4) Remove air cleaner outlet hose (1) and breather
hose (2).
5) Remove electric throttle body assembly referring to
“Electric Throttle Body Assembly Removal and
Installation: For J20 Engine”.
6) Disconnect the following electric lead wires:
• EVAP canister purge valve coupler (1)
• MAP sensor coupler (2)
7) Disconnect the following hoses:
• Brake booster hose (3) from intake manifold
• PCV hose (4) from PCV valve
• Fuel pressure regulator vacuum hose (5) from
intake manifold
• Vacuum hose (6) from EVAP canister purge valve
• Vacuum hose (7) from vacuum tank
• EVAP canister purge hose (8) from EVAP canister
purge valve
8) Remove EGR pipe bolt (9) from EGR pipe.
9) Remove EVAP canister purge valve bracket (10)
form intake manifold.
10) Remove water pump and generator drive belt
11) With hose connected, detach P/S pump referring to
“P/S Pump Removal and Installation (J20A Engine
Model) in Section 6C”.
12) Remove intake manifold and O-ring from cylinder
head.
Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold O-ring.
• Use new EGR pipe gasket.
• Install intake manifold bolt (2) and nut (1) as shown in
figure.
• Check to ensure that all removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
• Adjust water pump and generator drive belt referring
• 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.
Cylinder Head Cover Removal and Installation
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Removal
1) Disconnect negative cable at battery.
2) Remove engine cover.
3) Disconnect ignition coil couplers (1).
4) Remove ignition coils (4).
5) Remove oil level gauge (6).
6) Disconnect CMP sensor coupler (5) from cylinder
head cover.
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