Suzuki Grand Vitara JB416 / JB420. Manual — part 12
1-iv Table of Contents
Valve Spring Inspection . . . . . . . . . 1D-41
Pistons, Piston Rings, Connecting Rods and
Cylinders Components. . . . . . . . . 1D-42
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation. . . . .1D-42
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly . . . 1D-44
Cylinders, Pistons and Piston Rings
Inspection. . . . . . . . . . . . . . 1D-45
Piston Pins and Connecting Rods Inspection ...1D-47
Crank Pin and Connecting Rod Bearings
Inspection. . . . . . . . . . . . . . 1D-48
Main Bearings, Crankshaft and Cylinder
Block Components. . . . . . . . . . ..1D-52
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation . . . . . ...1D-53
Crankshaft Inspection . . . . . . . . . ...1D-56
Main Bearings Inspection. . . . . . . . ..1D-57
Sensor Plate Inspection . . . . . . . . . 1D-61
Rear Oil Seal Inspection . . . . . . . . ...1D-61
Flywheel Inspection. . . . . . . . . . ...1D-62
Cylinder Block Inspection. . . . . . . . ..1D-62
Specifications. . . . . . . . . . . . . .1D-63
Tightening Torque Specifications. . . . . ..1D-63
Special Tools and Equipment . . . . . . ...1D-64
Recommended Service Material . . . . . ...1D-64
Special Tool . . . . . . . . . . . . . ..1D-64
For J20 Engine . . . . . . . . . . . . . ..1D-66
General Description . . . . . . . . . . ...1D-66
Engine Construction Description. . . . . ...1D-66
Air Cleaner Element Introduction . . . . . ..1D-68
IMT (Intake Manifold Tuning) System
Description . . . . . . . . . . . . . ..1D-68
Diagnostic Information and Procedures. . ..1D-70
Compression Check. . . . . . . . . . ..1D-70
Engine Vacuum Check. . . . . . . . . ..1D-71
Valve Lash (Clearance) Inspection . . . . ...1D-72
Repair Instructions . . . . . . . . . . . 1D-75
Air Cleaner Assembly Removal and
Installation. . . . . . . . . . . . . ...1D-75
Air Cleaner Filter Removal and Installation. ...1D-75
Air Cleaner Filter Inspection and Cleaning. . 1D-75
Throttle Body and Intake Manifold
Components. . . . . . . . . . . . . 1D-76
Throttle Body On-Vehicle Inspection. . . . .1D-76
Electric Throttle Body Assembly Removal and
Installation. . . . . . . . . . . . . ...1D-76
Throttle Body Cleaning. . . . . . . . . ..1D-77
Intake Manifold Removal and Installation . . .1D-77
Cylinder Head Cover Removal and
Installation. . . . . . . . . . . . . ...1D-78
Engine Mountings Components . . . . . . 1D-80
Engine Assembly Removal and Installation . ..1D-81
Timing Chain Cover Components . . . . . .1D-84
Timing Chain Cover Removal and Installation ..1D-84
Timing Chain Cover Cleaning and Inspection...1D-87
2nd Timing Chain and Chain Tensioner
Components. . . . . . . . . . . . . 1D-87
2nd Timing Chain and Chain Tensioner
Removal and Installation. . . . . . . . .1D-88
2nd Timing Chain and Chain Tensioner
Inspection. . . . . . . . . . . . . . 1D-91
1st Timing Chain and Chain Tensioner
Components. . . . . . . . . . . . . 1D-91
1st Timing Chain and Chain Tensioner
Removal and Installation. . . . . . . . .1D-92
1st Timing Chain and Chain Tensioner
Inspection. . . . . . . . . . . . . . 1D-94
Camshafts, Tappet and Shim Components . ..1D-95
Camshafts, Tappet and Shim Removal and
Installation . . . . . . . . . . . . . ...1D-96
Camshaft, Tappet and Shim Inspection . . . 1D-97
Valves and Cylinder Head Components . . .1D-100
Valves and Cylinder Head Removal and
Installation . . . . . . . . . . . . . .1D-100
Valves and Cylinder Head Disassembly and
Assembly. . . . . . . . . . . . . ...1D-102
Valves and Valve Guides Inspection. . . ...1D-105
Cylinder Head Inspection . . . . . . . . 1D-107
Valve Spring Inspection . . . . . . . . ..1D-108
Pistons, Piston Rings, Connecting Rods and
Cylinders Components. . . . . . . . ..1D-109
Pistons, Piston Rings, Connecting Rods and
Cylinders Removal and Installation. . . ...1D-109
Pistons, Piston Rings, Connecting Rods and
Cylinders Disassembly and Assembly . . ..1D-110
Pistons, Piston Rings, Connecting Rods and
Cylinders Inspection and Cleaning. . . . 1D-113
Main Bearings, Crankshaft and Cylinder
Block Components . . . . . . . . . . 1D-119
Main Bearings, Crankshaft and Cylinder
Block Removal and Installation . . . . . .1D-120
Main Bearings, Crankshaft and Cylinder
Block Inspection . . . . . . . . . . . 1D-123
Specifications . . . . . . . . . . . . ...1D-129
Tightening Torque Specifications. . . . . 1D-129
Special Tools and Equipment . . . . . . .1D-130
Recommended Service Material . . . . . .1D-130
Special Tool . . . . . . . . . . . . . 1D-130
Engine Lubrication System . . . . . 1E-1
For M16A Engine with VVT. . . . . . . . . .1E-1
General Description . . . . . . . . . . . .1E-1
Engine Lubrication Description . . . . . . ...1E-1
Diagnostic Information and Procedures . . . 1E-3
Oil Pressure Check . . . . . . . . . . . .1E-3
Repair Instructions . . . . . . . . . . . ..1E-4
Oil Pan and Oil Pump Strainer Components. ...1E-4
Oil Pan and Oil Pump Strainer Removal and
Installation . . . . . . . . . . . . . . .1E-5
Oil Pan and Oil Pump Strainer Cleaning. . . .1E-6
Oil Pump Components . . . . . . . . . . 1E-7
Oil Pump Removal and Installation . . . . . .1E-7
Oil Pump Disassembly and Reassembly . . . 1E-7
Oil Pump Inspection . . . . . . . . . . . 1E-8
Table of Contents 1-v
Special Tools and Equipment . . . . . . ... 1E-10
Recommended Service Material. . . . . ... 1E-10
Special Tool . . . . . . . . . . . . . ..1E-10
For J20 Engine . . . . . . . . . . . . . ..1E-11
General Description . . . . . . . . . . ... 1E-11
Engine Lubrication Description . . . . . . .1E-11
Diagnostic Information and Procedures. . .. 1E-13
Oil Pressure Check . . . . . . . . . . ... 1E-13
Repair Instructions . . . . . . . . . . . 1E-14
Oil Pan and Oil Pump Strainer Components. .1E-14
Oil Pan and Oil Pump Strainer Removal and
Installation. . . . . . . . . . . . . ...1E-15
Oil Pan and Oil Pump Strainer Cleaning. . ... 1E-16
Oil Pump Components. . . . . . . . . ..1E-16
Oil Pump Removal and Installation . . . . ...1E-17
Oil Pump Disassembly and Assembly . . . .. 1E-17
Oil Pump Inspection . . . . . . . . . . ..1E-18
Specifications. . . . . . . . . . . . . . 1E-19
Tightening Torque Specifications. . . . . ..1E-19
Special Tools and Equipment . . . . . . ... 1E-20
Recommended Service Material. . . . . ... 1E-20
Special Tool . . . . . . . . . . . . . ..1E-20
Engine Cooling System . . . . . . ...1F-1
General Description . . . . . . . . . . . . 1F-1
Cooling System Description. . . . . . . . 1F-1
Coolant Description. . . . . . . . . . . . 1F-1
Schematic and Routing Diagram. . . . . . 1F-2
Coolant Circulation. . . . . . . . . . . .. 1F-2
Diagnostic Information and Procedures. . . 1F-3
Engine Cooling Symptom Diagnosis. . . . ... 1F-3
Repair Instructions . . . . . . . . . . . .. 1F-4
Cooling System Components . . . . . . . . 1F-4
Coolant Level Check. . . . . . . . . . ... 1F-6
Engine Cooling System Inspection and
Cleaning. . . . . . . . . . . . . . . 1F-6
Cooling System Draining . . . . . . . . . 1F-7
Cooling System Flush and Refill . . . . . . . 1F-7
Cooling Water Pipes or Hoses Removal and
Installation. . . . . . . . . . . . . . . 1F-8
Thermostat Removal and Installation (For
M16 Engine Model). . . . . . . . . . ... 1F-8
Thermostat Removal and Installation (For J20
Engine Model). . . . . . . . . . . . ... 1F-9
Thermostat Inspection . . . . . . . . . . 1F-9
Radiator Cooling Fan Motor On-Vehicle
Inspection. . . . . . . . . . . . . . 1F-10
Radiator Cooling Fan Relay Inspection. . . . 1F-10
Radiator Cooling Fan Assembly Removal and
Installation. . . . . . . . . . . . . ... 1F-11
Radiator On-Vehicle Inspection and Cleaning .. 1F-11
Radiator Removal and Installation . . . . . 1F-12
Water Pump Removal and Installation (For
M16 Engine Model). . . . . . . . . . . 1F-12
Water Pump Removal and Installation (For
J20 Engine Model) . . . . . . . . . . .. 1F-13
Water Pump Inspection. . . . . . . . . . 1F-13
Specifications. . . . . . . . . . . . . . 1F-14
Tightening Torque Specifications. . . . . .. 1F-14
Special Tools and Equipment . . . . . . ... 1F-14
Recommended Service Material . . . . . ... 1F-14
Fuel System . . . . . . . . . . . . 1G-1
Precautions. . . . . . . . . . . . . . .. 1G-1
Precautions on Fuel System Service . . . . . 1G-1
General Description . . . . . . . . . . . 1G-1
Fuel System Description . . . . . . . . . 1G-1
Fuel Delivery System Description . . . . . .. 1G-1
Fuel Pump Description. . . . . . . . . ... 1G-2
Schematic and Routing Diagram. . . . . ... 1G-2
Fuel Delivery System Diagram. . . . . . ... 1G-2
Diagnostic Information and Procedures. . ... 1G-3
Fuel Pressure Inspection . . . . . . . . ... 1G-3
Fuel Cut Operation Inspection . . . . . . ... 1G-4
Repair Instructions . . . . . . . . . . . . 1G-5
Fuel System Components. . . . . . . . .. 1G-5
Fuel Hose Disconnecting and Reconnecting . . 1G-8
Fuel Pressure Relief Procedure . . . . . ... 1G-10
Fuel Leakage Check Procedure. . . . . ... 1G-10
Fuel Lines On-Vehicle Inspection . . . . . 1G-10
Fuel Pipe Removal and Installation. . . . .. 1G-10
Fuel Injector On-Vehicle Inspection . . . . . 1G-11
Fuel Injector Removal and Installation . . . . 1G-11
Fuel Injector Inspection . . . . . . . . . 1G-13
Fuel Pressure Regulator Removal and
Installation . . . . . . . . . . . . . .. 1G-14
Installation . . . . . . . . . . . . . .. 1G-15
Fuel Tank Inlet Valve Inspection . . . . . .. 1G-16
Fuel Tank Removal and Installation. . . . . 1G-16
Fuel Tank Inspection. . . . . . . . . . 1G-18
Fuel Tank Purging Procedure . . . . . . .. 1G-18
Fuel Pump On-Vehicle Inspection. . . . . 1G-19
Fuel Pump Assembly Removal and
Installation . . . . . . . . . . . . . .. 1G-19
Main Fuel Level Sensor Removal and
Installation . . . . . . . . . . . . . .. 1G-20
Fuel Pump Inspection . . . . . . . . . .. 1G-21
Sub Fuel Level Sensor Removal and
Installation . . . . . . . . . . . . . .. 1G-21
Sub Fuel Level Sensor Inspection . . . . ... 1G-21
Specifications. . . . . . . . . . . . . 1G-22
Tightening Torque Specifications. . . . . . 1G-22
Special Tools and Equipment . . . . . . .. 1G-22
Recommended Service Material . . . . . .. 1G-22
Special Tool . . . . . . . . . . . . . . 1G-23
Ignition System. . . . . . . . . . 1H-1
General Description . . . . . . . . . . . .1H-1
Ignition System Construction . . . . . . . ..1H-1
Schematic and Routing Diagram. . . . . . 1H-2
Ignition System Wiring Circuit Diagram. . . ...1H-2
Component Location . . . . . . . . . . ...1H-3
Ignition System Components Location. . . . 1H-3
1-vi Table of Contents
Reference Waveform of Ignition System. . . .1H-4
Ignition System Check . . . . . . . . . . 1H-4
Ignition Spark Test . . . . . . . . . . . ..1H-6
Repair Instructions . . . . . . . . . . . ..1H-7
High-Tension Cord Removal and Installation
(For M16 Engine) . . . . . . . . . . . ..1H-7
High-Tension Cord Inspection (For M16
Engine). . . . . . . . . . . . . . . ..1H-7
Spark Plug Removal and Installation . . . . ..1H-7
Spark Plug Inspection . . . . . . . . . . .1H-8
Ignition Coil Assembly (Including ignitor)
Removal and Installation. . . . . . . . ...1H-8
Ignition Coil Assembly (Including ignitor)
Inspection. . . . . . . . . . . . . . ..1H-9
Ignition Timing Inspection . . . . . . . . .1H-10
Specifications. . . . . . . . . . . . . .1H-11
Tightening Torque Specifications. . . . . ..1H-11
Special Tools and Equipment . . . . . . ...1H-11
Special Tool . . . . . . . . . . . . . ..1H-11
Starting System . . . . . . . . . . . 1I-1
Precautions. . . . . . . . . . . . . . . 1I-1
Cranking System Note . . . . . . . . . . . 1I-1
General Description . . . . . . . . . . . .. 1I-1
Diagnostic Information and Procedures. . . . 1I-2
Cranking System Symptom Diagnosis. . . . . 1I-2
Starting Motor Performance Test . . . . . . . 1I-4
Repair Instructions . . . . . . . . . . . ... 1I-5
Starting Motor Dismounting and Remounting . .. 1I-5
Starting Motor Components . . . . . . . . . 1I-6
Starting Motor Inspection . . . . . . . . . . 1I-7
Specifications. . . . . . . . . . . . . .. 1I-10
Special Tools and Equipment . . . . . . . 1I-10
Recommended Service Material . . . . . . 1I-10
Charging System. . . . . . . . . .. 1J-1
General Description . . . . . . . . . . . . 1J-1
Battery Description. . . . . . . . . . . .. 1J-1
Generator Description . . . . . . . . . . . 1J-2
Diagnostic Information and Procedures . . . 1J-3
Battery Inspection . . . . . . . . . . . ... 1J-3
Generator Symptom Diagnosis . . . . . . ... 1J-4
Generator Test (Undercharged Battery
Check). . . . . . . . . . . . . . . ... 1J-4
Generator Test (Overcharged Battery Check) . 1J-5
Repair Instructions . . . . . . . . . . . .. 1J-6
Jump Starting in Case of Emergency. . . . .. 1J-6
Battery Dismounting and Remounting . . . . 1J-7
Water Pump and Generator Drive Belt
Removal and Installation (For M16 Engine). .. 1J-7
Water Pump and Generator Drive Belt
Tension Inspection and Adjustment (For
M16 Engine). . . . . . . . . . . . . .. 1J-8
Water Pump and Generator Drive Belt On-
Vehicle Inspection (For J20 Engine) . . . . . 1J-9
Water Pump and Generator Drive Belt
Removal and Installation (For J20 Engine) . . 1J-10
Generator Dismounting and Remounting. . .. 1J-11
Generator Components. . . . . . . . . . 1J-12
Generator Inspection. . . . . . . . . . . 1J-13
Specifications . . . . . . . . . . . . . . 1J-16
Exhaust System. . . . . . . . . ... 1K-1
General Description . . . . . . . . . . . .1K-1
Exhaust System Description . . . . . . . ...1K-1
Diagnostic Information and Procedures . . . 1K-1
Exhaust System Check . . . . . . . . . ...1K-1
Repair Instructions . . . . . . . . . . . ..1K-1
Exhaust System Components. . . . . . . .1K-1
Exhaust Manifold Removal and Installation
(For M16 Engine Model) . . . . . . . . ...1K-4
Exhaust Manifold Removal and Installation
(For J20 Engine Model). . . . . . . . . .1K-4
Exhaust Pipe and Muffler Removal and
Installation . . . . . . . . . . . . . . .1K-5
Precautions: 1-1
Engine
Precautions
Precautions
Precautions for Engine
S5JB0A1000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
Precautions on Engine Service
Refer to “Precautions on Engine Service in Section 1A”.
Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 1A”.
Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service in Section 1G”.
Engine Cooling System Warning
Refer to “Coolant Description in Section 1F”.
Cranking System Note
Refer to “Cranking System Note in Section 1I”.
Exhaust System Caution
Refer to “Exhaust System Check in Section 1K”.
Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in Section 00”.
Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter in Section 00”.
Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service in Section 00”.
Precautions of ECM Circuit Inspection
Refer to “Precautions of ECM Circuit Inspection in Section 1A”.
Precautions of Electric Throttle Body System Calibration
Refer to “Precautions of Electric Throttle Body System Calibration in Section 1A”.
Precaution in Replacing ECM
Refer to “Precaution in Replacing ECM in Section 10C”.
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