Suzuki Grand Vitara JB416 / JB420. Manual — part 103

1D-80 Engine Mechanical: For J20 Engine

Engine Mountings Components

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1. Engine front mounting

6. Engine splash cover

2. Engine front mounting right bracket

7. Engine front mounting nut

3. Engine front mounting left bracket

8. Engine rear mounting member bolt

4. Engine rear mounting member

9. Engine front mounting bracket bolt

5. Engine rear mounting

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)

Engine Mechanical: For J20 Engine 1D-81

Engine Assembly Removal and Installation

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Removal

1) Relieve fuel pressure according to “Fuel Pressure

Relief Procedure in Section 1G”.

2) Disconnect negative cable at battery.
3) Drain engine oil referring to “Engine Oil and Filter

Change in Section 0B”.

4) Drain transmission oil referring to “Manual

Transmission Oil Change in Section 5B”.

5) Drain A/T fluid referring to “A/T Fluid Change in

Section 5A”.

6) Drain coolant referring to “Cooling System Draining

in Section 1F”.

7) Remove Air cleaner case referring to “Air Cleaner

Assembly Removal and Installation: For J20
Engine”.

8) Remove water pump and generator drive belt

referring to “Water Pump and Generator Drive Belt
Removal and Installation (For J20 Engine) in Section
1J”.

9) Disconnect the following electric wires:

• MAP sensor (1)
• ECT sensor (2)
• EGR valve (3)
• CMP sensor (4)
• EVAP canister purge valve (5)
• Ignition coil assembly (6)
• Injectors (7)
• HO2S (8)
• A/F sensor (9)
• Engine oil pressure switch (10)
• CKP sensor (11)
• Back up light switch (For M/T model) (12)
• Generator (13)
• Starting motor (14)
• Ground terminal
• Magnet clutch switch of A/C compressor (if

equipped) (15)

• P/S pump (16)
• Electric throttle body (17)
• Transfer actuator (18)
• Center differential switch (19)
• 4L/N switch (20)
• Each wire harness clamps
• Input shaft speed sensor (For A/T model) (26)
• Output shaft speed sensor (For A/T model) (27)
• Solenoid valve (For A/T model) (28)
• Transmission range sensor (For A/T model) (29)

10) Disconnect the following hoses:

• Brake booster hose (21) from intake manifold
• Radiator inlet and outlet hoses (22) from each

pipe

• Heater inlet and outlet hoses (23) from each pipe
• Fuel hoses (24) from fuel pipes
• Purge hose (25) from purge valve
• Clutch oil pipe from transmission front case (For

M/T model)

• A/T fluid cooler hoses from radiator (For A/T

model)

11) Disconnect A/T select cable from A/T (For A/T

model).

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1D-82 Engine Mechanical: For J20 Engine

12) For M/T model, remove shift control lever referring to

“Transmission Shift Control Lever Removal and
Installation in Section 5B”.

13) Remove exhaust No.1, No.2 and center pipes

referring to “Exhaust System Components in Section
1K”.

14) Remove front and rear propeller shafts referring to

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

15) With hose connected, detach P/S pump from its

bracket (if equipped) referring to “P/S Pump
Removal and Installation for J20 Engine Model in
Section 6C”.

CAUTION

!

Suspend removed P/S pump at a place where
no damage will be caused during removal
and installation of engine assembly.

16) With hose connected, detach A/C compressor from

its bracket (if equipped) referring to “Compressor
Assembly Removal and Installation for J20 Engine
Model in Section 7B”.

CAUTION

!

Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

17) Support front suspension frame and engine rear

mounting member using jack (2).

18) Carry out Step 1) to 12) of “Removal” under “Front

Suspension Frame, Stabilizer Bar and/or Bushings
Removal and Installation in Section 2B” in order to
lower engine with front suspension frame.

19) Remove front suspension frame mounting bolts (1).

20) Remove engine rear mounting member bolts (1).

21) Before lowering engine, recheck to make sure all

hoses, electric wires and cables are disconnected
from engine.

22) Lower engine with transmission, transfer, front

suspension frame and engine rear mounting
member from engine compartment.

CAUTION

!

Before lowering engine, in order to avoid
damage to A/C compressor and P/S pump,
make clearance by rising them.

23) Disconnect transmission from engine referring to

“Manual Transmission Assembly Dismounting and
Remounting in Section 5B” or “Automatic
Transmission Unit Components in Section 5A”, if
necessary.

24) Remove engine with engine front mounting bracket

(1) from engine front mounting (2), if necessary.

25) Remove clutch cover and clutch disk referring to

“Clutch Cover, Clutch Disc and Flywheel Removal
and Installation in Section 5C”, if necessary.

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Engine Mechanical: For J20 Engine 1D-83

Installation

1) Install clutch cover and clutch disk referring to

“Clutch Cover, Clutch Disc and Flywheel Removal
and Installation in Section 5C”, if removed.

2) Install engine with engine front mounting bracket to

engine front mounting. For tightening torque,
referring to “Engine Mountings Components: For J20
Engine”, if removed.

3) Connect transmission from engine referring to

“Manual Transmission Assembly Dismounting and
Remounting in Section 5B” or “Automatic
Transmission Unit Components in Section 5A”, if
removed.

4) Lift engine with transmission, front suspension frame

and engine rear mounting member into engine
compartment with jack.

CAUTION

!

Before lifting engine, to avoid damage to A/C
compressor and P/S pump, make clearance
by rising them.

5) Tighten engine rear mounting member bolt referring

to “Engine Mountings Components: For J20 Engine”.

6) Carry out Step 5) to 19) of “Installation” under “Front

Suspension Frame, Stabilizer Bar and/or Bushings
Removal and Installation in Section 2B” in order to lift
engine with front suspension frame.

7) Remove engine jack.
8) Install front and rear propeller shafts referring to

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

9) Install exhaust No.1, No.2 and center pipes referring

to “Exhaust System Components in Section 1K”.

10) Install A/C compressor to its bracket (if equipped)

referring to “Compressor Assembly Removal and
Installation for J20 Engine Model in Section 7B”.

11) Install P/S pump to its bracket referring to “P/S Pump

Removal and Installation for J20 Engine Model in
Section 6C”.

12) Return disconnected hoses, cables and electric wire

noting the followings.
• Tighten nuts to specified torque.

Tightening torque
Starting motor terminal nut: 11 N·m (1.1 kgf-m,
8.0 lb-ft)
Generator terminal nut: 7 N·m (0.7 kgf-m, 5.0 lb-
ft)

13) Install water pump and generator drive belt referring

to “Water Pump and Generator Drive Belt Removal
and Installation (For J20 Engine) in Section 1J”.

14) Adjust water pump and generator drive belt tension

referring to “Water Pump and Generator Drive Belt
On-Vehicle Inspection (For J20 Engine) in Section
1J”.

15) Install air cleaner assembly referring to “Air Cleaner

Assembly Removal and Installation: For J20
Engine”.

16) Check all removed parts are back in place.
17) For A/T model, adjust select cable referring to

“Select Cable Adjustment in Section 5A”.

18) Refill cooling system with coolant referring to

“Cooling System Flush and Refill in Section 1F”.

19) Refill engine with engine oil referring to “Engine Oil

and Filter Change in Section 0B”.

20) Bleed air from clutch system referring to “Air

Bleeding of Brake System in Section 4A” for air
bleeding procedure.

21) Install engine hood after disconnecting windshield

washer hose.

22) Connect negative cable at battery.
23) With engine OFF, turn ignition switch to ON position

and check for fuel leakage.

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

leakage at each connection.