Suzuki Grand Vitara JB416 / JB420. Manual — part 86

1D-12 Engine Mechanical: For M16A Engine with VVT

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

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 in Section 1F”.

8) Connect negative cable at battery.
9) Perform calibration of electric throttle body assembly

referring to “Electric Throttle Body System
Calibration in Section 1C” if replaced.

Throttle Body Cleaning

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Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.

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3, (a)

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Engine Mechanical: For M16A Engine with VVT 1D-13

Intake Manifold Removal and Installation

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Removal

1) Relieve fuel pressure in fuel feed line referring to

“Fuel Pressure Relief Procedure 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 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 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.

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2. Short bolt

3. Long bolt

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1D-14 Engine Mechanical: For M16A Engine with VVT

Engine Mountings Components

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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 coolant referring to “Cooling System Draining

in Section 1F”.

5) Disconnect breather hose (1) from air intake pipe (2).
6) Remove air intake pipe (2).

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1. Engine front mounting

4. Engine rear mounting member

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)

2. Engine front mounting right bracket

5. Engine rear mounting

: 17 N

⋅m (1.7 kgf-m, 12.5 lb-ft)

3. Engine front mounting left bracket

6. Engine mounting nut

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Engine Mechanical: For M16A Engine with VVT 1D-15

7) Disconnect MAF sensor connector (1).
8) Remove air cleaner case (2).

9) Disconnect radiator inlet hose (1).

10) Remove P/S pump belt referring to “P/S Pump and

A/C Compressor (If Equipped) Drive Belt Removal
and Installation for M16 Engine Model in Section
6C”.

11) 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)
• A/F sensor (8)
• HO2S (9)
• Engine oil pressure switch (10)
• CKP sensor (11)
• Back-up light switch (12)
• Generator (13)
• Starting motor
• Ground terminal from intake manifold (14)
• Magnet clutch switch of A/C compressor (15) (if

equipped)

• P/S pump (16) (if equipped)
• Electric throttle body (17)
• Oil control valve (18)
• Transfer actuator (19)
• Differential lock switch (20)
• 4H switch (21)

• Each wire harness clamps

12) Disconnect the following hoses:

• Brake booster hose (22) from intake manifold
• Radiator inlet and outlet hoses (26) from each

pipe

• Heater inlet and outlet hoses (23) from each pipe
• Fuel hoses (24) from fuel pipes
• EVAP canister purge (25) hose from purge valve
• Clutch oil pipe from transmission housing

13) Remove shift control lever referring to “Transmission

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

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

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

15) Remove front and rear propeller shafts referring to

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

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

bracket (if equipped) referring to “P/S Pump
Removal and Installation for M16 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.

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