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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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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