Suzuki Grand Vitara JB627. Manual - part 83

1D-13 Engine Mechanical: 

12) Disconnect brake booster hose (2) and vacuum tank 

hose (4) from intake manifold (1) then EVAP canister 
purge valve hose (3) from fuel No.2 pipe (5).

13) Disconnect fuel feed hose (1) and fuel return hose 

(2).

14) Remove fuel No.2 pipe bolts (3).

15) Remove intake manifold bolts (8 pcs.) and nuts (4 

pcs.).

16) Remove intake manifold.

Installation
Reverse removal procedure for installation noting the 
following.
• Use new intake manifold gaskets (1).

• Use new intake collector gaskets, and EGR pipe 

gasket (if equipped).

• Install electric throttle body assembly referring to 

“Electric Throttle Body Assembly Removal and 
Installation”.

• Check to ensure that all removed parts are back in 

place.
Reinstall any necessary parts which have not been 
reinstalled.

• Refill cooling system referring to “Cooling System 

Flush and Refill in Section 1F”.

• Connect negative cable (–) at battery.
• Upon completion of installation, verify that there is no 

fuel leakage at each connection according to “Fuel 
Leakage Check Procedure in Section 1G”.

• If EGR valve is removed, use new EGR valve gasket. 

(with EGR system)

• If EGR plate is removed, use new EGR plate gasket. 

(without EGR system)

4

3

5

2

1

I6JB01140024-02

3

1

2

I6JB01140025-01

I6JB01140026-01

IYSQ01143022-01

Engine Mechanical:  1D-14

Cylinder Head Covers Removal and Installation

S6JB0B1406010

Removal

1) Remove electric throttle body assembly, intake 

collector and intake manifold. Refer to “Intake 
Collector and Intake Manifold Removal and 
Installation” and “Electric Throttle Body Assembly 
Removal and Installation”.

2) Remove heater outlet pipe (1).
3) Detach engine harness (2) from cylinder head 

covers.

4) Disconnect ignition coil couplers and remove ignition 

coils referring to “Ignition Coil Assembly (Igniter and 
Ignition Coil) Removal and Installation in Section 
1H”.

5) Remove cylinder head covers (1).

Installation

1) Clean sealing surfaces on cylinder heads and 

covers.

2) Remove oil, old sealant, and dust from sealing 

surfaces. After cleaning, apply sealant “A” to cylinder 
heads sealing surface area as shown in figure.

“A”:  Water tight sealant 99000–31250 (SUZUKI 
Bond No.1207F)

3) Install new spark plug hole gaskets (3) and new 

cylinder head cover gaskets (2) to head covers (1).

4) Apply sealant “A” to cylinder head gaskets searing 

surface area as shown in figure.

“A”:  Water tight sealant 99000–31250 (SUZUKI 
Bond No.1207F)

[A]: RH (No.2) bank

2. Nut

[B]: LH (No.2) bank

3. Seal washer

1

2

I6JB01140027-01

1

2

3

1

[A]

[B]

I6JB01140028-01

[A]: RH (No.2) bank

[B]: LH (No.1) bank

[A]: RH (No.2) bank

[B]: LH (No.1) bank

[A]

[B]

“A”

“A”

“A”

I6JB01140029-03

1

3

2

3

1

[A]

[B]

“A”

“A”

“A”

“A”

“A”

I6JB01140030-03

1D-15 Engine Mechanical: 

5) Install cylinder head covers (1) to cylinder heads.
6) Using new seal washers (3), tighten nuts (2) 

following sequence (“1” – “4”) as indicated in figure. 
Tighten a little at a time and evenly among nuts and 
repeat tightening sequence 2 or 3 times before they 
are tightened to specified torque.

Tightening torque
Cylinder head cover nut (a):  10.5 N·m (1.1 kgf-
m, 7.5 lb-ft)

7) Install ignition coils and connect ignition coil couplers 

referring to “Ignition Coil Assembly (Igniter and 
Ignition Coil) Removal and Installation in Section 
1H”.

8) Clamp engine harness (2) to cylinder head cover.
9) Install heater outlet pipe (1).

10) Install intake manifold and intake collector referring 

to “Intake Collector and Intake Manifold Removal 
and Installation”.

11) Install electric throttle body assembly referring to 

“Electric Throttle Body Assembly Removal and 
Installation”.

[A]: RH (No.2) bank

[B]: LH (No.1) bank

1

2

3

[A]

[B]

1

“4”

“3”

“2”

“1”

“1”

“2”

“3”

“4”

I6JB01140031-03

1

2

I6JB01140032-01

Engine Mechanical:  1D-16

Engine Mounting Components

S6JB0B1406011

4

6

5

1

3

2

(a)

(a)

7

(a)

(a)

(a)

7

(a)

(a)

(a)

(a)

(a)

1

I6JB01140033-02

1. Engine front mounting

Be sure to align dowel pin with dowel hole of engine front mounting bracket.

5. Engine rear mounting

2. Engine front mounting right bracket

6. Engine splash cover (if equipped)

3. Engine front mounting left bracket

7. Engine front mounting nut

4. Engine rear mounting member

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)