Suzuki Grand Vitara JB419. Manual - part 40

Engine Mechanical:  1D-6

3) Disconnect intercooler inlet hose (1) and outlet hose 

(2) from intercooler (4).

4) Remove intercooler brackets (3) and intercooler (4).

Installation

1) Install intercooler brackets (1) and intercooler (2).
2) Connect intercooler inlet hose (3) and outlet hose 

(4).

Tightening torque
Intercooler inlet hose clamp (a):  4.5 N·m (0.45 
kgf-m, 3.5 lb-ft)
Intercooler outlet hose clamp (b):  4.5 N·m (0.45 
kgf-m, 3.5 lb-ft)

3) Install resonator (1).

4) Install front bumper referring to “Front Bumper 

Components in Section 9K in related manual” and 
“Rear Bumper Components in Section 9K in related 
manual”.

Air intake Pipe Removal and Installation

S5JB0B1406074

Removal

1) Disconnect negative (–) cable at battery.
2) Disconnect boost presser sensor connector (1) and 

intake throttle valve connector (2).

3) Disconnect intercooler outlet pipe (3) from air intake 

pipe (5) after removing intercooler outlet pipe clamp 
(6).

4) Remove vacuum pipe (4) and air intake pipe.

Installation
Reverse removal procedure for installation noting the 
following.
• Tighten air intake pipe bolt and nut to specified torque.

Tightening torque
Air intake pipe bolt and nut:  21 N·m (2.1 kgf-m, 
15.5 lb-ft)

• Tighten intercooler outlet pipe clamp to specified 

torque as follows.
a. Tighten intercooler outlet pipe clamp to 5 N

⋅m (0.5 

kgf-m, 4.0 lb-ft).

b. Wait 5 minutes.
c. Retighten intercooler outlet pipe clamp to 5 N

⋅m 

(0.5 kgf-m, 4.0 lb-ft).

Tightening torque
Intercooler outlet pipe clamp:  Tighten 5 N

⋅m (0.5 

kgf-m, 4.0 lb-ft) and 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft) after 5 

minutes

3

1

3

4

3

2

3

I5JB0B140008-01

1

3

1

2

1

4

1

(a)

(b)

I5JB0B140009-02

1

I5JB0B140007-01

4

1

2

3

5

6

I5JB0B140144-01

1D-7 Engine Mechanical: 

Cylinder Head Cover Components

S5JB0B1406047

Cylinder Head Cover Removal and Installation

S5JB0B1406048

Removal

1) Disconnect CMP sensor connector (1).

2) Remove harness bracket and timing belt cover No.2 

(1).

3) Remove air intake pipe (1) referring to “Air intake 

Pipe Removal and Installation”.

4) Disconnect ventilation hose No.2 (2) from ventilation 

pipe No.2 (3).

5) Disconnect ventilation hose No.3 (4) from oil vapor 

recirculation valve (5).

6) Remove fuel injector cover (6).

7) Remove cylinder head cover bolts evenly and 

gradually in numerical order (“1” through “3”) as 
shown in figure.

1. Cylinder head cover

3. Cylinder head cover gasket

: Do not reuse.

2. Cylinder head cover bolt gasket

: Tighten 12 N

⋅m (1.2 kgf-m, 9.0 lb-ft) by the specified procedure.

1

(a)

2

3

I5JB0B140010-01

1

I5JB0B140011-01

1

I5JB0B140012-01

5

2

3

1

6

4

I5JB0B140013-02

I5JB0B140014-01

Engine Mechanical:  1D-8

8) Remove cylinder head cover (1), cylinder head cover 

gasket (2) and cylinder head cover bolt gaskets (3).

Installation

1) Remove oil and dust from sealing surfaces on 

cylinder head and cylinder head cover.

2) Install cylinder head cover (1), new cylinder head 

cover gasket (2) and new cylinder head cover bolt 
gaskets (3).

3) Tighten cylinder head cover bolts evenly and 

gradually in numerical order (“1” through “3”) by 
repeating tightening sequence two or three times 
until specified torque is obtained.

Tightening torque
Cylinder head cover bolt (a):  Tighten 12 N

⋅m (1.2 

kgf-m, 9.0 lb-ft) by the specified procedure

4) Install fuel injector cover (1).

Tightening torque
Injector cover bolt (a):  8 N·m (0.8 kgf-m, 6.0 lb-ft)

5) Connect ventilation hose No.2 (2) to ventilation pipe 

No.2 (3).

6) Connect ventilation hose No.3 (4) to oil vapor 

recirculation valve (5).

7) Install air intake pipe (6) referring to “Air intake Pipe 

Removal and Installation”.

8) Connect CMP sensor connector (1).

I5JB0B140015-01

I5JB0B140015-01

I5JB0B140016-02

5

2

3

(a)

6

1

4

I5JB0B140017-03

1

I5JB0B140011-01

1D-9 Engine Mechanical: 

9) Install timing belt cover No.2 (1) and harness 

bracket.

Tightening torque
Timing belt cover No.2 bolt (a):  55 N·m (5.5 kgf-
m, 40.0 lb-ft)

Oil Separator Components

S5JB0B1406075

Oil Separator Removal and Installation

S5JB0B1406049

Removal

1) Remove intercooler outlet pipe referring to “Air intake 

Pipe Removal and Installation”.

2) Disconnect ventilation hose No.2 (1), oil separator 

return hose (2), flesh air vent hose (3) and ventilation 
hose No.3 (4) from oil separator (5).

3) Remove oil separator (5) from cylinder head.

(a)

1

I5JB0B140018-01

6

7

(b)

9

10

(a)

3

2

4

1

8

5

(a)

(c)

(d)

I5JB0B140145-02

1. Ventilation hose No.2

6. Ventilation hose No.1

: 25 N

⋅m (2.5 kgf-m, 18.5 lb-ft)

2. Oil separator return hose

7. Ventilation pipe No.1

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

3. Flesh air vent hose

8. Oil level gauge

: 8 N

⋅m (0.8 kgf-m, 6.0 lb-ft)

4. Oil separator

9. O-ring

: 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft)

5. Ventilation pipe No.2

10. Ventilation hose No.3 union bolt

: Do not reuse.

4

1

5

2

3

I5JB0B140019-01