Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 137

1D-74 Engine Mechanical: For J20 Engine

Repair Instructions

Air Cleaner Assembly Removal and Installation

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Removal

1) Disconnect breather hose (1) from air cleaner outlet 

hose (2).

2) Remove air cleaner outlet hose (2).
3) Disconnect MAF sensor connector (3).
4) Remove air cleaner case (4).

Installation

1) Install air cleaner case (4).
2) Connect MAF sensor connector (3).
3) Install air cleaner outlet hose (2).
4) Connect breather hose (1) to air cleaner outlet hose 

(2).

Air Cleaner Filter Removal and Installation

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Removal

1) Remove air cleaner upper case (1) from lower case 

after hooking clamps (2) from upper case.

2) Remove air cleaner filter.

Installation
Reverse removal procedure for installation.

Air Cleaner Filter Inspection and Cleaning

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Inspection
Check air cleaner filter for dirt.

Cleaning
Blow off dust by compressed air from air outlet side of 
element.

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Engine Mechanical: For J20 Engine 1D-75

Throttle Body and Intake Manifold Components

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1. Intake manifold

: Never disassemble intake manifold. Disassembly will spoil its original performance. If faulty condition is 
found, replace it with new one.

4. Electric throttle body assembly

2. O-ring

: Do not reuse.

3. MAP sensor

1D-76 Engine Mechanical: For J20 Engine

Throttle Body On-Vehicle Inspection

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Check electric throttle body assembly referring to 
“Throttle Valve Operation Check” and “Electric Throttle 
Body Assembly Operation Check” under “Electric 
Throttle Body Assembly On-Vehicle Inspection: For 
Petrol Engine Model in Section 1C”.

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: 

For Petrol Engine Model in Section 1F”.

3) Disconnect breather hose (1) from air cleaner outlet 

hose (2).

4) Disconnect air cleaner outlet hose (2) from air 

cleaner case and electric throttle body assembly.

5) Disconnect engine coolant hoses (1) from electric 

throttle body assembly (2).

6) Disconnect connector (3) 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 cleaner outlet hose (1) to air cleaner 

case and electric throttle body assembly.

6) Connect breather hose (2) to air cleaner outlet hose 

(1).

7) Refill coolant referring to “Cooling System Flush and 

Refill: For Petrol Engine Model in Section 1F”.

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

referring to “Electric Throttle Body System 
Calibration: For Petrol Engine Model in Section 1C” if 
replaced.

Throttle Body Cleaning

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Clean electric throttle body assembly referring to 
“Throttle Valve Operation Check” under “Electric Throttle 
Body Assembly On-Vehicle Inspection: For Petrol 
Engine Model in Section 1C”.

Intake Manifold Removal and Installation

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CAUTION

!

 

Never disassemble intake manifold. 
Disassembly will spoil its original 
performance. If faulty condition is found, 
replace it with new one.

 

Removal

1) Disconnect negative cable at battery.

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Engine Mechanical: For J20 Engine 1D-77

2) Drain cooling system referring to “Cooling System 

Draining: For Petrol Engine Model in Section 1F”.

3) Remove engine cover.
4) Remove air cleaner outlet hose (1) and breather 

hose (2).

5) Remove electric throttle body assembly referring to 

“Electric Throttle Body Assembly Removal and 
Installation: For J20 Engine”.

6) Disconnect the following electric lead wires:

• EVAP canister purge valve coupler (1)
• MAP sensor coupler (2)

7) Disconnect the following hoses:

• Brake booster hose (3) from intake manifold
• PCV hose (4) from PCV valve
• Fuel pressure regulator vacuum hose (5) from 

intake manifold

• Vacuum hose (6) from EVAP canister purge valve
• Vacuum hose (7) from vacuum tank
• EVAP canister purge hose (8) from EVAP canister 

purge valve

8) Remove EGR pipe bolt (9) from EGR pipe.
9) Remove EVAP canister purge valve bracket (10) 

form intake manifold.

10) Remove water pump and generator drive belt 

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

11) With hose connected, detach P/S pump referring to 

“P/S Pump Removal and Installation (J20A Engine 
Model) in Section 6C”.

12) Remove intake manifold and O-ring from cylinder 

head.

Installation
Reverse removal procedure for installation noting the 
followings.
• Use new intake manifold O-ring.
• Use new EGR pipe gasket.
• Install intake manifold bolt (2) and nut (1) as shown in 

figure.

• Check to ensure that all removed parts are back in 

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

• Adjust water pump and generator drive belt referring 

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

• Refill cooling system referring to “Cooling System 

Flush and Refill: For Petrol Engine Model 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.

Cylinder Head Cover Removal and Installation

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Removal

1) Disconnect negative cable at battery.
2) Remove engine cover.
3) Disconnect ignition coil couplers (1).
4) Remove ignition coils (4).
5) Remove oil level gauge (6).
6) Disconnect CMP sensor coupler (5) from cylinder 

head cover.

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