Suzuki Grand Vitara JB627. Manual - part 82

1D-9 Engine Mechanical: 

Air Cleaner Filter Removal and Installation

S6JB0B1406002

Removal

1) Disconnect connector from MAF and IAT sensor.
2) Open air cleaner upper case (1) after unhooking its 

clamps (2).

3) Remove air cleaner filter.

Installation
Reverse removal procedure for installation.

Air Cleaner Filter Inspection and Cleaning

S6JB0B1406003

Inspection
Check filter for dirt. Replace if filter is excessively dirty.

Cleaning
When cleaning filter, blow off dust by blowing 
compressed air from air outlet side of filter (i.e., the side 
facing up when installed in air cleaner case).

Intake Collector and Intake Manifold Components

S6JB0B1406004

1

2

I6JB01140011-01

I6JB01140012-01

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16

3

4

5

12

10

13

9

8

6

8

9

17

14

7

11

15

2

15

15

7

I6JB01140018-01

1. Intake manifold

6. Intake collector

11. Electric throttle body assembly gasket

16. IMT (Intake manifold tuning) valve

2. Intake manifold gasket

7. Intake collector gasket

12. Electric throttle body assembly nut

17. Surge tank pipe nut

3. Intake manifold bolt (long)

8. Intake collector nut

13. Electric throttle body assembly bolt

: Do not reuse.

4. Intake manifold bolt (short)

9. Intake collector bolt

14. Surge tank pipe

Engine Mechanical:  1D-10

Electric Throttle Body Assembly On-Vehicle 
Inspection

S6JB0B1406005

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

Electric Throttle Body Assembly Removal and 
Installation

S6JB0B1406006

Removal

1) Release fuel pressure in fuel feed line by referring to 

“Fuel Pressure Relief Procedure in Section 1G”.

2) Disconnect negative (–) cable at battery.
3) Drain engine coolant referring to “Cooling System 

Draining in Section 1F”.

4) Remove surge tank cover.
5) Remove intake air pipe (1), surge tank pipe (2) and 

IMT valve (3).

6) Disconnect connectors from electric throttle body 

assembly (1) and fuel injectors (2) of LH (No.1) 
bank.

7) Disconnect fuel connect pipe (1) from delivery pipe.
8) Disconnect water hose (2) from electric throttle body 

assembly.

9) Remove LH (No.1) bank delivery pipe (1) with fuel 

pressure regulator (2).

10) Detach electric throttle body assembly (1) from 

intake collector.

11) Disconnect water hose (2) from electric throttle body 

assembly.

5. Intake manifold nut

10. Electric throttle body assembly

15. Surge tank pipe gasket

2

1

3

I6JB01140112-01

2

1

I6JB01140014-01

2

1

I6JB01140015-01

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2

I6JB01140016-01

2

1

I6JB01140017-01

1D-11 Engine Mechanical: 

Installation
Reverse removal procedure for installation noting the 
following.
• Clean mating surfaces and use new throttle body 

gasket (1).

• Use new fuel connector pipe gaskets.
• Tighten fuel connector pipe union bolts and delivery 

pipe bolts to specified torque referring to “Fuel System 
Components in Section 1G”.

• Use new surge tank pipe gaskets.
• 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”.

• Upon completion of installation, verify that there is no 

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

IMT (Intake Manifold Tuning) Valve Removal and 
Installation

S6JB0B1406007

Refer to “Electric Throttle Body Assembly Removal and 
Installation”.

IMT (Intake Manifold Tuning) Valve Inspection

S6JB0B1406008

1) Connect special tool (A) to IMT valve (1).

Special tool
(A):  09917–47011

2) Apply vacuum to IMT valve (1) and verify that throttle 

(2) fully closes within the specified range. If IMT 
valve (1) fails this check, replace it.

CAUTION

!

 

Do not apply above 88 kPa (0.88 kg/cm

2

, 661 

mmHg, 880 mbar) of negative pressure. 
Damage may occur to IMT valve (1).

 

IMT valve operation pressure
1.3 – 34 kPa (0.01 – 0.34 kg/cm

2

, 9.8 – 255 mmHg, 

13 – 340 mbar)

3) Let the throttle (2) close for 15 seconds with no 

vacuum application and inspect throttle travel. If 
throttle travel decreases, replace IMT valve (1).

1

I6JB01140109-01

1

(A)

2

I4JA01140010-01

Engine Mechanical:  1D-12

Intake Collector and Intake Manifold Removal 
and Installation

S6JB0B1406009

Removal

1) Remove electric throttle body assembly referring to 

“Electric Throttle Body Assembly Removal and 
Installation”.

2) Disconnect water hose (1) from heater outlet pipe.
3) Remove heater outlet pipe bolts (2).

4) Disconnect MAP sensor connector (if equipped) (1) 

and fuel injector harness connector (2).

5) Remove harness clamp bracket (right side) (3) from 

intake collector.

6) Disconnect vacuum hose (4) of EVAP canister purge 

valve from intake collector.

7) Disconnect EVAP canister purge valve connector (1) 

and ground terminals (2).

8) Remove harness clamp bracket (left side) (3) from 

intake collector.

9) With EGR system

a) Disconnect connector from EGR valve assembly 

(1).

b) Disconnect EGR pipe (2) and PCV hose (3).
Without EGR system
a)  Disconnect PCV hose (3).

10) Detach intake collector (4) from intake manifold, and 

then disconnect water hose (5).

11) Remove EGR valve assembly (1) (if equipped) and 

PCV pipe (2) from intake collector, if necessary.

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2

I6JB01140019-01

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3

2

4

I6JB01140020-01

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2

I6JB01140021-01

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I6JB01140022-01

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I6JB01140023-01