Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 122

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: For Petrol Engine Model in 
Section 1G”.

2) Disconnect negative cable at battery.
3) Drain engine oil referring to “Engine Oil and Filter 

Change (Petrol Engine Model) in Section 0B”.

4) Drain coolant referring to “Cooling System Draining: 

For Petrol Engine Model 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 (M16A 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: For 
Petrol Engine Model in Section 5B”.

14) Remove exhaust No.1, No.2 and center pipes 

referring to “Exhaust System Components: For 
Petrol Engine Model 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 (M16A 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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1D-16 Engine Mechanical: For M16A Engine with VVT

17) With hose connected, detach A/C compressor from 

its bracket (if equipped) referring to “Compressor 
Assembly Removal and Installation for M16 Engine 
Model in Section 7B”.

CAUTION

!

 

Suspend removed A/C compressor at a place 
where no damage will be caused during 
removal and installation of engine assembly.

 

18) Support front suspension frame and engine rear 

mounting member using jack (2).

19) Carry out Step 1) to 12) of “Removal” under “Front 

Suspension Frame, Stabilizer Bar and/or Bushings 
Removal and Installation in Section 2B” in order to 
lower engine with front suspension frame.

20) Remove front suspension frame mounting bolt (1).

21) Remove engine rear mounting member bolt (1).

22) Before lowering engine with transmission and front 

suspension frame from engine compartment, 
recheck to make sure all hoses, electric wires and 
cables are disconnected from engine.

23) Lower engine with transmission and front 

suspension frame from engine compartment.

CAUTION

!

 

Before lowering engine, in order to avoid 
damage to A/C compressor and P/S pump, 
make clearance by rising them.

 

24) Disconnect transmission from engine referring to 

“Manual Transmission Assembly Dismounting and 
Remounting: For Petrol Engine Model in Section 
5B”, if necessary.

25) Remove engine with engine front mounting bracket 

(1) from engine front mounting (2), if necessary.

26) Remove clutch cover and clutch disc referring to 

“Clutch Cover, Clutch Disc and Flywheel Removal 
and Installation in Section 5C”, if necessary.

Installation

1) Install clutch cover and clutch disc referring to 

“Clutch Cover, Clutch Disc and Flywheel Removal 
and Installation in Section 5C”, if necessary.

2) Install engine with engine front mounting bracket to 

engine front mounting.
For tightening torque, refer to “Engine Mountings 
Components: For M16A Engine with VVT”, if 
necessary.

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Engine Mechanical: For M16A Engine with VVT 1D-17

3) Connect transmission to engine referring to “Manual 

Transmission Assembly Dismounting and 
Remounting: For Petrol Engine Model in Section 
5B”, if necessary.

4) Lift engine with transmission and front suspension 

frame into engine compartment with jack.

CAUTION

!

 

Before lifting engine, in order to avoid 
damage to A/C compressor and P/S pump, 
make clearance by rising them.

 

5) Tighten engine rear mounting member bolt referring 

to “Engine Mountings Components: For M16A 
Engine with VVT”.

6) Carry out Step 5) to 19) of “Installation” under “Front 

Suspension Frame, Stabilizer Bar and/or Bushings 
Removal and Installation in Section 2B” in order to lift 
engine with front suspension frame.

7) Remove engine jack.
8) Install front and rear propeller shafts referring to 

“Propeller Shaft Removal and Installation in Section 
3D”.

9) Install exhaust No.1, No.2 and center pipes referring 

to “Exhaust System Components: For Petrol Engine 
Model in Section 1K”.

10) Install A/C compressor to its bracket (if equipped) 

referring to “Compressor Assembly Removal and 
Installation for M16 Engine Model in Section 7B”.

11) Install P/S pump to its bracket (if equipped) referring 

to “P/S Pump Removal and Installation (M16A 
Engine Model) in Section 6C”.

12) Return disconnected hoses, cables and electric 

wires noting the followings.
• Tighten nuts to specified torque.

Tightening torque
Starting motor terminal nut:  11 N·m (1.1 kgf-m, 
8.0 lb-ft)
Generator terminal nut:  7 N·m (0.7 kgf-m, 5.0 lb-
ft)

13) Install P/S pump and A/C compressor (if equipped) 

drive belt referring to “P/S Pump and A/C 
Compressor (If Equipped) Drive Belt Removal and 
Installation (M16A Engine Model) in Section 6C”.

14) Adjust P/S pump and A/C compressor (if equipped) 

drive belt tension referring to “P/S Pump and A/C 
Compressor (If Equipped) Drive Belt Inspection and 
Adjustment (M16A Engine Model) in Section 6C”.

15) Install air cleaner case (2).
16) Connect MAF sensor connector (1).

17) Install air intake pipe (2).
18) Connect breather union (1) to air intake pipe (2).

19) Check all removed parts are back in place.
20) Refill cooling system with coolant referring to 

“Cooling System Flush and Refill: For Petrol Engine 
Model in Section 1F”.

21) Refill engine with engine oil referring to “Engine Oil 

and Filter Change (Petrol Engine Model) in Section 
0B”.

22) Install engine hood after disconnecting windshield 

washer hose.

23) After installation, bleed air from clutch system.

Refer to “Air Bleeding of Clutch System in Section 
5C” for air bleeding procedure.

24) Connect negative cable at battery.
25) With engine OFF, turn ignition switch to ON position 

and check for fuel leakage.

26) Start engine and check coolant oil and exhaust gas 

leakage at each connection.

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