Suzuki Grand Vitara JB419. Service manual - part 46

 

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Suzuki Grand Vitara JB419. Service manual - part 46

 

 

Engine Mechanical:  1D-30

Installation

CAUTION

!

 

Before starting engine (including when 
performing oil level check and air bleeding 
process of cooling system) for the first time 
after installing turbocharger, be sure to 
lubricate turbocharger while disabling engine 
to start according to the following 
procedure.Otherwise, lack of lubrication will 
cause turbocharger damage.
1. Disconnect fuel pressure sensor 

connector.

2. Crank engine for 20 seconds to lubricate 

turbocharger with engine oil.

3. Connect fuel pressure sensor connector.
4. As DTC is stored in ECM memory in Step 

2), make sure to clear it.

 

1) Install turbocharger lubrication pipe union nut (1) 

with new copper ring, turbocharger lubrication pipe 
(2), turbocharger water inlet pipe (3) and 
turbochanger water outlet pipe (4) to turbocharger 
with new gasket and new clamp, if removed.

Tightening torque
Turbocharger lubrication pipe union nut (a):  36 
N·m (3.6 kgf-m, 26.5 lb-ft)
Turbocharger lubrication pipe union bolt 
(turbocharger side) (b):  16 N·m (1.6 kgf-m, 12.0 
lb-ft)
Turbocharger water inlet pipe union bolt (c):  29 
N·m (2.9 kgf-m, 21.0 lb-ft)
Turbocharger water outlet pipe union bolt  (d):  
29 N·m (2.9 kgf-m, 21.0 lb-ft)

2) Install turbocharger (1) to exhaust manifold with new 

gasket.

Tightening torque
Turbocharger nut (a):  37 N·m (3.7 kgf-m, 27.0 lb-
ft)

3) Fit turbocharger inlet pipe (11) to turbocharger and 

install turbocharger stiffener (2). Tighten 
turbocharger stiffener bolt by hand temporarily.

4) Tighten turbocharger inlet pipe clamp by specified 

torque.

Tightening torque
Turbocharger inlet pipe clamp (i):  16 N·m (1.6 
kgf-m, 12.0 lb-ft)

5) Tighten turbocharger stiffener bolt by specified 

torque.

Tightening torque
Turbocharger stiffener bolt (b):  21 N·m (2.1 kgf-
m, 15.5 lb-ft)

6) Install exhaust manifold heat shield (3) to exhaust 

manifold.

Tightening torque
Exhaust manifold heat shield bolt (c):  11 N·m (
1.1 kgf-m, 8.0 lb-ft)

7) Connect turbocharger lubrication pipe (4) and 

lubrication pipe stiffeners to cylinder block.

Tightening torque
Turbocharger lubrication pipe union bolt 
(cylinder block side) (d):  44 N·m (4.4 kgf-m, 32.0 
lb-ft)
Turbocharger lubrication pipe stiffener bolt (e):  
25 N·m (2.5 kgf-m, 18.0 lb-ft)

8) Install oil return pipe No.1 (5) and No.2 (6) with new 

gasket and O-ring.

Tightening torque
Oil return pipe No.1 bolt (f):  12 N·m (1.2 kgf-m, 
9.0 lb-ft)
Oil return pipe No.1 stiffener bolt (g):  12 N·m (
1.2 kgf-m, 9.0 lb-ft)
Oil return pipe No.2 bolt (h):  12 N·m (1.2 kgf-m, 
9.0 lb-ft)

9) Connect boost pressure control actuator hose (7) to 

boost pressure control actuator.

10) Connect turbocharger water inlet hose (8) and outlet 

hose (9).

11) Connect turbocharger outlet hose (10) to 

turbocharger (1).

Tightening torque
Turbocharger outlet hose clamp (turbocharger 
side) (j):  5 N·m (0.5 kgf-m, 4.0 lb-ft)

2

1, (a)

3

4

(b)

(c)

(d)

I5JB0B140055-04

1D-31 Engine Mechanical: 

12) Install catalytic converter referring to “Exhaust 

System Components in Section 1K”.

13) Install thermostat assembly referring to “Thermostat 

Assembly Removal and Installation in Section 1F”.

14) Install engine assembly referring to “Engine 

Assembly Removal and Installation”.

Turbocharger Assembly Inspection

S5JB0B1406069

Turbocharger
Rotate turbine shaft (1) by hand and verify that it turns 
smoothly without any abnormal noise and excessive 
runout.
If a malfunction is found, replace turbocharger.

Boost Presser Control Valve

1) Remove turbocharger referring to “Turbocharger 

Assembly Removal and Installation”.

2) Set magnetic base (1) with dial gauge (2) as shown 

in figure.

3) Connect special tool to boost presser control valve 

(3).

Special tool
(A):  09917–47011

4) Measure stroke of boost presser control valve rod (4) 

when applying specified pressure.
If measure stroke is out of specification, adjust rod 
stroke referring to “Turbocharger Assembly 
Adjustment” or
 replace turbocharger. 

Boost presser control valve rod stroke
1.3 – 3.3 mm (0.052 – 0.129 in.) at 20 kPa (–0.2 kg/
cm

2

, 2.84 psi)

9.5 – 11.5 mm (0.374 – 0.452 in.) at 55 kPa (–
0.55kg/cm

2

, 7.81 psi)

Stop at 60 kPa (–0.6kg/cm

2

, 8.52 psi) or more

8

9

3

(g)

6

4

7

2

1

10

(a)

(b)

(c)

(d)

(e)

5

(f)

(h)

(e)

11

(i)

(j)

I5JB0B140056-04

1

I4RH0A140020-01

I5JB0B140139-01

Engine Mechanical:  1D-32

Turbocharger Assembly Adjustment

S5JB0B1406070

1) Loosen lock nut (1).
2) Tighten or loose adjusting wheel (2) so as to adjust 

stroke of boost presser control valve rod with 
applying specified pressure.
For correct stroke and specified pressure, refer to 
“Boost Presser Control Valve” under “Turbocharger 
Assembly Inspection”.

3) Tighten lock nut after adjusting.

Intake Manifold and Exhaust Manifold Components

S5JB0B1406058

I5JB0B140140-01

1

4

2

(a)

(b)

3

I5JB0B140057-01

1. Intake manifold

3. Intake and exhaust manifold gasket

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

2. Exhaust manifold

4. Exhaust manifold heat shield

: Do not reuse.

3. Intake and exhaust manifold gasket

: Tighten 28 N

⋅m (0.8 kgf-m, 6.0 lb-ft) by the specified procedure.

1D-33 Engine Mechanical: 

Intake Manifold and Exhaust Manifold Removal 
and Installation

S5JB0B1406059

Removal

1) Remove turbocharger assembly referring to 

“Turbocharger Assembly Removal and Installation”.

2) Remove EGR pipe and cooler referring to “EGR Pipe 

and EGR Cooler Removal and Installation”.

3) Remove EGR valve referring to “EGR Valve 

Removal and Installation”.

4) Remove engine hanger (1).

5) Loosen intake and exhaust manifold nuts (1) from 

outside to center in symmetry and evenly.

6) Remove intake and exhaust manifolds.
7) Remove exhaust gas temperature sensor-1 from 

exhaust manifold referring to “Exhaust Gas 
Temperature Sensor 1, 2 and 3 Removal and 
Installation in Section 1B”,
 if necessary.

Installation

1) Install exhaust gas temperature sensor-1 to exhaust 

manifold “Exhaust Gas Temperature Sensor 1, 2 and 
3 Removal and Installation in Section 1B”, 
if 
removed.

2) Install intake and exhaust manifolds as follows.

a) Fit intake and exhaust manifolds to cylinder head 

with new gasket.

b) Tighten new intake and exhaust manifold nuts 

from center to outside in symmetry and evenly 
until specified torque is obtained.

Tightening torque
Intake and exhaust manifolds nut  (a):  
Tighten 28 N

m (0.8 kgf-m, 6.0 lb-ft) by the 

specified procedure

3) Install engine hanger (1).

Tightening torque
Engine hanger bolt (a):  25 N·m (2.5 kgf-m, 18.5 
lb-ft)

4) Install EGR pipe and cooler referring to “EGR Pipe 

and EGR Cooler Removal and Installation”.

5) Install EGR valve referring to “EGR Valve Removal 

and Installation”.

6) Install turbocharger referring to “Turbocharger 

Assembly Removal and Installation”.

1

I5JB0B140059-02

1

I5JB0B140058-01

(a) 

(a) 

(a) 

(a) 

(a) 

(a) 

(a) 

(a) 

(a) 

I5JB0B140060-01

1

(a)

I5JB0B140061-01

 

 

 

 

 

 

 

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