Suzuki Grand Vitara JB419. Service manual - part 41

Engine Mechanical:  1D-10

Installation

1) Install oil separator (5) to cylinder head.

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

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

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

3) Install intercooler outlet pipe referring to “Intercooler 

and Air Intake Pipe Components”.

Vacuum Pump Removal and Installation

S5JB0B1406077

Removal

1) Disconnect negative (–) cable at battery.
2) Remove engine cover.
3) Remove air intake pipe referring to “Air intake Pipe 

Removal and Installation”.

4) Disconnect vacuum hose (1) from vacuum pump (2).
5) Remove vacuum pump from cylinder head.

Installation

1) Install vacuum pump (1) to cylinder head with new 

gasket.

Tightening torque
Vacuum pump bolt (a):  23 N·m (2.3 kgf-m, 17.0 
lb-ft)

2) Connect vacuum hose (2) to vacuum pump.

3) Install air intake pipe referring to “Air intake Pipe 

Removal and Installation”.

4) Install engine cover.
5) Connect negative (–) cable at battery.

Vacuum Pump Inspection

S5JB0B1406076

Install a vacuum gauge to the vacuum circuit using 3-
way joint (1) as shown in the figure and measure 
vacuum.
If vacuum is out of specification, check vacuum leakage, 
if OK than replace vacuum pump.

Vacuum pump specification
–75 kPa (–10.9 psi) or more (keep for 20 seconds at 
engine speed 1,500 r/min first)
–85 kPa (–12.3 psi) or more (keep for 20 seconds at 
engine speed 3,000 r/min first)

Special tool
(A):  09915–67311
(B):  09918–08210 

4

1

5

2

3

(a)

I5JB0B140020-01

1

2

I5JB0B120002-01

2

1

(a)

I5JB0B120003-01

A

1

B

I5JB0B120005-02

1D-11 Engine Mechanical: 

Timing Belt and Belt Tensioner Components

S5JB0B1406050

3

2

1

4

5

6

7

(a)

(b)

(d)

(c)

I5JB0B140021-01

1. Timing belt

: 10 N

⋅m (1.0 kgf-m, 7.5 lb-ft)

2. Timing belt cover No.1

: 45 N

⋅m (4.5 kgf-m, 32.5 lb-ft)

3. Camshaft pulley

: Tighten 40 N

⋅m (4.0 kgf-m, 29.0 lb-ft) and 110° by the specified procedure.

4. Crankshaft timing belt pulley

: 55 N

⋅m (5.5 kgf-m, 40.0 lb-ft)

5. Timing belt tensioner pulley

: Do not reuse.

6. Timing belt tensioner plate
7. Timing belt cover No.2

Engine Mechanical:  1D-12

Timing Belt and Belt Tensioner Removal and 
Installation

S5JB0B1406051

CAUTION

!

 

• Never turn injection pump pulley 

counterclockwise. It may cause damage of 
injection pump.

• After timing belt is removed, never turn 

crankshaft and camshafts independently. If 
turned, interference may occur between 
piston and valves and valves themselves, 
and parts related to piston and valves may 
be damaged.

• Do not bend or twist timing belt.
• Do not allow timing belt to come into 

contact with oil, water, etc. It may be 
adversely affect belt life.

• When replacing a timing belt, be sure to 

replace timing belt pulley and crankshaft 
pulley bolt.

 

Removal

1) Remove accessory drive belt referring to “Accessory 

Drive Belt and Idler Pulley Removal and Installation 
in Section 1J”.

2) Remove timing belt cover No.1 (1) and timing belt 

cover No.2 (2).

3) Turn crankshaft pulley clockwise, and stop turning 

crankshaft pulley immediately before mark (2) of 
camshaft pulley (3) matches with mark (1) of belt 
inner cover.

4) Remove TDC pin cap, and insert special tool (A) into 

TDC pin hole as shown in figure.

Special tool
(A):  09912–46510

1

2

I5JB0B140022-01

I5JB0B140023-01

I5JB0B140024-01

1D-13 Engine Mechanical: 

5) Turn crankshaft pulley clockwise until crankshaft 

touches special tool (A).

6) Remove crankshaft pulley as follows.

a) Lock ring gear (2) of flywheel by inserting flat 

head screw driver (1) or the like into hole of 
clutch housing.

CAUTION

!

 

Never lock flywheel with CKP sensor ring (3). 
It may cause damage of sensor ring.

 

NOTE
For unit disassembly service, lock ring gear 
of flywheel using special tool (B).

 

Special tool
(B):  09916–98110 

b) Remove special tool (A) from TDC pin hole.
c) Loosen crankshaft pulley bolt, and remove 

crankshaft pulley.

d) Insert special tool (A) into TDC pin hole.
e) Remove special tool (B) or screw driver or the 

like.

7) Remove tensioner pulley (1) and timing belt (2).

8) Remove timing belt tensioner plate (1), if necessary.

9) Remove crankshaft timing belt pulley (1) using 

special tools as shown in finger, if necessary.

Special tool
(C):  09919–76510
(D):  09926–37610–001

NOTE
Be sure to use bolts (2) of M6 size and 1.0 
mm (0.039 in.) pitch for fixing crankshaft 
timing belt pulley by special tools.

 

[A]: For on-vehicle service

[B]: For unit disassembly service

I5JB0B140025-01

1

2

I5JB0B140026-01

I5JB0B140027-01

1

(C)

(D)

2

I5JB0B140028-01