Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual

Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 212

1K-8 Exhaust System: For Diesel Engine Model

Repair Instructions

Exhaust System Components

S6JB0A1B26001

WARNING

To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any
service on the exhaust system should be performed when the system is cool.

I6JB0A1B2001-04

[A]: Diesel particulate filter model

3. Exhaust pipe No.3

: 21 N

⋅m (2.1 kgf-m, 15.5 lb-ft)

[B]: Non-Diesel particulate filter model

4. Muffler

: 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft)

Exhaust System: For Diesel Engine Model 1K-9

Exhaust Manifold Removal and Installation

S6JB0A1B26002

For removal and installation, refer to “Intake Manifold
and Exhaust Manifold Removal and Installation: For F9Q
Engine in Section 1D”.

Diesel Particulate Filter Removal and
Installation

S6JB0A1B26003

WARNING

To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

CAUTION

When replacing diesel particulate filter,
perform “Initialize diesel PF data” mode of
SUZUKI scan tool referring to “SUZUKI Tech
2 Operator's Manual”.

Removal

1) Disconnect negative (–) cable at battery.
2) Remove exhaust gas temperature sensor 2 and 3

from diesel particulate filter.

3) Remove diesel particulate filter differential pressure

sensor union nut.

4) Remove diesel particulate filter differential pressure

sensor pipe from diesel particulate filter.

5) Remove diesel particulate filter.

Installation
Reverse removal procedure noting the following.
• Tighten bolts and nuts to specified torque referring to

“Exhaust System Components: For Diesel Engine
Model”.

• When replacing diesel particulate filter, perform

“Initialize diesel PF data” mode of SUZUKI scan tool
referring to “SUZUKI Tech 2 Operator's Manual”.

Specifications

Tightening Torque Specifications

S6JB0A1B27001

NOTE
The specified tightening torque is also described in the following.
“Exhaust System Components: For Diesel Engine Model”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S6JB0A1B28001

NOTE
Required service material is also described in the following.
“Exhaust System Components: For Diesel Engine Model”

[C]: 3 door model

5. Diesel particulate filter differential

pressure sensor

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

[D]: 5 door model

6. Exhaust gas temperature sensor 2

: 35 N

⋅m (3.5 kgf-m, 25.5 lb-ft)

[E]: View [E]

7. Exhaust gas temperature sensor 3

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

a. 90

8. Mounting No.1

: 44 N

⋅m (4.4 kgf-m, 32.0 lb-ft)

b. Flat face

9. Mounting No.2

: Do not reuse.

1. Exhaust pipe No.1

10. Catalytic converter

: : Apply grease 99000-25280 to

all around thread part.

2. Exhaust pipe No.2

11. Clamp

1K-10 Exhaust System: For Diesel Engine Model