Cylinder Head Cover Removal And Installation - Suzuki Grand Vitara 2011 Manual

2) Drain cooling system referring to "Cooling System
Draining: For Petrol Engine Model in Section 1F".
3) Remove engine cover.
4) Remove air cleaner outlet hose (1) and breather
hose (2).
5) Remove electric throttle body assembly referring to
"Electric Throttle Body Assembly Removal and
Installation: For J20 Engine".
6) Disconnect the following electric lead wires:
• EVAP canister purge valve coupler (1)
• MAP sensor coupler (2)
7) Disconnect the following hoses:
• Brake booster hose (3) from intake manifold
• PCV hose (4) from PCV valve
• Fuel pressure regulator vacuum hose (5) from
intake manifold
• Vacuum hose (6) from EVAP canister purge valve
• Vacuum hose (7) from vacuum tank
• EVAP canister purge hose (8) from EVAP canister
purge valve
8) Remove EGR pipe bolt (9) from EGR pipe.
9) Remove EVAP canister purge valve bracket (10)
form intake manifold.
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9
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2
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10) Remove water pump and generator drive belt
referring to "Water Pump and Generator Drive Belt
Removal and Installation (For J20 Engine): For
Petrol Engine Model in Section 1J".
11) With hose connected, detach P/S pump referring to
"P/S Pump Removal and Installation (J20A Engine
Model) in Section 6C".
12) Remove intake manifold and O-ring from cylinder
head.
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Engine Mechanical: For J20 Engine 1D-77
Installation
Reverse removal procedure for installation noting the
followings.
• Use new intake manifold O-ring.
• Use new EGR pipe gasket.
• Install intake manifold bolt (2) and nut (1) as shown in
figure.
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• Check to ensure that all removed parts are back in
place.
Reinstall any necessary parts which have not been
reinstalled.
• Adjust water pump and generator drive belt referring
to "Water Pump and Generator Drive Belt On-Vehicle
Inspection (For J20 Engine): For Petrol Engine Model
in Section 1J".
• Refill cooling system referring to "Cooling System
Flush and Refill: For Petrol Engine Model in Section
1F".
• Upon completion of installation, turn ignition switch
ON but engine OFF and check for fuel leaks.
• Finally, start engine and check for engine coolant
leaks.

Cylinder Head Cover Removal and Installation

Removal
1) Disconnect negative cable at battery.
2) Remove engine cover.
3) Disconnect ignition coil couplers (1).
4) Remove ignition coils (4).
5) Remove oil level gauge (6).
6) Disconnect CMP sensor coupler (5) from cylinder
head cover.
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