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Contents Section: Exhaust All sections

Engine Exhaust System Suzuki Grand Vitara II рестайлинг

Exhaust 20 illustrations ~1095 words

Exhaust System Description

The exhaust system consists of exhaust manifold(s), TWC(s) (three-way catalytic converter(s)) in the exhaust manifold(s), exhaust pipes, a muffler, seals, gaskets, etc.

The TWC(s) can reduce HC (hydrocarbon), CO (carbon monoxide) and NOx (oxides of nitrogen) in exhaust gases simultaneously.

Exhaust System Check

WARNINGTo avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must be completely cool before beginning any service on it.

At every periodical vehicle inspection, and when vehicle is raised for other service, check exhaust system as follows

Scheme 1

Scheme 1
Scheme 1
  1. Check rubber mountings for damage, deterioration, and out of position.
  2. Check distortion of exhaust manifold seating surface(s) of cylinder head.
  3. Check exhaust system for exhaust fume leakage, loose connection, dent and damage.
  4. If bolts or nuts are loosened, tighten them to specified torque.
  5. Check any damages, holes or cracks which may permit exhaust fumes to enter the vehicle.
  6. Make sure that exhaust system components have enough clearance from other underbody components to avoid overheating and possible damage to these components.
  7. Any defect should be fixed at once whenever it is found.

Exhaust System Components

WARNINGTo avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must be completely cool before beginning any service on it.

Scheme 2

Scheme 2
Scheme 2

20. and 21.: For tightening order see EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)

Exhaust Manifold Removal and Installation (N32A)

Removal

WARNINGTo avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must be completely cool before beginning any service on it.
CAUTIONExhaust manifold has three-way catalytic converter which reduce harmful exhaust emissions. Be careful not to drop exhaust manifold. If it is dropped, inside catalytic converter may be damage on impact.

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK: N32A .

Scheme 3

Scheme 3: Bank 1
Scheme 3: Bank 1

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. Remove battery. See «BATTERY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system__battery-removal-and-installation) .
  2. Remove battery tray (1) and bracket (2).
  3. Remove air cleaner assembly, see «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation)
  4. Disconnect front HO2S connector (1) of bank-1, rear HO2S connectors (2) of both bank-1 and bank-2. Detach disconnected connectors from their brackets.
  5. Remove exhaust manifold cover.
  6. Remove exhaust pipe No. 1 according to the following procedure. Remove engine rear mounting (1). Remove exhaust pipe No. 1. Install engine rear mounting (1) without installing exhaust pipe No. 1. Tightening torque Engine rear mounting bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
  7. Remove exhaust manifold stiffener (1).
  8. Remove exhaust manifold bolts and nuts in numerical order ("1" - "7") evenly and gradually, and remove bank-1 exhaust manifold and its gasket from cylinder head.
  9. Remove front HO2S and rear HO2S, if necessary. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .

Scheme 7

Scheme 7: Bank 2
Scheme 7: Bank 2

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Disconnect negative (-) cable from battery.
  2. Remove front HO2S (1) from bank-2 exhaust manifold. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .
  3. Remove exhaust manifold cover (2).
  4. Disconnect rear HO2S connectors (3), and then detach them from their bracket.
  5. Remove oil level gauge (4) and oil level gauge guide (5).
  6. Remove exhaust pipe No. 1 according to the following procedure. Remove engine rear mounting (1). Remove exhaust pipe No. 1. Install engine rear mounting (1) without installing exhaust pipe No. 1. Tightening torque Engine rear mounting bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
  7. Remove fuel pipe cover (1).
  8. Remove exhaust manifold stiffener (2).
  9. Remove exhaust manifold bolts and nuts in numerical order ("1" - "7") evenly and gradually.
  10. Remove heat protector panel (1).
  11. Support front suspension frame (1) with a transmission jack or the like, and loosen suspension frame bolts (2).
  12. Lower suspension frame a little to make a space above it, then remove bank-2 exhaust manifold and its gasket from cylinder head.
  13. Remove rear HO2S if necessary. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .

Installation

Reverse removal procedure for both bank-1 and bank-2 noting the following.

Scheme 13

Scheme 13: Installation
Scheme 13: Installation

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Use new gaskets and new seal rings. Tighten front HO2S and rear HO2S to specified torque. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .
  2. Use new O-ring (2) for oil level gauge guide (1) and apply engine oil to O-ring when installing oil level gauge guide to cylinder block (3).
  3. Tighten oil level gauge guide bolt (1) to specified torque. Tightening torque Oil level gauge guide bolt (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft) (for N32A)
  4. Use new exhaust manifold bolts.
  5. Tighten exhaust manifold bolts and nuts in numerical order ("1" - "7") evenly and gradually. Tightening torque Exhaust manifold bolt*: 20 N.m (2.0 kg-m, 15.0 lbf-ft) Exhaust manifold nut*: 20 N.m (2.0 kg-m, 15.0 lbf-ft) CAUTION: Retighten exhaust manifold bolts and nuts to specified torque once in numerical order ("1" - "7").
  6. Tighten suspension frame mounting bolts to specified torque.
  7. Run engine and check for exhaust leaks.

Exhaust Manifold Removal and Installation (J24B)

WARNINGTo avoid getting burned, do not work on exhaust system when it is hot. Exhaust system must be completely cool before beginning any service on it.
CAUTIONExhaust manifold has three-way catalytic converter which reduce harmful exhaust emissions. Be careful not to drop exhaust manifold. If it is dropped, inside catalytic converter may be damages on impact.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. Disconnect negative (-) cable from battery.
  2. Remove exhaust manifold cover.
  3. Disconnect A/F sensor connector (1) and HO2S connector (2), and then detach them from their brackets.
  4. Remove exhaust pipe No. 1 (1).
  5. Remove oil level gauge and oil level gauge guide (1).
  6. Remove exhaust manifold (2) and its gasket from cylinder head.
  7. Remove A/F sensor and HO2S if necessary. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .

Reverse removal procedure noting the following.

Scheme 19

Scheme 19: Installation
Scheme 19: Installation

Scheme 20

Scheme 20
Scheme 20
  1. Use new gaskets and new seal rings.
  2. Install A/F sensor and HO2S. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .
  3. Use new O-ring (2) for oil level gauge guide (1) and apply engine oil to it when installing oil level gauge guide to oil pan (3).
  4. Tighten oil level gauge guide bolt (1) to specified torque. Tightening torque Oil level gauge guide bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) (for J24B)
  5. Run engine and check for exhaust leaks.

Exhaust Pipe and Muffler Removal and Installation

To remove and install exhaust pipes and muffler, refer to and the following.

  1. For N32A, remove engine rear mounting to remove and install exhaust pipe No. 1. When engine rear mounting is installed, tighten bolts to specified torque referring to «ENGINE MOUNTINGS COMPONENTS: N32A»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
  2. Tighten bolts and nuts to specified torques when reassembling exhaust pipes and muffler. See «EXHAUST SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-system-components) .
  3. Run engine and check for exhaust leaks.

Tightening Torque Specifications

CAUTIONFor fastener with * (asterisk) below, be sure to tighten it according to specified procedure in "Repair Instructions".
Fastening partTightening torque
N.mKgf-mLbf-ft
Engine rear mounting bolt555.640.5
Oil level gauge guide bolt101.07.5
Exhaust manifold bolt*202.015.0
Exhaust manifold nut*202.015.0
Oil level gauge guide bolt111.18.5

TIGHTENING TORQUE SPECIFICATIONS

Note. The specified tightening torque is also described in the following. EXHAUST SYSTEM COMPONENTS

Reference

For the tightening torque of fastener not specified in this section, refer to FASTENER INFORMATION .