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Notes Specified value Measured value

Vehicle identification
No. of cylinders Type 4/DOHC  
Capacity (Fiscal) cc 1586  
Compression ratio :1 9,7  
Suitable for unleaded petrol Yes  
Minimum octane rating RON 95  
Ignition system Make Suzuki  
Ignition system Description Map-DIS  
Trigger location Cam / Crankshaft  
Fuel system Make Suzuki  
Fuel system Description MFI-s  
Air metering Type MAP  
Combined ignition and fuel ECM Yes  
Diagnostic socket Yes  
Ignition system
Ignition coil supply voltage + with ballast V 12,0  
Secondary resistance Ohm 7600-10200  
Firing order 1-3-4-2  
Tuning and emissions
Ignition timing - basic BTDC °Engine/rpm 12±5/660 Not adjustable  
Ignition advance checks °Engine/rpm ECM Controlled  
Idle speed rpm 660±50 Not adjustable  
Idle speed - alternative rpm AC=750±50 Not adjustable  
Oil temperature for CO test °C 80  
CO level at idle speed - tailpipe Vol. % CO 0,5 Max Not adjustable  
HC level at idle speed ppm 100  
CO2 level at idle speed Vol. % CO2 14,5-16  
O2 level at idle speed Vol. % O2 0,1-0,5  
Increased idle speed for CO test rpm 2500-2800  
CO content at increased idle speed Vol. % 0,2  
Lambda at increased idle λ 0,97-1,03  
Spark plugs
Spark plugs Original equipment NGK  
Spark plug Type IFR5J11  
Electrode gap mm 1,0-1,1  
Spark plugs Make NGK  
Spark plug Type IFR6J11  
Electrode gap mm 1,0-1,1  

Manufacturer: Suzuki Model: Grand Vitara (05-) 1,6 (c) Autodata Limited 2013
Engine code: M16A Output: 78 (106) 5900 . 27/10/20
Tuned for: R-Cat Year: 2005-14 V9.200-
 Fuel system
System pressure bar 2,5-3,1  
Regulated pressure with vacuum bar 2,1-2,6  
Engine coolant temperature (ECT) sensor Ohm/°C 1,15-5,74  
00000033 Lambda sensor (Oxygen) heater Ohm  
Service checks and adjustments
Valve clearance -INLET mm 0,21-0,27 hot  
Valve clearance -EXHAUST mm 0,30-0,36 hot  
Compression pressure bar 11,0-14,0  
Oil pressure bar/rpm 2,7/4000  
Radiator cap bar 1,10  
Thermostat opens °C 80-84  
Drive belt tension - alternator/PAS/AC mm 4,5-5,5  
Drive belt tension - AC mm 7-8  
Lubricants and capacities
Engine oil options
Ambient temperature range Cold climate  
Engine oil grade SAE 5W-30  
Engine oil classification API/ACEA SM/A3  
Ambient temperature range Moderate climate  
Engine oil grade SAE 10W-30  
Engine oil classification API/ACEA SM/A3  
Ambient temperature range Moderate climate alternative  
Engine oil grade SAE 10W-40  
Engine oil classification API/ACEA SM/A3  
Ambient temperature range Hot climate  
Engine oil grade SAE 20W-50  
Engine oil classification API/ACEA SM/A3  
Engine with filter(s) litres 4,5  
Other lubricants and capacities
00000112 Manual transmission oil grade SAE 75W-90  
Manual transmission oil classification GL-4  
Manual transmission litres 2,0  
Differential oil grade - front SAE 80W-90  
Differential oil classification - front GL-5  
Differential front/AT litres 1,0  
Differential oil grade - rear SAE 80W-90 Synthetic  
Differential oil classification - rear GL-5  
Differential rear litres 0,8-1,1  
Transfer box oil grade SAE 75W-90 Semi-synthetic  
Transfer box oil classification GL-4  
Transfer box litres 1,5  
Coolant Type Ethylene glycol  
Cooling system - total capacity litres 6,9  
Brake fluid Type DOT 4  
Power steering fluid Type Dexron II  
Power steering fluid litres 0,8  
Tightening torques
Cylinder head instructions  
Cylinder head

Manufacturer: Suzuki Model: Grand Vitara (05-) 1,6 (c) Autodata Limited 2013
Engine code: M16A Output: 78 (106) 5900 . 27/10/20
Tuned for: R-Cat Year: 2005-14 V9.200-
 Renew bolts Yes  
Stage 1 Tighten 20 Nm  
Stage 2 Tighten 40 Nm  
Stage 3 Tighten 60°  
Stage 4 Tighten 60°  
Stage 5 Tighten M8=25 Nm  
Other engine tightening torques
00000063 Main bearings Renew bolts/nuts  
00000064 Big end bearings Renew bolts/nuts  
Big end bearings Stage 1 15 Nm  
Big end bearings Stage 2 45°+45°  
Oil pump to cylinder block 11 Nm  
Sump bolts 11 Nm  
Sump drain bolt 35 Nm  
00000026 Flywheel/driveplate 70 Nm  
Clutch pressure plate 23 Nm  
Crankshaft pulley/damper centre bolt 150 Nm  
Camshaft sprocket/gear 60 Nm  
Camshaft carrier/cap 11 Nm  
Camshaft/rocker cover 8 Nm  
Inlet manifold to cylinder head 25 Nm  
Exhaust manifold to cylinder head 50 Nm  
Exhaust downpipe to manifold 50 Nm  
Water pump 25 Nm  
Spark plugs 25 Nm  
Fuel rail 25 Nm  
Crankshaft position (CKP) sensor/engine speed (RPM) sensor 10 Nm  
Camshaft position (CMP) sensor 10 Nm  
Engine coolant temperature (ECT) sensor 12 Nm  
Lambda sensor (Oxygen) 45 Nm  
Knock sensor (KS) 22 Nm  
Engine oil pressure switch 13 Nm  
Oil filter 14 Nm  
Chassis tightening torques
00000026 Front hub 220 Nm  
00000026 Front hub - wheel bearing housing bolts 50 Nm  
00000026 Rear hub 220 Nm  
00000026 Rear hub - wheel bearing housing bolts 50 Nm  
Steering wheel 33 Nm  
Steering rack/box mounting 105 Nm  
00000085 Steering track rod end 35 Nm  
Brake caliper to carrier Front 36 Nm  
Brake caliper/carrier to hub Front 85 Nm  
Brake caliper to carrier Rear 43 Nm  
Brake caliper/carrier to hub Rear 85 Nm  
ABS sensor Front 10 Nm  
ABS sensor Rear 10 Nm  
Road wheels 100 Nm  
Starting and charging
Battery V/RC(Ah) 12  

Manufacturer: Suzuki Model: Grand Vitara (05-) 1,6 (c) Autodata Limited 2013
Engine code: M16A Output: 78 (106) 5900 . 27/10/20
Tuned for: R-Cat Year: 2005-14 V9.200-
 Maximum cranking amps A 90  
Alternator output at engine speed A/V/rpm 80/12/1200  
Brake disc and drum dimensions
Minimum disc thickness for replacement - ventilated Front 23 mm  
Minimum disc thickness for replacement Rear 14 mm  
Disc runout Front 0,10 mm  
Disc runout Rear 0,10 mm  
Maximum drum diameter for replacement Rear 256 mm  
Minimum pad thickness Front 2 mm  
Minimum pad thickness Rear 1,5 mm  
Minimum shoe thickness Rear 1 mm  
Parking brake travel No. of notches 5-7  
Air conditioning
No. of AC service connectors 2  
Air conditioning restrictor type Expansion valve  
Compressor clutch/magnetic coupling Yes  
Compressor variable displacement solenoid No  
Air conditioning refrigerant Type R134a  
Air conditioning refrigerant quantity grams 570±30  
Air conditioning oil Type 99000-99015-00A  
Air conditioning oil quantity cm³ 120±10  

Autodata Note 26

Use new nuts/bolts.

Autodata Note 33

Lambda sensor heater resistance

HO2S-1 = 5,0-6,4 Ω
HO2S-2 = 11,7-14,3 Ω.

Autodata Note 63

Main bearings

Renew bolts if diameter difference between A and B exceeds 0,2 mm.

a = 60 mm
b = 90 mm
Fig. 108202
Inner bolts:
1) 30 Nm
2) 50 Nm
3) 60°
Outer bolts:
1) 12 Nm
2) 25 Nm

Autodata Note 64

Manufacturer: Suzuki Model: Grand Vitara (05-) 1,6 (c) Autodata Limited 2013
Engine code: M16A Output: 78 (106) 5900 . 27/10/20
Tuned for: R-Cat Year: 2005-14 V9.200-
 Big end bearings

a = 32 mm
b = 40 mm
Renew bolts if diameter difference between A and B exceeds 0,1 mm.
Fig. 108201

Autodata Note 85

Steering track rod end

Tighten nut to align split pin (60° max.).

Autodata Note 112

Manual transmission oil grade

VIN 600001→ = 75W-80

108202 108201

Timing mark Tightening sequence

Manufacturer: Suzuki Model: Grand Vitara (05-) 1,6 (c) Autodata Limited 2013
Engine code: M16A Output: 78 (106) 5900 . 27/10/20
Tuned for: R-Cat Year: 2005-14 V9.200-