Suzuki Grand Vitara JB419. Manual - part 67

Fuel System:  1G-26

Fuel Tank Inlet Valve Inspection

S5JB0B1706016

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
• Damage
• Smooth opening and closing

Fuel Pump Assembly Removal and Installation

S5JB0B1706019

WARNING

!

 

Before servicing fuel system, be sure to 
observe “Precautions on Fuel System 
Service”.

 

Removal

1) Remove fuel tank from vehicle. Refer to “Fuel Tank 

Removal and Installation”.

2) Disconnect fuel feed pipe (1) and fuel return pipe (3) 

from fuel pump assembly (2) referring to “Fuel Hose 
Disconnecting and Reconnecting”.

3) Remove fuel pump assembly (1) from fuel tank (2) 

and disconnect suction hose.

Installation

CAUTION

!

 

When connecting joint, clean outside surface 
of pipe where joint is to be inserted, push 
joint into pipe till joint lock clicks and check 
to ensure that pipes are connected securely, 
or fuel leak may occur.

 

1) Clean mating surfaces of fuel pump assembly (1) 

and fuel tank.

2) Put plate (2) on fuel pump assembly (1) by matching 

the protrusion of fuel pump assembly (3) to plate 
hole (4) as shown.

3) Connect suction hose to fuel pump assembly (1), 

and install new gasket (2) and fuel pump assembly 
with plate (3) to fuel tank (4).

Tightening torque
Fuel pump assembly bolt (a):  11 N·m (1.1 kgf-m, 
8.0 lb-ft)

4) Connect fuel feed pipe (1) (pipe joint) and fuel return 

pipe (3) (pipe joint) to fuel pump assembly (2).

5) Install fuel tank to vehicle. Refer to “Fuel Tank 

Removal and Installation”.

I2RH0B170019-01

3

1

2

I5JB0A171024-01

1

2

I3RM0A170021-01

3

1

2

4

I5JB0A171025-01

3

1

2

(a)

4

I3RM0A170023-01

3

1

2

I5JB0A171024-01

1G-27 Fuel System: 

Fuel Pump Inspection

S5JB0B1706043

• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and 

contamination.
If present, replace or clean and check for presence of 
dirt in fuel tank.

• For electrical circuit.

Main Fuel Level Gauge Removal and Installation

S5JB0B1706039

CAUTION

!

 

• Do not touch resister plate (1) and deform 

arm (2). It may cause main fuel level gauge 
to fail.

• Be very careful not to cause damage to 

fuel tube installed section (sealed section 
in bore). If it be damaged, replace it with 
new one, or fuel will leak from the part.

 

Removal

1) Remove fuel pump assembly from fuel tank referring 

to “Fuel Pump Assembly Removal and Installation”.

2) Disconnect main fuel level gauge connector (3).
3) With pressing snap-fit part (2), remove main fuel 

level gauge (1) by sliding it in the arrow direction as 
shown in figure.

Installation
Reverse removal procedure for installation.

Main Fuel Level Gauge Inspection

S5JB0B1706041

• Check main fuel level gauge for damage.
• For inspection of main fuel level gauge (1), refer to 

“Fuel Level Sensor Inspection in Section 9C”.

Sub Fuel Level Gauge Removal and Installation

S5JB0B1706040

CAUTION

!

 

Do not touch resister plate (1) and deform 
arm (2). It may cause sub fuel level gauge to 
fail.

 

Removal

1) Remove fuel tank from vehicle Referring to “Fuel 

Tank Removal and Installation”

2) Disconnect sub fuel level gauge connector (1) 

referring to “Fuel Hose Disconnecting and 
Reconnecting”.

3) Remove sub fuel level gauge (2).

1

2

I5JB0B170036-01

1

3

1

2

I5JB0B170037-01

1

I5JB0A171027-01

2

1

I5JB0A171028-01

2

2

1

I5JB0A171029-01

Fuel System:  1G-28

Installation
Reverse removal procedure for installation noting the 
following.
• Replace O-ring with new one using care not to 

damage it.

• Apply thin coat of fuel to O-ring, and then install sub 

fuel level sensor.

Sub Fuel Level Gauge Inspection

S5JB0B1706042

• Check sub fuel level gauge for damage.
• For inspection of sub fuel level gauge (1), refer to 

“Fuel Level Sensor Inspection in Section 9C”.

Tightening Torque Specifications

S5JB0B1707001

NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”
“Injection Pump Components”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to .

1

I5JB0A171030-01

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Fuel filter case bolt

5

0.5 

4.0

)

Common rail bolt

22

2.2 

16.0

)

High pressure pipe union nut

25

2.5 

18.0

)

 / )

Common rail mounting bolt

22

2.2 

16.0

)

Common rail bolt

25

2.5 

18.0

)

Throttle body to EGR valve pipe bolt and nut

21

2.1 

15.5

)

Injector cover bolt

8

0.8 

6.0

)

Fuel injector bracket bolt

25

2.5 

18.0

)

Injection pump bolt

30

3.0 

22.0

)

Injection pump pulley nut

70

7.0 

51.0

)

Injection pump front bracket bolt

Tighten 20 N

⋅m (0.2 kgf-m, 14.5 lb-ft) and 

80

° by the specified procedure.

)

Injection pump rear bracket bolt

44

4.4 

32.0

)

Fuel flow actuator bolt

Tighten 3 N

⋅m (0.3 kgf-m, 2.5 lb-ft) and 6 

N

⋅m (0.6 kgf-m, 4.5 lb-ft) by the specified 

procedure.

)

Fuel tank bolt

50

5.0 

36.5

)

Fuel filler hose clamp

2

0.2 

1.5

)

Fuel pump assembly bolt

11

1.1 

8.0

)

1G-29 Fuel System: 

Special Tools and Equipment

Recommended Service Material

S5JB0B1708001

NOTE
Required service material is also described in the following.
“Injection Pump Components”

 

Special Tool

S5JB0B1708002

09911–75410

09911–75420

Diesel injection-line wrench

Crow foot flare-nut wrench

DM.19A) / ) / ) / )

18.17)

09912–96510

09912–96520

Injection pump pulley 
remover

Adaptation crow

Mot. 1525)

Mot. 1525-03)

09912–96530

09919–47020

Injection pump pulley 
locking

Quick joint remover

Mot. 1668) / )

)

SUZUKI scan tool
—
This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12.)