Suzuki Grand Vitara JB627. Manual - part 107

1G-11 Fuel System:

• Tighten delivery pipe bolts (5) and fuel union bolt (8)

to specified torque and make sure that injectors rotate
smoothly.

Tightening torque
Fuel delivery pipe bolt (a): 25 N·m (2.5 kgf-m, 18.0
lb-ft)
Fuel union bolt (b): 30 N·m (3.0 kgf-m, 22.0 lb-ft)

• After installation, with engine OFF and ignition switch

ON, check for fuel leaks around fuel line connection.

Fuel Injector Inspection

S6JB0B1706009

WARNING

Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

1) Install injector (1) and pressure regulator (2) to

special tool (A), and connect pressure regulator to
fuel return pipe (4) using hose included in special
tool (A).

Special tool
(A): 09912–58421

2) Connect special tools (B) to fuel feed pipe (3) and

injector (1).

Special tool
(B): 09912–58442

3) Connect special tool (C) to injector (1).

Special tool
(C): 09930–88530

4) Install suitable vinyl tube onto injector nozzle to

prevent fuel from splashing out when injecting.

5) Put graduated cylinder under injector.
6) Operate fuel pump and apply fuel pressure to

injector as follows:
a) When using scan tool:

Connect scan tool to DLC with ignition switch
OFF.

ii) Turn ignition switch ON, clear DTC and

select “MISC TEST” mode on scan tool.

iii) Turn fuel pump ON by using scan tool.

Special tool
(A): SUZUKI scan tool

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(A)

I5JB0A171009-01

Fuel System: 1G-12

b) When not using scan tool:

Remove fuel pump relay from connector.

ii) Connect two terminals of relay connector

using service wire (1) as shown in figure.

CAUTION

Check to make sure that connection is made
between correct terminals. Wrong
connection can cause damage to ECM, wire
harness, etc.

iii) Turn ignition switch ON.

7) Apply battery voltage to injector (1) for 15 seconds

and measure injected fuel volume with graduated
cylinder. Test each injector two or three times.

Reference injected fuel volume
Approx. 65 cc / 15 sec. (2.20/2.29 US/Imp oz / 15
sec.)

8) Check fuel leakage from injector nozzle. Do not

operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.

Fuel leakage
Less than 1 drop/min.

Fuel Pressure Regulator Removal and
Installation

S6JB0B1706010

WARNING

Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service”in order to reduce the risk or fire and
personal injury.

Removal

1) Relieve fuel pressure according to “Fuel Pressure

Regulator Inspection”.

2) Disconnect negative (–) cable at battery.
3) Remove surge tank cover.
4) Disconnect vacuum hose (1) from fuel pressure

regulator.

5) Remove fuel pressure regulator (1) from delivery

pipe (3).

6) Disconnect fuel return hose (2) from fuel pressure

regulator (1).

I5JB0A171010-02

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1G-13 Fuel System:

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 fuel

pressure regulator (1) to delivery pipe.

• Tighten fuel pressure regulator bolts to specified

torque.

Tightening torque
Fuel pressure regulator bolt: 11 N·m (1.1 kgf-m,
8.0 lb-ft)

• After installation, with engine OFF and ignition switch

ON, check for fuel leaks around fuel line connection.

Fuel Pressure Regulator Inspection

S6JB0B1706011

Confirm fuel pressure of fuel line is decreased when fuel
pressure regulator is applied negative pressure by
special tool.

Special tool
(A): 09917–47011

Fuel Filler Cap Inspection

S6JB0B1706012

WARNING

Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Remove cap (1), and check gasket for even filler neck
imprint, and deterioration or any damage. If gasket (2) is
in malcondition, replace cap.

NOTE
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in fire and
personal injury.

Fuel Tank Inlet Valve Removal and Installation

S6JB0B1706013

WARNING

Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal

1) Remove fuel filler cap.
2) Insert hose of a hand operated pump into fuel filler

hose (1) and drain fuel in space “A” as shown in
figure.

CAUTION

Do not force pump hose into fuel tank, or
pump hose may damage to fuel tank inlet
valve (2).

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(A)

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I2RH01170008-01

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Fuel System: 1G-14

3) Hoist vehicle, and remove clamps (2) and fuel filler

hose (1) from fuel filler neck.

4) Remove fuel tank inlet valves (1) using flat head rod

(2) or the like.

CAUTION

Be careful not to damage fuel tank inlet valve
(1) with flat head rod (2) or the like.

Installation

1) Install fuel tank inlet valves (1) to fuel filler neck (3)

and fuel tank (2).

2) Install fuel filler hose (1) to fuel filler neck and fuel

tank and secure it with clamps (2).
For proper installation, refer to “Fuel Hose
Disconnecting and Reconnecting”.

Tightening torque
Fuel filler hose clamp (a): 4 N·m (0.4 kgf-m, 3.0
lb-ft)

3) Lower vehicle and install fuel filler cap.

Fuel Tank Inlet Valve Inspection

S6JB0B1706014

WARNING

Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

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

[A]: Fuel tank side (if equipped)
[B]: Fuel filler neck side

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[A]: Fuel tank side (if equipped)
[B]: Fuel filler neck side

2, (a)

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