Suzuki Grand Vitara JB419. Service manual — part 62
Fuel System: 1G-6
Repair Instructions
Fuel System Components
S5JB0B1706001
22
23
29
27
26
25
31
20
28
19
18
4
6
1
7
9
8
12
5
2
14
15
11
10
25
27
13
(a)
(b)
(c)
(d)
(e)
16
30
3
17
(e)
21
(e)
24
I5JB0B170047-01
1. Fuel tank
13. O-ring
25. To injection pump
2. Fuel pump assembly
14. Fuel heater
26. To fuel filter
1G-7 Fuel System:
Fuel Pressure Relief Procedure
S5JB0B1706002
1) Check that engine is cold.
2) Connect SUZUKI scan tool to DLC (1) with ignition
switch turned OFF.
Special tool
(A): SUZUKI scan tool
3) Turn ON ignition switch.
4) Confirm that fuel high pressure line is not under
pressure by using “Fuel Rail Pressure” under “Data
List” of SUZUKI scan tool.
Fuel Leakage Check Procedure
S5JB0B1706003
1) Prime fuel line using priming pump (1).
2) Check low pressure fuel supply circuit for fuel
leakage.
3) Start engine and run it at idle speed for about 10
seconds.
4) Stop engine and then check for fuel leakage in each
part, which was serviced.
5) Start engine and run it at 4,000 r/min. for about 10
seconds.
6) Stop engine and then check for fuel leakage in each
part, which was serviced.
3. Gasket
15. Fuel filter water detection sensor
27. To fuel injector return hose
4. Fuel pump assembly plate
16. Injection pump
: For detail of component, refer to “Injection Pump
Components”.
28. To high pressure pipe between common rail and
injection pump
5. Main fuel level gauge
17. High pressure pipe between injection pump and common
29. To common rail
6. Sub fuel level gauge
18. Common rail
30. Sealing washer
7. Fuel tank belt
19. Common rail cover
31. To fuel return line
8. Fuel feed line
20. Common rail cushion
: 11 N
⋅m (1.1 kgf-m, 8.0 lb-ft)
9. Fuel return line
21. High pressure pipe between common rail and fuel injector
: 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
10. Priming pump
22. Fuel injector
: 5 N
⋅m (0.5 kgf-m, 4.0 lb-ft)
11. Fuel filter case
23. Fuel injector bracket
: 22 N
⋅m (2.2 kgf-m, 16.0 lb-ft)
12. Fuel filter
24. Fuel injector return hose
: 25 N
⋅m (2.5 kgf-m, 18.5 lb-ft)
(A)
1
I5JB0A110019-01
1
I5JB0B170002-01
Fuel System: 1G-8
Water Draining of Fuel Filter
S5JB0B1706023
1) Disconnect negative (–) cable at battery.
2) Place container under fuel filter (1).
3) Loosen bleed screw (2), and drain water until fuel
flow out from fuel filter.
4) Tighten bleed screw (2).
5) Connect negative (–) cable at battery.
6) Check fuel leakage referring to “Fuel Leakage Check
Air Bleeding of Fuel System
S5JB0B1706024
Air bleeding must be carried out when fuel system has
been disassembled or when vehicle ran out of fuel.
Pump priming pump (1) 20 times or more, and then
check engine starts.
Fuel Filter and Fuel Heater Removal and
Installation
S5JB0B1706025
Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect fuel heater connector (1) and fuel filter
water detection sensor connector (2).
3) Clean filter and its surrounding area.
4) Pull out fuel hoses (3) with pushing lock button (4).
5) Plug fuel hoses, fuel filter (5) and fuel heater with
plug cap according to “Precautions on Fuel System
Service” for parts number and handling.
6) Remove fuel filter (5) from its bracket (6).
7) Remove fuel heater (1) and fuel filter (2) from fuel
filter case (3).
1
2
I5JB0B170003-01
1
I5JB0B170002-01
1
5
3
2
3
3
4
I5JB0B170004-01
I5JB0B170005-01
1G-9 Fuel System:
Installation
1) Clean fuel heater and fuel filter case.
2) Install fuel heater (1) and fuel filter (2) to fuel filter
case (3) after applying diesel fuel to its new O-rings
(4).
CAUTION
!
Be sure to position claw (5) of the fuel filter
case (3) to such position of the fuel heater(1)
as shown in the figure.
If fuel pipes (fuel heater) are not positioned
as specified, an abnormal force is applied to
the fuel hoses and may cause damage to
them.
Tightening torque
Fuel filter case bolt (a): 5 N·m (0.5 kgf-m, 4.0 lb-
ft)
3) Install fuel filter (1) to its bracket.
4) Remove plug cup from fuel hoses (2) and fuel filter.
5) Connect fuel hoses to fuel filter.
6) Connect fuel heater connector (3) and fuel filter
water detection sensor (4).
7) Connect negative (–) cable at battery.
8) Bleed air in fuel system referring to “Air Bleeding of
9) Check fuel leakage referring to “Fuel Leakage Check
Fuel Heater Inspection
S5JB0B1706026
• Check for terminals of fuel heater for damage.
If damage is found, replace fuel heater.
• Check resistance between terminals of fuel heater
connector.If resistance is out of specification, replace
fuel heater.
Fuel Heater Resistance
Approx. 0.6
Ω
I5JB0B170049-01
I5JB0B170006-01
3
1
2
4
2
I5JB0B170007-01
I5JB0B170008-01
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