Suzuki Grand Vitara JB419. Service manual — part 65

Fuel System: 1G-18

Injection Pump Removal and Installation

S5JB0B1706030

WARNING

!

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

CAUTION

!

Never disassemble injection pump.
Disassembly will spoil its original function. If
faulty condition is found, replace it with new
one.

Removal

1) Check that engine is cold and fuel pressure is not

under pressure referring to “Fuel Pressure Relief
Procedure”.

2) Remove timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation in Section 1D”.

3) Clean all fuel connectors on injection pump.
4) Disconnect fuel flow actuator connector (1).
5) Disconnect fuel feed hose (2) and fuel return hose

(3) from injection pump.

6) Clean and vacuum any contamination, and plug all

joint part of disconnected fuel circuit with plug cap
referring to “Precautions on Fuel System Service”

7) Remove injection pump to common rail high

pressure pipe referring to “High Pressure Pipe
Removal and Installation”.

8) Remove timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation in Section 1D”.

9) Remove injection pump rear bracket (1).

10) Remove injection pump (1) with front bracket (2) and

timing belt cover plate (3) from cylinder head.

11) Remove injection pump pulley (1) as follows, if

necessary.
a) Support injection pump front bracket (2) using

vise (3).

b) Install special tool (A) to injection pump front

bracket in order to fix injection pump pulley.

Special tool
(A): 09912–96530

c) Remove injection pump pulley nut (3).

2

1

3

I5JB0B170018-01

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I5JB0B170019-02

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2

3

I5JB0B170020-01

I5JB0B170021-04

1G-19 Fuel System:

d) Fit special tool (A) and (B) to injection pulley (1).

Special tool
(A): 09912–96510
(B): 09912–96520

e) Remove injection pump pulley by tightening bolt

(2) of special tool (B).

12) Remove injection pump (1) from injection pump front

bracket (2), if necessary.

Installation

1) Support injection pump front bracket (1) using vise

(2).

2) Install injection pump (3) to injection pump front

bracket, if removed.

Tightening torque
Injection pump bolt (a): 30 N·m (3.0 kgf-m, 22.0
lb-ft)

3) Install injection pump pulley as follows, if removed.

a) Install injection pump pulley (4) to injection pump

(2) aligning key (3) to groove (1).

I5JB0B170023-03

I5JB0B170022-03

I5JB0B170024-02

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2

3

4

I5JB0B170025-02

Fuel System: 1G-20

b) Install special tool to injection pump front bracket

(1) in order to fit injection pump pulley (2).

Special tool
(A): 09912–96530

c) Tighten injection pulley nut to specified torque.

Tightening torque
Injection pump pulley nut (a): 70 N·m (7.0
kgf-m, 51.0 lb-ft)

d) Remove special tool (A).

4) Install injection pump (1) with injection pump front

bracket (2) and timing belt cover plate (3) to cylinder
block.

5) Tighten new injection pump front bracket bolts as

follows.
a) Tighten injection pump front bracket bolts to 20

N

⋅m (2.0 kgf-m, 14.5 lb-ft).

b) Retighten them by turning through 80

°.

Tightening torque
Injection pump front bracket bolt (a):
Tighten 20 N

⋅m (0.2 kgf-m, 14.5 lb-ft) and 80°

by the specified procedure.

6) Install injection pump rear bracket (1).

Tightening torque
Injection pump rear bracket bolt (a): 44 N·m (4.4
kgf-m, 32.0 lb-ft)

7) Connect fuel flow actuator connector (1).
8) Connect fuel feed hose (2) and fuel return hose (3)

to injection pump.

9) Install new high pressure pipe referring to “High

Pressure Pipe Removal and Installation”.

10) Install timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation in Section 1D”.

11) Check fuel leakage referring to “Fuel Leakage Check

Procedure”.

12) Check DTC referring to “DTC Check in Section 1A”.

I5JB0B170026-02

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2

(a)

3

I5JB0B170027-01

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(a)

I5JB0B170028-01

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1

3

I5JB0B170040-01

1G-21 Fuel System:

Fuel Flow Actuator Inspection

S5JB0B1706033

Check resistance between terminals of fuel flow
actuator.
If resistance is out of specification, replace fuel flow
actuator referring to “Fuel Flow Actuator Removal and
Installation”.

Fuel flow actuator resistance
2.9 – 3.1

Ω at 20 °C (68 °F)

Fuel Flow Actuator Removal and Installation

S5JB0B1706032

WARNING

!

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

CAUTION

!

• Do not reuse fuel flow actuator and fuel

flow actuator bolt because it has the
possibility that fuel leaks.

• Never leave fuel flow actuator orifice open.

Replace new fuel flow actuator at once in
order to prevent fuel circuit from
contamination.

Removal

1) Relief fuel pressure referring to “Fuel Pressure Relief

Procedure”.

2) Disconnect negative (–) cable at battery.
3) Clean fuel flow actuator and its surrounding area.
4) Disconnect fuel flow actuator connector.
5) Remove fuel flow actuator (1) from injection pump by

pulling and twisting it gradually.

Installation

1) Apply clean fuel to O-rings.
2) Fit new fuel flow actuator (1) to injection pump.
3) Tighten new fuel flow actuator bolts (2) as follows.

a) Tighten fuel flow actuator bolts to 3 N

⋅m (0.3 kgf-

m, 2.5 lb-ft).

b) Retighten fuel flow actuator bolts to 6 N

⋅m (0.6

kgf-m, 4.5 lb-ft).

Tightening torque
Fuel flow actuator bolt (a): 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.

4) Connect fuel flow actuator connector.
5) Connect negative (–) cable at battery.
6) Check fuel leakage referring to “Fuel Leakage Check

Procedure”.

7) Check DTC referring to “DTC Check in Section 1A”.

I5JB0B170029-01

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I5JB0B170030-01

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(a)

I5JB0B170031-01