Suzuki Grand Vitara JB627. Manual — part 106

1G-7 Fuel System:

The other than fuel tank system

For Quick Joint (other than Fuel Vapor Line)
Disconnecting

1) Remove mud, dust and/or foreign material between

pipe (1) and quick joint (2) by blowing compressed
air.

2) Unlock joint lock by inserting special tool between

pipe and quick joint.

Special tool
(A): 09919–47020

3) Disconnect quick joint from pipe.

Reconnecting
Insert quick joint to fuel pipe until they lock securely (a
click is heard), and confirm that quick joint is not
disconnected by hand.

I3RM0A170001-01

[A]: With short pipe, fit hose as far as it reaches pipe joint as shown.
[B]: With the following type pipe, fit hose as far as its peripheral projection

as shown.

[C]: With bent pipe, fit hose as its bent part as shown or till depth “b”.
[D]: With straight pipe, fit hose till depth “b”.

[E]: With red marked pipe, fit hose end reaches red mark on pipe.

[F]: For fuel tank filler hose, insert it to spool or welding-bead.

“a”: Clamp securely at a position 3 – 7 mm (0.12 – 0.27 in.) from hose end.
“b”: 20 – 30 mm (0.79 – 1.18 in.)

“c”: 0 – 5 mm (0 – 0.19 in.)

“d”: 5 – 12 mm (0.2 – 0.47 in.)
“e”: 40 mm (1.57 in.)

4. Red mark

1

2

1

2

(A)

I4RS0A170019-01

Fuel System: 1G-8

For Quick Joint (Fuel Vapor Line)
Disconnecting

1) Remove mud, dust and/or foreign material between

pipe (1) and quick joint (fuel vapor line) (2) by
blowing compressed air.

2) Disconnect hose joint while joint lock is unlocked by

pushing both sides of joint.

Reconnecting

1) For quick joint, push joint into pipe till joint lock clicks

and check that quick joint does not pull out by pulling
quick joint in arrow direction.

2) Confirm that quick joint is not disconnected by hand.

Fuel Pressure Relief Procedure

S6JB0B1706003

CAUTION

!

This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift

select lever in “P” range for A/T model), set parking
brake and block drive wheels.

3) Remove fuse box No.2 cover.
4) Disconnect fuel pump relay (1) from fuse box No.2

(2).

5) Remove fuel filter cap in order to release fuel vapor

pressure in fuel tank, and then reinstall it.

6) Start engine and run it until engine stops for lack of

fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.

7) After servicing, connect fuel pump relay (1) to fuse

box No.2 and install fuse box No.2 cover.

Fuel Leakage Check Procedure

S6JB0B1706004

After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.

1) Turn ON ignition switch for 3 seconds (to operate

fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.

2) In this state, check to see that there are no fuel

leakages from any part of fuel system.

Fuel Lines On-Vehicle Inspection

S6JB0B1706005

CAUTION

!

Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all clamps are secure.
Replace parts as needed.

2

1

I6JB01170006-01

I6JB01170007-01

1

2

I5JB0A171006-01

1G-9 Fuel System:

Fuel Pipe Removal and Installation

S6JB0B1706006

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 in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative (–) cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe referring to

“Fuel Hose Disconnecting and Reconnecting”.

4) Mark the location of clamps (1) on fuel pipes (2) so that the clamps can be reinstalled to where they were.
5) Remove pipes (2) with clamp from vehicle.
6) Remove clamp (1) from pipes (2).

Installation

1) Install clamps to white painted at pipes. If clamp is deformed, its claw is bent or broken, replace it with new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe referring to “Fuel Hose Disconnecting and Reconnecting”.
4) Connect negative (–) cable at battery.
5) With engine OFF, turn ignition switch to ON position and check for fuel leaks.

3

2

1

2

1

1

I7JB01170003-01

Fuel System: 1G-10

Fuel Injector On-Vehicle Inspection

S6JB0B1706007

1) Remove surge tank cover.
2) Using sound scope (1) or such, check operating

sound of injector when engine is running or cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.

3) Disconnect connector (1) from injector, connect

ohmmeter between terminals of injector and check
resistance.

Reference resistance of fuel injector
11.5 – 12.5

Ω at 20 °C, 68 °F

4) Connect connector to injector securely.

Fuel Injector Removal and Installation

S6JB0B1706008

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

Relief Procedure”.

2) Disconnect negative (–) cable at battery.
3) Remove surge tank cover.
4) Remove intake air pipe (1) and surge tank pipe (2).

5) Disconnect fuel injector couplers and release fuel

injector harness from clamps.

6) Disconnect fuel return hose (1) from pressure

regulator.

7) Disconnect vacuum hose (2) from pressure

regulator.

8) Remove fuel pipe bolt (3).
9) Remove fuel union bolt (4) of fuel delivery pipe (right

side).

10) Remove fuel delivery pipes (right and left) (5) from

intake manifold.

Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) and insulator (7) with new

one using care not to damage it.

• Check if cushion (2) is scored or damaged. If it is,

replace with new one.

• Apply O-ring oil to O-rings (1), and then install

injectors (3) into delivery pipes (4) and intake
manifold.
Make sure that injectors rotate smoothly (6). If not,
probable cause is incorrect installation of O-ring.
Replace O-ring with new one.

“A”: Oil 99000–25320 (SUZUKI DI O RING
OIL(500CC))

IYSQ01173015-01

IYSQ01173016-01

1

2

I6JB01170022-01

3

5

5

2

1

4

I6JB01170009-01