Suzuki Grand Vitara JB416 / JB420. Manual — part 125

1G-2 Fuel System:

Fuel Pump Description

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The fuel pump (1) is an in-tank type electric pump.
Incorporated in the pump assembly are;
a fuel filter (2) included and a fuel level gauge (3)
attached.
Also, the jet pump (4) installed in the fuel pump sucks up
the fuel from the sub fuel level sensor side to main fuel
level sensor side through the fuel suction pipe / hose by
using the negative pressure produced when the part of
pressurised fuel with the fuel pump passes the venturi
(5).

Schematic and Routing Diagram

Fuel Delivery System Diagram

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20

7

10

6

9

13

15

14

2

12

11

19

17

18

16

1

4

5

3

8

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1. Fuel tank

6. Fuel feed line

11. Fuel filter

16. Fuel suction filter

2. Fuel pump

7. Fuel vapor line

12. Main fuel level sensor

17. Pressurised fuel from fuel pump

3. Fuel pressure regulator

8. Intake manifold

13. Sub fuel level sensor

18. Fuel feeded from fuel suction hose

4. Delivery pipe

9. EVAP canister

14. Jet pump

19. Venturi

5. Fuel injector

10. Fuel return line

15. Fuel suction pipe / hose

20. EVAP canister purge valve

Fuel System: 1G-3

Diagnostic Information and Procedures

Fuel Pressure Inspection

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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) Relieve fuel pressure in fuel feed line referring to

“Fuel Pressure Relief Procedure”.

2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed

hose (1) and fuel delivery pipe as shown in the
figure, and clamp hoses securely in order to ensure
that no leaks occur during checking.

Special tool
(A): 09912–58413
(B): 09912–58490

4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.

If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and

after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.

Fuel pressure specification with fuel pump
operating and engine stopped
: 270 – 310 kPa (2.7 – 3.1 kg/cm

2

, 38.4 – 44.0

psi)

b) Start engine and warm it up to normal operating

temperature, and measure fuel pressure at
idling.

Fuel pressure specification at specified idle
speed
: 270 – 310 kPa (2.7 – 3.1 kg/cm

2

, 38.4 – 44.0

psi)

c) Stop engine, and measure fuel pressure at one

minute after stopping.

Fuel pressure specification with 1 min. after
engine (fuel pump) stop (Pressure reduces
as time passes)
For M16 engine model: Over 250 kPa (2.5 kg/
cm

2

, 35.6 psi)

For J20 engine model: Over 200 kPa (2.0 kg/
cm

2

, 28.4 psi)

[A]. For M16 engine model
[B]. For J20 engine model

[A]

[B]

(A)

(B)

(A)

(B)

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1G-4 Fuel System:

6) After checking fuel pressure, remove fuel pressure

gauge.

WARNING

!

As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut

slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel

feed hose.

8) Connect fuel feed hose to fuel delivery pipe and

clamp it securely.

9) With engine OFF and ignition switch ON, check for

fuel leaks.

Fuel Cut Operation Inspection

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NOTE
Before inspection, make sure that gear shift
lever is in neutral position (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using

sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.

3) Check to make sure that injector operation sound is

stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.

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Fuel System: 1G-5

Repair Instructions

Fuel System Components

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