Suzuki Grand Vitara JB416 / JB420. Manual — part 128

1G-14 Fuel System:

iii) Turn ignition switch ON.

8) 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
(For M16 engine model) Approx. 46 cc / 15 sec.
(1.62/1.55 US/Imp oz / 15 sec.)
(For J20 engine model) Approx. 65 cc / 15 sec.
(2.20/2.29 US/Imp oz / 15 sec.)

9) 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

S5JB0A1706024

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) Disconnect fuel return hose (1) and vacuum hose (2)

from fuel pressure regulator.

4) Remove fuel pressure regulator (3) from delivery

pipe.

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Fuel System: 1G-15

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 (a): 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

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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

S5JB0A1706011

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

S5JB0A1706015

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).

(a)

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1G-16 Fuel System:

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

hose (1) from fuel filler neck.

4) Remove fuel tank inlet valve (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 valve (1) to fuel tank.

2) Install fuel filler hose (1) to fuel tank and secure it

with clamp (2).
For proper installation, refer to “Fuel Hose
Disconnecting and Reconnecting”.

3) Lower vehicle and install fuel filler cap.

Fuel Tank Inlet Valve Inspection

S5JB0A1706016

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

Fuel Tank Removal and Installation

S5JB0A1706012

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) Hoist vehicle.
4) Remove exhaust center pipe.
5) Remove rear propeller shaft referring to “Propeller

Shaft Removal and Installation in Section 3D”

6) With cable connected, detach parking brake cable

clamp from fuel tank cover referring to “Parking
Brake Cable Location in Section 4D”

7) Disconnect fuel filler hose and breather hose from

filler neck referring to “Fuel Tank Inlet Valve Removal
and Installation”.

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Fuel System: 1G-17

8) For J20 engine, disconnect fuel pump connector (1).

9) Due to absence of fuel tank drain plug, drain fuel

tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.

CAUTION

!

• Do not force pump hose into fuel tank, or

pump hose may damage fuel tank inlet
valve.

• Never store fuel in an open container due

to possibility of fire or explosion.

10) Disconnect fuel pipe joint and fuel hoses (1) from

fuel pipes (2) referring to “Fuel Hose Disconnecting
and Reconnecting”.

11) Remove fuel tank cover (1).

12) Support fuel tank (1) with jack (2) and remove its

mounting bolts.

13) For M16 engine, lower fuel tank a little as to

disconnect connectors (1) of fuel pump (2) and sub
fuel level gauge (3), then remove fuel tank.

Installation

CAUTION

!

• When connecting joint, clean outside

surfaces of pipe where joint is to be
inserted, push joint into pipe till joint lock
clicks and check to ensure that pipes are
connected securely, or fuel leak may
occur.

• Never let the fuel hoses touch the ABS

sensor harness (if equipped).

1) If parts have been removed from fuel tank, install

them before installing fuel tank to vehicle.

2) Raise fuel tank (1) with jack, and connect connectors

of fuel pump and sub fuel level gauge and clamp
wire harness.

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