Suzuki Grand Vitara JB419. Manual — part 64

Fuel System: 1G-14

• For high pressure pipe between injection pump and

common rail
a. Loosen high pressure pipe union nut (1) using

special tool and wrench.

CAUTION

!

When loosing union nut of injection pump
side, hold union nut (2) with wrench (3) as
shown in figure.

Special tool
(A): 09911–75410

9) Clean and vacuum any contamination, and plug all

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

Installation

CAUTION

!

• Do not touch pipes with wrench when

tightening union nut to avoid a damage of
high pressure pipe.

• In case of extension special tool combined

with torque wrench, reading value of
torque wrench is smaller than specified
tightening torque. When using extension
special tool, reading value should be
calculated according to formula below.

Tightening torque formula.
M = T x L / (L + “a”)
M: Reading value using extension special tool
T: Specified tightening torque
L: Length of torque wrench
“a”: Length of special tool

Special tool
(A): 09911–75410
(B): 09911–75420

[A]: Injection pump side

[B]: Common rail side

3

1

(A)

(A)

1

2

[A]

[B]

I5JB0B170012-01

“a”: 35 mm (1.38 in.)

“b”: 23 mm (0.97 in.)

L

L1

1

(B)

(A)

(B)

"a"

"b"

I4RH0A170002-01

1G-15 Fuel System:

1) Loosen common rail mounting bolts fully in order not

to install high pressure pipe under stress.

2) Install new high pressure pipes as follows.

CAUTION

!

• Be sure not to interfere high pressure pipe

with glow plug.

• Before installing high pressure pipe, be

sure to lubricate not threads with oil
included in spare part without allowing oil
into high pressure pipe.
Do not lubricate high pressure pipe
supplied without oil so that this fuel pipe is
lubricated previously.

• For high pressure pipe between fuel injector and

common rail
a. Remove plug caps from fuel injector and

common rail.

b. Tighten high pressure pipe union nut as

follows.
i.

Tighten fuel injector side union nuts then
common rail side union nuts by hand.

ii. Tighten common rail bolts to specified

torque.

Tightening torque
Common rail bolt: 22 N·m (2.2 kgf-m,
16.0 lb-ft)

iii. Tighten fuel injector side union nut then

common rail side union nut to specified
torque in the same manner as removal
procedure.

Tightening torque
High pressure pipe union nut: 25 N·m (
2.5 kgf-m, 18.0 lb-ft)

• For high pressure pipe between injection pump

and common rail
a. Remove plug caps from fuel injector and

common rail.

b. Tighten high pressure pipe union nut as

follows.
i.

Tighten injection pump side union nuts
then common rail side union nuts by hand.

ii. Tighten common rail mounting bolts to

specified torque.

Tightening torque
Common rail mounting bolt: 22 N·m (
2.2 kgf-m, 16.0 lb-ft)

iii. Tighten injection pump side union nut then

common rail side union nut to specified
torque in the same manner as removal
procedure.

CAUTION

!

When tightening union nut of injection pump
side, hold union nut (2) with wrench (3) as
shown in figure.

Special tool
(A): 09911–75410

Tightening torque
High pressure pipe union nut (a): 25
N·m (2.5 kgf-m, 18.0 lb-ft)

3) Tighten common rail bolts.

Tightening torque
Common rail bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)

4) Install fuel injector cover (1), throttle body (2) with

throttle body to EGR valve pipe (3) and vacuum pipe
(4).

Tightening torque
Throttle body to EGR valve pipe bolt and nut
(a): 21 N·m (2.1 kgf-m, 15.5 lb-ft)
Injector cover bolt (b): 8 N·m (0.8 kgf-m, 6.0 lb-ft)

5) Connect inlet throttle valve connector (5) and boost

pressure sensor connector (6).

6) Connect ventilation hose No.2 (7) to ventilation pipe

No.2 (9).

3

(a)

(A)

(A)

(a)

2

I5JB0B170013-01

Fuel System: 1G-16

7) Connect ventilation hose No.4 (8) to oil vapor

recirculation valve (10).

8) Install engine cover.
9) Connect negative (–) cable at battery.

10) Check fuel leakage referring to “Fuel Leakage Check

Procedure”.

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

Fuel Injector On-Vehicle Inspection

S5JB0B1706006

1) Disconnect negative (–) cable at battery.
2) Remove engine cover.
3) Remove fuel injector cover referring to Step 4)

through 7) in “Removal” of “High Pressure Pipe
Removal and Installation”.

4) Disconnect connector from fuel injector.
5) Measure resistance between terminals of fuel

injector.
If resistance is out of specification, replace fuel
injector.

Fuel Injector Resistance
Approx. 2

Ω or less

Fuel Injector Removal and Installation

S5JB0B1706007

WARNING

!

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

CAUTION

!

• Never disassemble fuel injector.

Disassembly will spoil its original function.
If faulty condition is found, replace it with
new one.

• Never use ultrasound and wire brush.

Removal

NOTE
The calibration code (1) is given to each fuel
injector, and it represents the performance
characteristics of the fuel injector. It is
registered in ECM, and ECM controls fuel
injection according to the performance
characteristics of the fuel injector.
Therefore, after removing fuel injectors, be
sure to install them as they were. In case that
the fuel injectors were replaced with new
ones, be sure to register each calibration
code in ECM referring to “Description of ECM
Registration in Section 1C”. If it is not
registered correctly, DTC is stored in ECM
and warning light is turned ON. Also
calibration codes registration in ECM can be
checked by SUZUKI scan tool.

10

4

5

6

7

9

2

3

1

8

(a)

(b)

I5JB0B170039-02

I5JB0B170014-01

1

I5JB0B170015-01

1G-17 Fuel System:

1) Remove high pressure pipe between fuel injector

and common rail referring to “High Pressure Pipe
Removal and Installation”.

2) Disconnect fuel injector connector (1) from fuel

injector.

3) Remove fuel return hose (2).
4) Remove fuel injector (3) with fuel injector bracket (4).

5) Remove sealing washer.
6) Plug fuel injector with plug caps referring to

“Precautions on Fuel System Service”.

Installation

1) Soak new fuel injector body in grease remover.
2) Wipe off fuel injector using a lint-free cloth.

3) Remove plug caps from fuel injector.
4) Install new sealing washer to fuel injector hole.
5) Install fuel injector (1) with bracket (2) to cylinder

head, and tighten fuel injector bracket bolt to
specified torque.

Tightening torque
Fuel injector bracket bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft)

6) Install new fuel return hose (3) with new clip (4).
7) Connect fuel injector connector (5) to fuel injector.

8) Install new high pressure pipe referring to “High

Pressure Pipe Removal and Installation”.

Injection Pump Components

S5JB0B1706037

4

2

1

3

I5JB0B170016-01

2

3

5

1

(a)

4

I5JB0B170017-02

5

3

1

2

(a)

(b)

(d)

(c)

4

(e)

(a)

(d)

(d)

I5JB0B170048-01

1. Injection pump pulley

: 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft)

2. Injection pump front bracket

: 70 N

⋅m (7.0 kgf-m, 51.0 lb-ft)

3. Injection pump

: Tighten 20 N

⋅m (0.2 kgf-m, 14.5 lb-ft) and 80° by the specified procedure.

4. Fuel flow actuator

: 44 N

⋅m (4.4 kgf-m, 32.0 lb-ft)

5. O-ring

: Apply clean fuel to O-ring.

: 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.

6. Injection pump rear bracket

: Do not reuse.