Suzuki Grand Vitara JB419. Manual — part 67
Fuel System: 1G-26
Fuel Tank Inlet Valve Inspection
S5JB0B1706016
Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
• Damage
• Smooth opening and closing
Fuel Pump Assembly Removal and Installation
S5JB0B1706019
WARNING
!
Before servicing fuel system, be sure to
observe “Precautions on Fuel System
Service”.
Removal
1) Remove fuel tank from vehicle. Refer to “Fuel Tank
2) Disconnect fuel feed pipe (1) and fuel return pipe (3)
from fuel pump assembly (2) referring to “Fuel Hose
Disconnecting and Reconnecting”.
3) Remove fuel pump assembly (1) from fuel tank (2)
and disconnect suction hose.
Installation
CAUTION
!
When connecting joint, clean outside surface
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.
1) Clean mating surfaces of fuel pump assembly (1)
and fuel tank.
2) Put plate (2) on fuel pump assembly (1) by matching
the protrusion of fuel pump assembly (3) to plate
hole (4) as shown.
3) Connect suction hose to fuel pump assembly (1),
and install new gasket (2) and fuel pump assembly
with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
4) Connect fuel feed pipe (1) (pipe joint) and fuel return
pipe (3) (pipe joint) to fuel pump assembly (2).
5) Install fuel tank to vehicle. Refer to “Fuel Tank
I2RH0B170019-01
3
1
2
I5JB0A171024-01
1
2
I3RM0A170021-01
3
1
2
4
I5JB0A171025-01
3
1
2
(a)
4
I3RM0A170023-01
3
1
2
I5JB0A171024-01
1G-27 Fuel System:
Fuel Pump Inspection
S5JB0B1706043
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.
• For electrical circuit.
Main Fuel Level Gauge Removal and Installation
S5JB0B1706039
CAUTION
!
• Do not touch resister plate (1) and deform
arm (2). It may cause main fuel level gauge
to fail.
• Be very careful not to cause damage to
fuel tube installed section (sealed section
in bore). If it be damaged, replace it with
new one, or fuel will leak from the part.
Removal
1) Remove fuel pump assembly from fuel tank referring
to “Fuel Pump Assembly Removal and Installation”.
2) Disconnect main fuel level gauge connector (3).
3) With pressing snap-fit part (2), remove main fuel
level gauge (1) by sliding it in the arrow direction as
shown in figure.
Installation
Reverse removal procedure for installation.
Main Fuel Level Gauge Inspection
S5JB0B1706041
• Check main fuel level gauge for damage.
• For inspection of main fuel level gauge (1), refer to
“Fuel Level Sensor Inspection in Section 9C”.
Sub Fuel Level Gauge Removal and Installation
S5JB0B1706040
CAUTION
!
Do not touch resister plate (1) and deform
arm (2). It may cause sub fuel level gauge to
fail.
Removal
1) Remove fuel tank from vehicle Referring to “Fuel
Tank Removal and Installation”
2) Disconnect sub fuel level gauge connector (1)
referring to “Fuel Hose Disconnecting and
Reconnecting”.
3) Remove sub fuel level gauge (2).
1
2
I5JB0B170036-01
1
3
1
2
I5JB0B170037-01
1
I5JB0A171027-01
2
1
I5JB0A171028-01
2
2
1
I5JB0A171029-01
Fuel System: 1G-28
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 sub
fuel level sensor.
Sub Fuel Level Gauge Inspection
S5JB0B1706042
• Check sub fuel level gauge for damage.
• For inspection of sub fuel level gauge (1), refer to
“Fuel Level Sensor Inspection in Section 9C”.
Tightening Torque Specifications
S5JB0B1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”
“Injection Pump Components”
Reference:
For the tightening torque of fastener not specified in this section, refer to .
1
I5JB0A171030-01
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Fuel filter case bolt
5
0.5
4.0
Common rail bolt
22
2.2
16.0
High pressure pipe union nut
25
2.5
18.0
Common rail mounting bolt
22
2.2
16.0
Common rail bolt
25
2.5
18.0
Throttle body to EGR valve pipe bolt and nut
21
2.1
15.5
Injector cover bolt
8
0.8
6.0
Fuel injector bracket bolt
25
2.5
18.0
Injection pump bolt
30
3.0
22.0
Injection pump pulley nut
70
7.0
51.0
Injection pump front bracket bolt
Tighten 20 N
⋅m (0.2 kgf-m, 14.5 lb-ft) and
80
° by the specified procedure.
Injection pump rear bracket bolt
44
4.4
32.0
Fuel flow actuator bolt
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.
Fuel tank bolt
50
5.0
36.5
Fuel filler hose clamp
2
0.2
1.5
Fuel pump assembly bolt
11
1.1
8.0
1G-29 Fuel System:
Special Tools and Equipment
Recommended Service Material
S5JB0B1708001
NOTE
Required service material is also described in the following.
“Injection Pump Components”
Special Tool
S5JB0B1708002
09911–75410
09911–75420
Diesel injection-line wrench
Crow foot flare-nut wrench
18.17)
09912–96510
09912–96520
Injection pump pulley
remover
Adaptation crow
Mot. 1525)
Mot. 1525-03)
09912–96530
09919–47020
Injection pump pulley
locking
Quick joint remover
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.)
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