Suzuki Grand Vitara JB416 / JB420. Manual - part 127

1G-10 Fuel System: 

Fuel Pressure Relief Procedure

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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

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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

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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.

Fuel Pipe Removal and Installation

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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.

 

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 (1) from vehicle.
6) Remove clamp (1) from pipes (2).

1

2

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Fuel System:  1G-11

Installation

1) Install clamps to marked

®® location on pipes. If 

clamp is deformed, its claw is bent or broken, 
replace it with new one.

2) Install pipes with pipe clamps to vehicle.

NOTE
For M16 engine model, be sure to tighten fuel 
pipe bolt as specified tightening order 
described in “Fuel System Components”.

 

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.

Fuel Injector On-Vehicle Inspection

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1) Using sound scope (1) or such, check operating 

sound of injector (2) 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.

2) Disconnect connector (1) from injector, connect 

ohmmeter between terminals of injector and check 
resistance.

Reference resistance of fuel injector
12 

Ω at 20 °C, 68 °F

3) Connect connector to injector securely.

Fuel Injector Removal and Installation

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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.

 

Removal

1) Relieve fuel pressure according to “Fuel Pressure 

Relief Procedure”.

2) Disconnect negative cable at battery.
3) Disconnect fuel injector couplers.
4) Disconnect fuel feed hose from fuel delivery pipe (1).
5) Disconnect fuel return hose from pressure regulator.
6) Disconnect vacuum hose from pressure regulator.
7) Remove fuel delivery pipe bolts (2).
8) Remove fuel injector(s) (3).

1

2

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[A]: For M16 engine model

[B]: For J20 engine model

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1G-12 Fuel System: 

Installation
Reverse removal procedure for installation noting the 
following.
• Replace injector O-ring (1) 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 pipe (4) and cylinder head.
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))

• Tighten delivery pipe bolts (5) to specified torque and 

make sure that injectors rotate smoothly.

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

• After installation, with engine OFF and ignition switch 

ON, check for fuel leaks around fuel line connection.

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[A]: For M16 engine model

[B]: For J20 engine model

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Fuel System:  1G-13

Fuel Injector 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) Install injector to special tool (injector checking tool).
2) Install pressure regulator to special tool (injector 

checking tool).

Special tool
(A):  09912–58421
(B):  09912–58442

3) Connect special tools (hose and attachment) to fuel 

feed pipe (1) of vehicle.

4) Connect special tool (test lead) to injector.

Special tool
(C):  09930–88530

5) Install suitable vinyl tube onto injector nozzle to 

prevent fuel from splashing out when injecting.

6) Put graduated cylinder under injector.
7) Operate fuel pump and apply fuel pressure to 

injector as follows:
a) When using scan tool:

i)

Connect scan tool to DLC with ignition switch 
OFF.

ii) Turn ignition switch ON, clear DTC and 

select “MISC TEST” mode on scan tool.

iii) Turn fuel pump ON by using scan tool.

Special tool
(A):  SUZUKI scan tool

b) When not using scan tool:

i)

Remove fuel pump relay from connector.

ii) Connect two terminals of relay connector 

using service wire (1) as shown in the figure.

CAUTION

!

 

Check to make sure that connection is made 
between correct terminals. Wrong 
connection can cause damage to ECM, wire 
harness, etc.

 

A

B

C

1

A

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(A)

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