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

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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 

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

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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.

 

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

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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) 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

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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) 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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