Suzuki Grand Vitara JB627. Manual - part 104

1F-10 Engine Cooling System: 

Water Pump Removal and Installation

S6JB0B1606014

Removal

1) Remove engine assembly from vehicle referring to 

“Engine Assembly Removal and Installation in 
Section 1D”.

2) Remove timing chain cover referring to “Timing 

Chain Cover Removal and Installation in Section 
1D”.

3) Remove water pump assembly (1) from cylinder 

block.

Installation

1) Install new O-rings (3) to water pump (1).
2) Install water pump to cylinder block. Tighten water 

pump bolts to specified torque.

Tightening torque
Water pump bolt (a):  25 N·m (2.5 kgf-m, 18.0 lb-
ft)

3) Install timing chain cover referring to “Timing Chain 

Cover Removal and Installation in Section 1D”.

4) Install engine assembly to vehicle referring to 

“Engine Assembly Removal and Installation in 
Section 1D”.

Water Pump Inspection

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CAUTION

!

 

Do not disassemble water pump.
If any repair is required on pump, replace it 
as assembly.

 

Rotate water pump by hand to check for smooth 
operation. If pump does not rotate smoothly or makes 
abnormal noise, replace it.

2. Impeller

I6JB01160012-01

I6JB01160013-01

I6JB01160014-01

Engine Cooling System:  1F-11

Specifications

Tightening Torque Specifications

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NOTE
The specified tightening torque is also described in the following.
“Cooling System Components”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Water pump bolt

25

2.5 

18.0

)

1G-1 Fuel System: 

Engine

Fuel System

Precautions

Precautions on Fuel System Service

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WARNING

!

 

Before attempting service of any type on fuel system, the following should be always observed in 
order to reduce the risk or fire and personal injury.
• Disconnect negative (–) cable at battery.
• Do not smoke, and place no smoking signs near work area.
• Be sure to have CO

2

 fire extinguisher handy.

• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot 

heater).

• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then 

reinstall it.

• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or 

disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or 
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief 
Procedure”.

• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the 

risk of personal injury, cover a shop cloth to the fitting to be disconnected. Be sure to put that cloth 
in an approved container after disconnecting.

• Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
• Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each 

hose correctly referring to “Fuel Hose Disconnecting and Reconnecting”.
After connecting, make sure that it has no twist or kink.

• When installing injector or fuel feed pipe, lubricate its O-ring with gasoline.

 

General Description

Fuel System Description

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CAUTION

!

 

This engine requires the unleaded fuel only. 
The leaded and/or low lead fuel can result in 
engine damage and reduce the effectiveness 
of the emission control system.

 

The main components of the fuel system are fuel tank, 
fuel pump assembly (with fuel filter and fuel level gauge), 
fuel pressure regulator, fuel feed line, fuel return line and 
fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System 
Diagram”.

Fuel Delivery System Description

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The fuel delivery system consists of the fuel tank, fuel 
pump assembly (with built-in fuel filter), fuel pressure 
regulator, delivery pipe, injectors, fuel return line, fuel 
vapor line and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump, 
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with built-in fuel 
filter, the fuel is filtered and its pressure is regulated after 
being sent to the feed pipe.
The excess fuel at fuel pressure regulation process is 
returned back into the fuel tank.
Also, fuel vapor generated in fuel tank is led through the 
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System 
Diagram”.

Fuel System:  1G-2

Fuel Pump Description

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The fuel pump (1) is an in-tank type electric pump. 
Incorporated in the pump assembly are;
a fuel filter (2) included and a fuel level gauge (3) 
attached.
Also, the jet pump (4) installed in the fuel pump sucks up 
the fuel from the sub fuel level sensor side to main fuel 
level sensor side through the fuel suction pipe / hose by 
using the negative pressure produced when the part of 
pressurised fuel with the fuel pump passes the venturi 
(5).

Schematic and Routing Diagram

Fuel Delivery System Diagram

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I5JB0A171001-03

20

7

10

6

9

13

15

14

2

12

11

19

17

18

16

1

4

4

5

3

8

I6JB01170001-01

1. Fuel tank

6. Fuel feed line

11. Fuel filter

16. Fuel suction filter

2. Fuel pump

7. Fuel vapor line

12. Main fuel level sensor

17. Pressurised fuel from fuel pump

3. Fuel pressure regulator

8. Intake manifold

13. Sub fuel level sensor

18. Fuel feeded from fuel suction hose

4. Delivery pipe

9. EVAP canister

14. Jet pump

19. Venturi

5. Fuel injector

10. Fuel return line

15. Fuel suction pipe / hose

20. EVAP canister purge valve