Suzuki Grand Vitara JB419. Manual - part 61

Fuel System:  1G-2

• The fuel system must be checked for leaks after service work referring to “Fuel Leakage Check Procedure”.
• The fuel system is very sensitive to contamination. The risks caused by the introduction of contamination are:

– damage or destruction of the high pressure injection system and the engine.
– seizing or leaking of a component.

• When servicing on the high pressure direct injection system, must be performed under very clean conditions.

This means that no impurities (particles a few microns in side) get into the system during dismantling or into the 
circuits via the fuel unions.

• The cleanliness principle must be applied from the fuel filter to the injectors.
• Contamination is caused by:

– metal or plastic chips,
– paint,
– fibres: boxes, brushes, paper, clothing, cloths,
– foreign bodies such as hair,
– ambient air,
– etc.

• It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections.

In addition, moisture may collect in the connectors and create electrical connection problems.

• The technician should wear clean overalls.
• Ensure that you have the plug caps (1) for the unions to be opened. Plug caps are to be used once only. After use, 

they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plug caps must be thrown away, also.

NOTE

• Plug cap set is available as a spare part.
• Plug unions as soon as possible when removing / disconnecting fuel system component in order to 

prevent dust from invading.
Similarly, do not remove plug cap immediately before when installing / connecting fuel system 
component.

 

1G-3 Fuel System: 

A

B

C

C

C

C

D

D

D

E

E

E

E

E

E

E

E

G

G

G

G

G

G

G

G

I

H

A

B

C

D

E

F

G

H

I

1

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1. Plug cap

: Do not reuse.

Fuel System:  1G-4

• Ensure that you have hermetically resalable plastic bags for storing removed parts. Stored parts will therefore be 

less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away.

• Make sure that lint-free towelettes. The use of a normal cloth or paper for cleaning purposes is forbidden.

These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be used 
once.

• Carry out any servicing as much as possible with the plug cap installed in order to prevent impurities from entering 

the system.

• Instructions to be followed before opening the fuel circuit.

– For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
– For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
– Use a brush and thinners to clean the connections to be opened.
– Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection 

system zone). Check that no bristles remain adhered.

– Wash your hands before and during the operation if necessary.
– When wearing leather protective gloves, cover these with latex gloves.

• Instructions to be followed during the operation.

– As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system by 

using the plug cap. They must not, under any circumstances, be reused.

– Close the hermetically sealed bag, even if it has to be reopened shortly afterwards.

Ambient air carries contamination.

– All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once 

the plugs have been inserted.

– The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been 

opened.
These items are likely to allow impurities to enter the system.

– A new component replacing an old one must not be removed from its packaging until it is to be fitted to the 

vehicle.

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1G-5 Fuel System: 

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.

 

Low-pressure fuel supply circuit [A]
The fuel in the fuel tank (1) is pumped up to the high pressure fuel supply circuit [B] through the priming pump (2), the 
fuel filter (3) and the fuel heater (4) by the low pressure fuel pump (5) built in the injection pump (6).
The fuel pump assembly (7) is composed of a fuel pump (8) a fuel suction filter (9), a main fuel level gauge (10) and a 
jet pump (11). The fuel pump is an in-tank type electric pump, and the fuel pump is equipped only for the jet pump. The 
jet pump sucks up the fuel from the sub fuel level gauge side (12) to the main fuel level gauge side (13) through the 
fuel suction pipe/hose (14) by using the negative pressure produced when the pressured fuel (15) with the fuel pump 
passes the venturi (16).

High-pressure fuel supply circuit [B]
The injection pump (6) driven by engine rotation creates high-pressure fuel from the low pressure fuel. The high-
pressure fuel is supplied to the common rail (17) through the high-pressure fuel pipe. And, the injectors (18) atomize 
the fuel in the cylinders.
The fuel flow actuator (19) located on the injection pump regulates the quantity of fuel to the injection pump by ECM 
signal in order to control the fuel pressure in the common rail.

[A]

[B]

[C]

4

2

3

1

7

11

14

9

17

20

18

8

10

12

15

13

16

11

5

6

19

21

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[C]: Return fuel circuit

20. Fuel pressure sensor

21. Sub fuel level gauge