Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 192

1G-41 Fuel System: For Diesel Engine Model

Injection Pump Removal and Installation

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WARNING

!

 

Before servicing fuel system, be sure to 
observe “Precautions on Fuel System 
Service: For Diesel Engine Model”.

 

CAUTION

!

 

Never disassemble injection pump. 
Disassembly will spoil its original function. If 
faulty condition is found, replace it with new 
one.

 

Removal

1) Check that engine is cold and fuel pressure is not 

under pressure referring to “Fuel Pressure Relief 
Procedure: For Diesel Engine Model”.

2) Remove timing belt referring to “Timing Belt and Belt 

Tensioner Removal and Installation: For F9Q Engine 
in Section 1D”.

3) Clean all fuel connectors on injection pump.
4) Disconnect fuel flow actuator connector (1).
5) Disconnect fuel feed hose (2) and fuel return hose 

(3) from injection pump.

6) Clean and vacuum any contamination, and plug all 

joint part of disconnected fuel circuit with plug cap 
referring to “Precautions on Fuel System Service: 
For Diesel Engine Model”

7) Remove injection pump to common rail high 

pressure pipe referring to “High Pressure Pipe 
Removal and Installation: For Diesel Engine Model”.

8) Remove timing belt referring to “Timing Belt and Belt 

Tensioner Removal and Installation: For F9Q Engine 
in Section 1D”.

9) Remove injection pump rear bracket (1).

10) Remove injection pump (1) with front bracket (2) and 

timing belt cover plate (3) from cylinder head.

2

1

3

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[A]: Type 2

[B]: Type 3

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Fuel System: For Diesel Engine Model 1G-42

11) Remove injection pump pulley (1) as follows, if 

necessary.
a) Support injection pump front bracket (2) using 

vise (3).

b) Install special tool (A) to injection pump front 

bracket in order to fix injection pump pulley.

Special tool
(A):  09912–96530

c) Remove injection pump pulley nut (3).

d) Fit special tool (A) and (B) to injection pulley (1).

Special tool
(A):  09912–96510
(B):  09912–96520

e) Remove injection pump pulley by tightening bolt 

(2) of special tool (B).

12) Remove injection pump (1) from injection pump front 

bracket (2), if necessary.

Installation

1) Support injection pump front bracket (1) using vise 

(2).

2) Install injection pump (3) to injection pump front 

bracket, if removed.

Tightening torque
Injection pump bolt (a):  30 N·m (3.0 kgf-m, 22.0 
lb-ft)

3) Install injection pump pulley as follows, if removed.

a) Install injection pump pulley (4) to injection pump 

(2) aligning key (3) to groove (1).

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2

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1G-43 Fuel System: For Diesel Engine Model

b) Install special tool to injection pump front bracket 

(1) in order to fit injection pump pulley (2).

Special tool
(A):  09912–96530

c) Tighten injection pulley nut to specified torque.

Tightening torque
Injection pump pulley nut (a):  70 N·m (7.0 
kgf-m, 51.0 lb-ft)

d) Remove special tool (A).

4) Install injection pump (1) with injection pump front 

bracket (2) and timing belt cover plate (3) to cylinder 
block.

5) Tighten new injection pump front bracket bolts as 

follows.
a) Tighten injection pump front bracket bolts to 20 

N

⋅m (2.0 kgf-m, 14.5 lb-ft).

b) Retighten them by turning through 80

°.

Tightening torque
Injection pump front bracket bolt (a):  
Tighten 20 N

⋅m (0.2 kgf-m, 14.5 lb-ft) and 80° 

by the specified procedure.

6) Install injection pump rear bracket (1).

Tightening torque
Injection pump rear bracket to cylinder block 
bolt (a):  44 N·m (4.4 kgf-m, 32.0 lb-ft)
Injection pump rear bracket to injection pump 
bolt (Type 2) (b):  44 N·m (4.4 kgf-m, 32.0 lb-ft)
Injection pump rear bracket to injection pump 
bolt M8 (Type 3) (c):  30 N·m (3.0 kgf-m, 22.0 lb-ft)
Injection pump rear bracket to injection pump 
bolt M6 (Type 3) (d):  10 N·m (1.0 kgf-m, 7.5 lb-ft)

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2

(a)

3

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[A]: Type 2

[B]: Type 3

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Fuel System: For Diesel Engine Model 1G-44

7) Connect fuel flow actuator connector (1).
8) Connect fuel feed hose (2) and fuel return hose (3) 

to injection pump.

9) Install new high pressure pipe referring to “High 

Pressure Pipe Removal and Installation: For Diesel 
Engine Model”.

10) Install timing belt referring to “Timing Belt and Belt 

Tensioner Removal and Installation: For F9Q Engine 
in Section 1D”.

11) Check fuel leakage referring to “Fuel Leakage Check 

Procedure: For Diesel Engine Model”.

12) Check DTC referring to “DTC Check: For Diesel 

Engine Model in Section 1A”.

Fuel Flow Actuator Inspection (Type 2)

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Check resistance between terminals of fuel flow 
actuator.
If resistance is out of specification, replace fuel flow 
actuator referring to “Fuel Flow Actuator Removal and 
Installation (Type 2): For Diesel Engine Model”.

Fuel flow actuator resistance
2.9 – 3.1 

Ω at 20 °C (68 °F)

Fuel Flow Actuator Removal and Installation 
(Type 2)

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WARNING

!

 

Before servicing fuel system, be sure to 
observe “Precautions on Fuel System 
Service: For Diesel Engine Model”.

 

CAUTION

!

 

• Do not reuse fuel flow actuator and fuel 

flow actuator bolt because it has the 
possibility that fuel leaks.

• Never leave fuel flow actuator orifice open. 

Replace new fuel flow actuator at once in 
order to prevent fuel circuit from 
contamination.

 

[A]: Type 2

[B]: Type 3

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