Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 193

1G-45 Fuel System: For Diesel Engine Model

Removal

1) Relief fuel pressure referring to “Fuel Pressure Relief 

Procedure: For Diesel Engine Model”.

2) Disconnect negative (–) cable at battery.
3) Clean fuel flow actuator and its surrounding area.
4) Disconnect fuel flow actuator connector.
5) Remove fuel flow actuator (1) from injection pump by 

pulling and twisting it gradually.

Installation

1) Apply clean fuel to O-rings.
2) Fit new fuel flow actuator (1) to injection pump.
3) Tighten new fuel flow actuator bolts (2) as follows.

a) Tighten fuel flow actuator bolts to 3 N

⋅m (0.3 kgf-

m, 2.5 lb-ft).

b) Retighten fuel flow actuator bolts to 6 N

⋅m (0.6 

kgf-m, 4.5 lb-ft).

Tightening torque
Fuel flow actuator bolt (a):  Tighten 3 N

⋅m (0.3 

kgf-m, 2.5 lb-ft) and 6 N

⋅m (0.6 kgf-m, 4.5 lb-ft) 

by the specified procedure.

4) Connect fuel flow actuator connector.
5) Connect negative (–) cable at battery.
6) Check fuel leakage referring to “Fuel Leakage Check 

Procedure: For Diesel Engine Model”.

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

Engine Model in Section 1A”.

Common Rail (High Pressure Fuel Injection 
Rail) 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 remove fuel rail pressure sensor from 
common rail because this may cause fuel 
circuit contamination problems.
If fuel rail pressure sensor fails, common rail 
and all high pressure pipes must be replaced.

 

Removal

1) Remove all high pressure pipes referring to “High 

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

2) Remove oil separator referring to “Oil Separator 

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

3) Disconnect fuel return hose (1).
4) Remove common rail (2) from cylinder head.

Installation

1) Install common rail (1) to cylinder head, and tighten 

common rail bolt by hand.

2) Install new high pressure pipes referring to “High 

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

3) Connect fuel return hose.

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Fuel System: For Diesel Engine Model 1G-46

4) Install oil separator referring to “Oil Separator 

Removal and Installation”.

5) Install fuel injector cover, throttle body and engine 

cover referring to Step 4) through 8) of “Installation” 
under “High Pressure Pipe Removal and Installation: 
For Diesel Engine Model”.

6) Connect negative (–) cable to battery.
7) Check fuel leakage referring to “Fuel Leakage Check 

Procedure: For Diesel Engine Model”.

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

Engine Model in Section 1A”.

Fuel Rail Presser Sensor Inspection

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CAUTION

!

 

Never remove fuel rail pressure sensor from 
common rail because this may cause fuel 
circuit contamination problems.
If fuel rail pressure sensor fails, common rail 
and all high pressure pipes must be replaced.

 

1) Disconnect negative (–) cable at battery.
2) Remove fuel injector cover referring to Step 2) 

through 7) of “Removal” under “High Pressure Pipe 
Removal and Installation: For Diesel Engine Model”.

3) Check for fuel rail pressure sensor (1) and its 

terminal for damage.
If damage is found, replace common rail referring to 
“Common Rail (High Pressure Fuel Injection Rail) 
Removal and Installation: For Diesel Engine Model”.

Fuel Filler Cap Inspection

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WARNING

!

 

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

 

CAUTION

!

 

If cap requires replacement, only a cap with 
the same features should be used. Failure to 
use correct cap can result in critical 
malfunction of system.

 

Remove cap (1), and check gasket for even filler neck 
imprint, and deterioration or any damage. If gasket (2) is 
in malcondition, replace cap.

Fuel Tank 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”.

 

Removal

1) Disconnect negative (–) cable at battery.
2) Hoist vehicle.
3) Remove exhaust center pipe.
4) Remove rear propeller shaft referring to “Propeller 

Shaft Removal and Installation in Section 3D”.

5) With cable connected, detach parking brake cable 

clamp from fuel tank cover referring to “Parking 
Brake Cable Location in Section 4D”.

6) Disconnect fuel filler hose and breather hose from 

filler neck referring to “Fuel Tank Inlet Valve Removal 
and Installation: For Diesel Engine Model”.

7) For 5 door model, disconnect fuel pump connector 

(1).

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1G-47 Fuel System: For Diesel Engine Model

8) 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.

 

9) Disconnect fuel pipe joint and fuel hoses (1) from 

fuel pipes (2) referring to “Fuel Hose Disconnecting 
and Reconnecting: For Diesel Engine Model”.

10) Support fuel tank (1) with jack (2) and remove its 

mounting bolts.

11) For 3 door model, lower fuel tank a little so 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.

3) Install fuel tank to vehicle.

Tightening torque
Fuel tank bolt (a):  50 N·m (5.0 kgf-m, 36.5 lb-ft)

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Fuel System: For Diesel Engine Model 1G-48

4) Connect fuel filler hose (1) and breather hose to filler 

neck as shown in figure, and clamp them securely.

Tightening torque
Fuel filler hose clamp (a):  2 N·m (0.2 kgf-m, 1.5 
lb-ft)

5) Connect fuel feed hoses (1) to each pipe as shown 

in figure, and clamp them securely referring to “Fuel 
Hose Disconnecting and Reconnecting: For Diesel 
Engine Model”.

6) Install parking brake cable clamp to fuel tank cover 

referring to “Parking Brake Cable Location in Section 
4D”.

7) Install rear propeller shaft referring to “Propeller 

Shaft Removal and Installation in Section 3D”

8) Install exhaust No.1 pipe referring to “Exhaust 

System Components: For Diesel Engine Model in 
Section 1K”.

9) Connect negative (–) cable at battery.

10) Check fuel leakage referring to “Fuel Leakage Check 

Procedure: For Diesel Engine Model”.

Fuel Tank Inspection

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After removing fuel tank, check hoses and pipes 
connected to fuel tank for leaks, loose connections, 
deterioration or damage. Also check fuel level gauge 
assembly gaskets for leaks, visually inspect fuel tank for 
leaks and damage.
Replace any damaged or malconditioned parts.

Fuel Tank Purging Procedure

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WARNING

!

 

This purging procedure will not remove all 
fuel vapor.
Do not attempt any repair on tank using heat 
of flame as an explosion resulting in personal 
injury could occur.

 

1) After removing fuel tank, remove all hoses, pipes 

and fuel level gauge assembly from fuel tank.

2) Drain all remaining fuel from tank.
3) Move tank to flushing area.
4) Fill tank with warm water or tap water, and agitate 

vigorously and drain. Repeat this washing until 
inside of tank is clean. Replace tank if its inside is 
rusty.

5) Completely flush out remaining water after washing.

CAUTION

!

 

Never remain water in fuel tank after washing, 
or fuel tank inside will get corrosion.

 

Fuel Tank Inlet Valve 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”.

 

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).

 

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