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Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 182

1G-1 Fuel System: For Petrol Engine Model

Engine

Fuel System

For Petrol Engine Model

Precautions

Precautions on Fuel System Service

S6JB0A1710001

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

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: For Petrol Engine Model”.

• 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: For Petrol Engine Model”.
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 and fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System
Diagram: For Petrol Engine Model”.

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: For Petrol Engine Model”.

Fuel System: For Petrol Engine Model 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

I5JB0A171002-03

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

1G-3 Fuel System: For Petrol Engine Model

Diagnostic Information and Procedures

Fuel Pressure Inspection

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WARNING

Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service: For Petrol Engine Model” in order to
reduce the risk or fire and personal injury.

1) Relieve fuel pressure in fuel feed line referring to

“Fuel Pressure Relief Procedure: For Petrol Engine
Model”.

2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel feed

hose (1) and fuel delivery pipe as shown in the
figure, and clamp hoses securely in order to ensure
that no leaks occur during checking.

Special tool
(A): 09912–58413
(B): 09912–58490

4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.

If measured pressure is out of specification, refer to
“Fuel Pressure Check: For Petrol Engine Model in
Section 1A” and check each possibly defective part.
Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and

after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.

Fuel pressure specification with fuel pump
operating and engine stopped
: 250 – 310 kPa (2.5 – 3.1 kg/cm

, 35.5 – 44.0

psi)

b) Start engine and warm it up to normal operating

temperature, and measure fuel pressure at
idling.

Fuel pressure specification at specified idle
speed
: 210 – 260 kPa (2.1 – 2.6 kg/cm

, 29.9 – 36.9

psi)

c) Stop engine, and measure fuel pressure at one

minute after stopping.

Fuel pressure specification in 1 min. after
engine (fuel pump) stop (Pressure reduces
as time passes)
Over 180 kPa (1.8 kg/cm

, 25.6 psi)

[A]. For M16 engine model
[B]. For J20 engine model

[A]

[B]

(A)

(B)

(A)

(B)

I5JB0A171003-01

Fuel System: For Petrol Engine Model 1G-4

6) After checking fuel pressure, remove fuel pressure

gauge.

WARNING

As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut

slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel

feed hose.

8) Connect fuel feed hose to fuel delivery pipe and

clamp it securely.

9) With engine OFF and ignition switch ON, check for

fuel leaks.

Fuel Cut Operation Inspection

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NOTE
Before inspection, make sure that gear shift
lever is in neutral position (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using

sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.

3) Check to make sure that injector operation sound is

stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.

I2RH01170032-01

I2RH0B170004-01

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