Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 189

1G-29 Fuel System: For Diesel Engine Model

Fuel Pressure Relief Procedure

S6JB0A1726002

1) Check that engine is cold.
2) Connect SUZUKI scan tool to DLC (1) with ignition 

switch turned OFF.

Special tool
(A):  SUZUKI scan tool

3) Turn ON ignition switch.
4) Confirm that fuel high pressure line is not under 

pressure by using “Fuel Rail Pressure” under “Data 
List” of SUZUKI scan tool.

Fuel Leakage Check Procedure

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1) Prime fuel line using priming pump (1).

2) Check low pressure fuel supply circuit for fuel 

leakage.

3) Start engine and run it at idle speed for about 10 

seconds.

4) Stop engine and then check for fuel leakage in each 

part, which was serviced.

5) Start engine and run it at 4,000 r/min. for about 10 

seconds.

6) Stop engine and then check for fuel leakage in each 

part, which was serviced.

3. Gasket

15. Fuel filter water detection sensor

27. To fuel injector return hose

4. Fuel pump assembly plate

16. Injection pump

: For detail of component, refer to “Injection Pump 
Components: For Diesel Engine Model”.

28. To high pressure pipe between common rail and 

injection pump

5. Main fuel level gauge

17. High pressure pipe between injection pump and common

29. To common rail

6. Sub fuel level gauge

18. Common rail

30. Sealing washer

7. Fuel tank belt

19. Common rail cover

31. To fuel return line

8. Fuel feed line

20. Common rail cushion

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

9. Fuel return line

21. High pressure pipe between common rail and fuel injector

: 50 N

⋅m (5.0 kgf-m, 36.5 lb-ft)

10. Priming pump

22. Fuel injector

: 5 N

⋅m (0.5 kgf-m, 4.0 lb-ft)

11. Fuel filter case

23. Fuel injector bracket

: 22 N

⋅m (2.2 kgf-m, 16.0 lb-ft)

12. Fuel filter

24. Fuel injector return hose

: 25 N

⋅m (2.5 kgf-m, 18.5 lb-ft)

(A)

1

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1

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Fuel System: For Diesel Engine Model 1G-30

Water Draining of Fuel Filter

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1) Disconnect negative (–) cable at battery.
2) Place container under fuel filter (1).
3) Loosen bleed screw (2), and drain water until fuel 

flow out from fuel filter.

4) Tighten bleed screw (2).

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

Procedure: For Diesel Engine Model”.

Air Bleeding of Fuel System

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Air bleeding must be carried out when fuel system has 
been disassembled or when vehicle ran out of fuel.
Pump priming pump (1) 20 times or more, and then 
check engine starts.

Fuel Filter and Fuel Heater Removal and 
Installation

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Removal

1) Disconnect negative (–) cable at battery.
2) Disconnect fuel heater connector (1) and fuel filter 

water detection sensor connector (2).

3) Clean filter and its surrounding area.
4) Pull out fuel hoses (3) with pushing lock button (4).
5) Plug fuel hoses, fuel filter (5) and fuel heater with 

plug cap according to “Precautions on Fuel System 
Service: For Diesel Engine Model” for parts number 
and handling.

6) Remove fuel filter (5) from its bracket (6).

7) Remove fuel heater (1) and fuel filter (2) from fuel 

filter case (3).

1

2

I5JB0B170003-01

1

I5JB0B170002-01

1

5

3

2

3

3

4

I5JB0B170004-01

I5JB0B170005-01

1G-31 Fuel System: For Diesel Engine Model

Installation

CAUTION

!

 

Be sure to position claw (5) of the fuel filter 
case (3) to such position of the fuel heater(1) 
as shown in the figure.
If fuel pipes (fuel heater) are not positioned 
as specified, an abnormal force is applied to 
the fuel hoses and may cause damage to 
them.

 

1) Clean fuel heater and fuel filter case.
2) Install fuel heater (1) and fuel filter (2) to fuel filter 

case (3) after applying diesel fuel to its new O-rings 
(4).

Tightening torque
Fuel filter case bolt (a):  5 N·m (0.5 kgf-m, 4.0 lb-
ft)

3) Install fuel filter (1) to its bracket.
4) Remove plug cup from fuel hoses (2) and fuel filter.
5) Connect fuel hoses to fuel filter.
6) Connect fuel heater connector (3) and fuel filter 

water detection sensor (4).

7) Connect negative (–) cable at battery.
8) Bleed air in fuel system referring to “Air Bleeding of 

Fuel System: For Diesel Engine Model”.

9) Check fuel leakage referring to “Fuel Leakage Check 

Procedure: For Diesel Engine Model”.

Fuel Heater Inspection

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• Check for terminals of fuel heater for damage.

If damage is found, replace fuel heater.

• Check resistance between terminals of fuel heater 

connector.If resistance is out of specification, replace 
fuel heater.

Fuel Heater Resistance
Approx. 0.6 

Ω

I5JB0B170049-01

I5JB0B170006-01

3

1

2

4

2

I5JB0B170007-01

I5JB0B170008-01

Fuel System: For Diesel Engine Model 1G-32

Fuel Hose Disconnecting and Reconnecting

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WARNING

!

 

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

 

For Connection Other Than Quick Joint
• Clamp around fuel tank

NOTE
Be sure to install hose to spool of pipe surely.

 

I6JB0A172002-01

1. Pipe

“a”: 3 – 7 mm (0.12 – 0.28 in.)

“f”: 0 – 2 mm (0.00 – 0.08 in.)

2. Hose

“b”: 5 – 12 mm (0.20 – 0.48 in.)

“g”: 25 – 30 mm (0.99 – 1.18 in.)

3. Clamp

“c”: 33 mm (1.30 in.)

: 2 N

⋅m (0.2 kgf-m, 1.5 lb-ft)

4. Fuel filler hose clamp screw

“d”: 30 mm (1.18 in.)

5. Vehicle leftward

“e”: 38 mm (1.50 in.)