1987 SUZUKI GRAND VITARA fuel cap release

1. CHARCOAL CANISTER REPLACEMENT
WARNING:
The following cautions should be always
observed.
l Disconnect negative cable at battery.
l DO NOT smoke and place “NO SMOK-
ING” signs near work area.
l Be sure to have COZ fire extinguisher
handy.
l Wear safety glasses.
l To release the fuel vapor pressure in
fuel tank, remove the fuel tank cap and
then reinstall it.
1) Disconnect 3 hoses from canister.
2) Remove canister from car body.
3) Install new canister.
4) Connect 3 hoses to canister securely.
5) Clamp them securely.
//valve
To fuel tank
12. EMISSION-RELATED HOSES AND
TUBES INSPECTION
Check each vacuum hose and tube for secure
connection. Also, check that it is free from any
bend or damage.
Correct faulty condition, if any.
13. EXHAUST GAS RECIRCULATION (EGR)
SYSTEM INSPECTION
NOTE:
l Before checking, confirm that altitude is not
higher than 1,220 m (4,088 ftt) (atmospheric
pressure is below 680mmHg) and gear shift
lever is at neutral position.
o When performing this check at higher than
1,220 m (4,000 ft) altitude, be sure to dis-
connect HAC coupler.
.
1) Run engine when it is cool (coolant tempe-
rature is below 55°C (131°F)) and check
that EGR valve diaphragm is not operating in
this state, by touching diaphragm with
finger.
WARNING:
If EGR valve is hot, it may be necessary to
wear gloves to avoid burning finger.
1. EGR valve
22. Diaphragm
Checking EGR valve diaphragm
2) Warm up engine to normal operating tempe-
rature and race it after warming up. Then
check to be sure that diaphragm moves
toward @ in below figure during acceleration
and toward @ during deceleration.
l- 11

21. FUEL TANK CAP GASKET INSPECTION
AND REPLACEMENT
Visually inspect gasket of fuel tank cap. If it is
damaged or deteriorated, replace it with new
one.
22. AIR CLEANER ELEMENT
REPLACEMENT
1) Remove air cleaner cap.
2) Take cleaner element @ out of air cleaner
case.
3) Install new cleaner element @ into cleaner
case.
4) Install air cleaner cap securely.
23. THERMOSTATICALLY CONTROLLED
AIR CLEANER SYSTEM INSPECTION
Check thermostatically controlled air cleaner
system for proper operation. Refer to p. 5-19
for checking procedure.
24. CARBURETOR CHOKE SYSTEM
LUBRICATION AND INSPECTION
1) Remove air intake case, and lubricate rotating
paItS.
2) Check choke for proper operation.
Refer to p. 4-22 for checking procedure.
25. FUEL FILTER REPLACEMENT
This work must be performed in a well
1) Disconnect negative cable from battery.
2) Remove fuel tank cap to release fuel vapor
pressure in fuel tank. After releasing, reinstall
the cap.
3) Disconnect inlet and outlet hoses from fuel
filter located at the front part of fuel tank,
inside the right-hand side of chassis.
4) Remove fuel filter with clamp.
5) Install new filter with clamp, and connect
inlet and outlet hoses to fuel filter.
NOTE:
The top connection is for the outlet hose, the
lower one for the inlet hose.
6) Connect negative cable to battery.
7) After installation, start engine and check it
for leaks.
26. FUEL LINES AND CONNECTIONS
INSPECTION AND REPLACEMENT
[INSPECTION]
Visually inspect fuel lines and connections for
evidence of fuel leakage, hose cracking, and
damage. Make sure all clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being
cracked.
[REPLACEMENT]
WARNING:
The following cautions should be always
observed.
l Disconnect negative cable at battery.
l DO NOT smoke and place “NO SMOK-
ING” signs near work area.
l Be sure to have CO2 fire extinguisher
handy.
0 Wear safety glasses.
l To release the fuel vapor pressure in fuel
tank, remove the fuel tank cap and
then reinstall it.
1-14

3-3. ENGINE REMOVAL
1) Disconnect negative (-) and positive (+)
cords from battery terminals.
‘)From starter motor terminals, disconnect
black/yellow lead wire and positive (+)
battery cord.
Disconnect coupler and white lead wire
from alternator terminals.
Disconnect lead wires from water tempera-
ture gauge and thermal switch. The gauge
and switch are on intake manifold.
Disconnect earth lead wire from intake
manifold.
5) Disconnect couplers of carburetor fuel cut
solenoid valve, vent solenoid valve and
mixture control solenoid valve, and dis-
connect couplers from TWSVS and VSV.
6) Remove warm air hose.
) Disconnect breather hose from air cleaner
case.
,) Remove air intake case from carburetor
body and air inlet hose.
1) Disconnect accelerator cable from carbure-
tor.
10) Disconnect vacuum hoses of TCAC and
canister from intake manifold.
11) Remove fuel tank filler cap to release fuel
vapor pressure in fuel tank. After releasing,
reinstall it. Disconnect fuel feed and return
hoses from fuel pump.
12) Disconnect lead wire from oil pressure unit
terminal and oxygen sensor lead wire at the
coupler.
13) Disconnect lead wires of back-up light
switch and fifth switch at their couplers.
14) Disconnect distributor lead wire at the
coupler.
15) Pull off high-tension cord from ignition coil.
16) Loosen radiator drain plug to drain cooling
water,
17) Disconnect water hoses from thermostat
cap and water inlet pipe. After removing
cooling fan & clutch and fan shroud, remove
radiator.
Fig. 3-3- 1
Fig. 3-3-2
16) Disconnect heater hoses from heater unit
outlet pipe and intake manifold.
Fig. 3-3-3
3)
4)
3-6

REMOVAL AND INSTALLATION
Removal and installation of carburetor
place where no fire is used around.
Removal
1) Disconnect negative battery cord from
battery.
2) Drain coolant.
WARNING:
To help avoid the danger of being burned,
do not remove the drain plug and the
radiator cap while the engine and radiator
are still hot. Scalding fluid and steam can
be blown out under pressure if the plug
and cap are taken off too soon.
3) Remove air intake case from carburetor.
4) Disconnect micro switches, switch vent sole-
noid valve, fuel cut solenoid valve and MCSV
lead wires at their couplers.
5) Disconnect VSV coupler from VSV.
6) Detach bracket with EGR modulator and
TWSV from carburetor.
1. Bracket3.EGRmodulator2. Twsv
Fig. 4- 1-16
7) Disconnect water inlet and outlet hoses from
carburetor.
8) Disconnect accelerator cable from carburetor.
9) Disconnect vacuum hoses from idle up
actuator and carburetor.
10) To release the pressure in fuel tank, remove
fuel tank filler cap and then, reinstall it.
11) Disconnect fuel inlet hose from carburetor.
12) Check all around carburetor for any other
parts required to be removed or disconnect-
ed for removal of carburetor and remove or
disconnect whatever necessary.
13) Remove carburetor from intake manifold.
Fig. 4- 7- 17
Installation
Install in the reverse order of removal using care
for the following.
l Install carburetor to intake manifold.
Tighten 4 carburetor nuts to the specified
torque.
Tightening torque
for nuts13.5 - 20.0 lb-ft
l Connect water hoses to carburetor.
1. Carburetor
Fig. 4- I- 18
2. Inlet hose3. Outlet hose
4-12

Fuel Filler Cap
The fuel tank filler neck has a pressure-vacuum
cap.
A ratchet tightening device on the threaded fuel
filler cap reduces the chances of incorrect
installation, which would prevent sealing fuel
vapors.
After the gasket on fuel filler cap and the filler
neck flange contact, the ratchet produces a
loud clicking noise, indicating the seal has been
set.
This cap has pressure relief valve and vacuum
relief valve inside.
If the pressure of fuel vapor in fuel tank should
exceed that for which fuel system is designed,
the pressure relief valve opens to relieve the
pressure.
The vacuum relief valve opens to relieve the
vacuum created in fuel tank.
1. Pressure relief valve2. Vacuum relief valve
3. Gasket
Fig. 4-2- 10Fuel filler cap cross-section
REMOVAL AND INSTALLATION
CALJTION:
Before attempting. service of any type on
fuel system, the following cautions should
be always observed.
l Disconnect negative cable at battery.
l DO NOT smoke, and place “NO SMOK-
I NG” signs near work area.
l Be sure to have COZ fire extinguisher
handy.
0 Wear safety glasses.
l To release fuel vapor pressure in fuel
tank, remove fuel filler cap from fuel
filler neck and then reinstall it. If prec
sure in fuel tank is not released before-
hand, fuel in fuel tank may come out of
fuel hoses due to the pressure when they
are disconnected.
l Note that fuel hose connection varies
with each type of pipe. Be sure to
connect and clamp each hose correctly
referring to the following.
With following type pipe, fit hose as far as it reachespipe joint as shown./
Clamp securely at a position
3 to 7 mm (0.12 - 0.27 in.)from hose end.
With following type pipe, fit hose as far as its peri-pheral projection as shown.
\
Clamp securely at a position
3 to 7 mm (0.12 - 0.27 in.)
from hose end.
With following type pipe, fit hose es far as its bentpart as shown or till pipe is about 20 to 30 mm (0.79
- 1.18 in.) into the hose.
Clamp securely at a positior
3 to 7 mm (0.12 - 0.27 in.:from hose end.
4-33

,Fuel Pump
[ Rem’oval]
1) Disconnect negative cable from battery.
2) Remove fuel filler cap from fuel filler neck to
release fuel vapor pressure in fuel tank. After
releasing, reinstall the cap.
3) Disconnect fuel inlet, outlet and return hoses
from fuel pump.
Fuel Filter
[Removal]
1) Disconnect negative cable from battery.
2) Remove fuel filler cap to release fuel vapor
pressure in fuel tank. After releasing, reinstall
the cap.
3) Disconnect inlet and outlet hoses from fuel
filter.
4) Remove fuel filter with clamp.
[Installation]
1) Install filter and clamp, and connect inlet
and outlet hoses to fuel filter.
NOTE:.
The top connection is for outlet hose, the
lower one for inlet hose.
1. Fuel pump
2. Inlet hose3. Outlet hose
4. Return hose
Fig. 4-2-l 1
4) Remove fuel pump from cylinder head.
5) Remove fuel pump rod from cylinder head.
2
1. Fuel pump rod
2. Cylinder head
[Installation]
Reverse removal procedure for installation
using care for the following.
l After oiling it,install fuel pump rod to
cylinder head.
0 Use new fuel pump gasket.
l Make sure for proper hose connection.
0 Upon completion of installation, start engine
and check fuel hose or its joints for leaks.
1.Fuel filter3.From fueltank
2.To fuel pump4.Clamp
Fig.4-2-13
2) Connect negative cable to battery.
3) After installation, start engine and check it
for leaks.
Fuel Tank
[Removal]
1) Disconnect negative cable from battery.
2) Disconnect fuel level gauge lead wire.
3) To release the pressure in fuel tank, remove
fuel filler cap and then, reinstall it.
4) Raise car on hoist.
5) Drain fuel by removing drain plug.
6) Remove filler hose protector.
7) Disconnect filler hose from fuel tank.
.8) Disconnect fuel hosesand pipe from fuel tank.
9) Remove fuel tank.
4-34