1987 SUZUKI GRAND VITARA open gas tank

2-1. ENGINE
Cond it ion
Poor starting
(Hard starting)
Possible cause
Starter will not run
1. Main fuse blown off
2. Contact not closing in main switch, or this
switch open-circuited
3. Run-down battery
4. Defective magnetic switch of starter
5. Loose battery terminal connection
6. Defective brushes in starter
7. Loose battery cord connection
8. Open in field or armature circuit of starter.
Correction
Replace
Repair or replace
Recharge
Replace
Clean and retighten
Replace
Retighten
Repair or replace
No sparking
1. Defective spark plugAdjust gap, or replace
2. High tension cord short-circuited (grounded)Repair or replace
3. Cracked rotor or cap in distributorReplace
4. Defective signal generator or ignitorReplace
5. Maladjusted signal rotor air gap.Adjust
6. Contact not closing positively in main switch,Replace
or this switch open-circuited
7. Loose or blown fuseSet right or replace
8. Improper ignition timingAdjust
9. Defective ignition coil.Replace
Faulty intake and exhaust systems
1. Carburetor out of adjustment
2. Fuel pump not discharging adequately
3. Clogged fuel filter
4. Defective choke mechanism
5. Loose intake manifold
6. Dirty and clogged carburetor
7. Float level out of adjustment
8. Clogged fuel hose or pipe
9. Not enough fuel in the tank
10. Malfunctioning fuel cut solenoid valve
Adjust
Replace
Clean, or replace
Repair or replace
Retighten
Disassemble and clean
Adjust
Clean or replace
Refill
Check solenoid valve for
proper operation and
replace if necessary
Abnormal engine internal condition
1. Ruptured cylinder head gasket
2. Improper valve clearance
3. Weakened or broken valve spring
4. Loose manifold, permitting air to be
drawn in
5. Worn pistons, rings or cylinders
Replace
Adjust
Replace
Retighten and, as neces-
sary, replace gasket
Replace worn rings and
pistons and rebore as
necessary
2-2

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 tank purging procedure]
WARNING:
This purging procedure will NOT remove
all fuel vapor. Do not attempt any repair
on tank where heat or flame is required, as
an explosion resulting in personal injury
cou Id occur.J
The following procedure is used for purging the
fuel tank.
1) After removing fuel tank, remove all hoses,
fuel level gauge 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 inside is rusty.
5) Completely flush out remaining water after
washing.
[ Installation]
Reverse removal procedure for installation using
care for the following.
Tightening torque30-45 Nm
for fuel tank(3.0- 4.5 kg-m)
drain plug(22.0 - 32.5 lb-ft)
Refer to Fig. 4-2-5 for piping and clamp posi-
tions.
l Make sure for correct hose-to-pipe connec-
tion.
l Clamp hoses securely.
l Upon completion of installation, start engine
and check hose joints for leaks.
MAINTENANCE SERVICES
Fuel Lines
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 crack-
ed.
Fig. 4-2-14
Fuel Filler (tank) Cap
Visually inspect gasket of fuel filler cap.
If it is damaged or deteriorated, replace filler cap
with new one.
NOTE:
If cap requires replacement, only a cap with
the same features should be used. Failure to
use correct cap can result in a serious malfunc-
tion of the system.
Fig. 4-2-15
1. Fuel filler cap
2. Fuel filler capgasket
Fuel Filter
As said before, this filter does not permit dis-
assembly: it is to be replaced with a new one
periodically.
Replace fuel filter referring to previous item of
“Fuel Filter Removal and Installation”.
This servicing must be performed in a well
ventilated area and away from any open
flames (such as gas hot water heaters).
4-35