1999 SUZUKI GRAND VITARA regulator

6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Air Intake System
The main components of the air intake system are air cleaner, mass air flow sensor, air cleaner, intake air pipe,
throttle body, intake collector, idle air control valve and intake manifold.
The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air
cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com-
bustion chamber.
When the idle air control valve is opened according to the signal from ECM (PCM), the air bypasses the throttle
valve through bypass passage and is finally drawn into the intake manifold.
“A” : Air 1. Air cleaner 6. PCV hose 11. Breather hose 16. IAC valve and fast idle control system
“B” : EGR 2. IAT sensor 7. Brake booster 12. MAF sensor 17. FIA valve
“C” : Engine coolant 3. Resonator 8. Fuel pressure
regulator hose13. EGR valve 18. Thermo - WAX
4. Intake manifold 9. Intake air pipe 14. TP sensor
5. Intake collector 10. Throttle body 15. IAC valve
18
10
17
15
16

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-7
Fuel Delivery System
The fuel delivery system consists of the fuel tank, fuel pump, fuel filter, fuel pressure regulator, delivery pipe and
fuel injectors.
The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each
injector through the delivery pipe.
As the fuel pressure applied to the injector (the fuel pressure in the fuel feed line) is always kept a certain
amount higher than the pressure in the intake manifold by the fuel pressure regulator, the fuel is injected into the
intake port of the cylinder head when the injector opens according to the injection signal from ECM (PCM).
The fuel relieved by the fuel pressure regulator returns through the fuel return line to the fuel tank.
[A] : Fuel 1. Fuel tank 5. Fuel return line 9. Fuel injector
[B] : Air 2. Fuel pump 6. Fuel pressure regulator 10. Fuel delivery pipe
3. Fuel filter 7. Vacuum hose for fuel pressure regulator 11. Throttle valve
4. Fuel feed line 8. Intake manifold surge tank

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-13
On-Vehicle Service
General
When hoses are disconnected and system components are removed for service, reinstall components properly,
and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of
hoses.
1. Brake booster hose pipe 8. EGR pipe (if equipped) 15. EVAP canister
2. Vacuum hose for fuel pressure regulator 9. Exhaust manifold 16. Tank pressure control valve
3. Fuel pressure regulator 10. Heated oxygen sensor 17. To fuel tank
4. MAP sensor (if equipped) 11. EGR valve (if equipped) 18. Cap
5. Engine coolant hose 12. PCV hose [A]: Vehicle without monitor connector
6. EVAP canister purge valve 13. IAC valve [B]: Vehicle with monitor connector
7. Breather hose 14. IAC hose

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-25
REMOVAL
Remove fuel tank from body according to procedure described in
Section 6C and remove fuel pump from fuel tank.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
Install fuel pump to fuel tank and then install fuel tank to body
according to procedure described in “Section 6C”.
Fuel pressure regulator
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6-1.
2) Disconnect negative (–) cable from battery.
3) Disconnect vacuum hose (1) from fuel pressure regulator.
4) Remove fuel pressure regulator (1) from fuel delivery pipe
(3).
5) Disconnect fuel return hose (2) from fuel pressure regulator.
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.
CAUTION:
A small amount of fuel may be released when hose is dis-
connected. Cover hose to be disconnected with a shop
cloth.

6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
INSTALLATION
For installation, reverse removal procedure and note the follow-
ings.
•Use new O-ring.
•Apply thin coat of gasoline to O-ring to facilitate installation.
•Tighten fuel pressure regulator (1) bolts to specified torque.
Tightening torque
Fuel pressure regulator bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
•With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.
Fuel injector
ON-VEHICLE INSPECTION
1) Using sound scope (1) or such, check operating sound of
injector when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, check injector cir-
cuit (wire or coupler) or injector.
2) Disconnect connector from injector, connect ohmmeter
between terminals of injector and check resistance.
If resistance is out of specification, replace.
Fuel injector resistance:
14.2 – 14.8 Ω
Ω Ω Ω (at 20°C, 68°F)
3) Connect connector to injector securely.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-27
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6-1.
2) Remove throttle body intake collector, refer to “THROTTLE
BODY” in this section.
3) Disconnect fuel feed hose (1) and fuel return hose (2).
4) Disconnect vacuum hose (4) and fuel return hose from fuel
pressure regulator (5).
5) Remove fuel feed pipe (8) and fuel connect pipe (7) from
delivery pipes (6) (right and left).
6) Disconnect connector (3) from each injector.
7) Remove delivery pipes (1) (right and left) from intake mani-
fold.
8) Remove fuel injector(s).
INSPECTION
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.

6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
1) Install injector (1) and fuel pressure regulator (2) to special
tool (injector checking tool).
Special tool
(A) : 09912-58421
2) Connect special tools (hoses and attachment) to pipes of
vehicle.
Special tool
(B) : 09912-58431
3) Connect special tool (test lead) to injector.
Special tool
(C) : 09930-88521
4) Install suitable vinyl tube onto injector (3) nozzle to prevent
fuel from splashing out when injecting.
5) Put graduated cylinder under injector as far apart as possi-
ble.
6) Disconnect fuel pump relay.
7) To operate fuel pump and apply fuel pressure to injector,
using wire harness (2) as thick as the one used for fuel pump
circuit, connect two terminals of relay connector (1) as
shown in the figure.
8) Apply battery (4) voltage to injector for 15 seconds and mea-
sure injected fuel volume with graduated cylinder.Test each
injector two or three times.If not within specification, replace
injector.
Injected fuel volume:
56 – 60 cc/15 sec. (1.89/1.97 – 2.02/2.11 US/lmp. oz/15 sec.)
9) Check fuel leakage from injector (1) nozzle. Do not operate
injector for this check (but fuel pump should be at work). If
fuel leaks more than following specifications, replace.
Fuel leakage:
Less than 1 drop/min. NOTE:
Remove grommet from injector, then install injector to
special tool and tighten bolts by hand.
[A]: Left-hand steering vehicle
[B]: Right-hand steering vehicle

6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
5) Install fuel connect pipe (1) and tighten union bolts to speci-
fied torque with new gaskets (3).
Tightening torque
Fuel connect pipe union bolt
(b) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
6) Install fuel feed pipe (2) and tighten union bolt to specified
torque with new gaskets.
Tightening torque
Fuel feed pipe union bolt
(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
7) Connect vacuum hose (5) and fuel return hose (4) to fuel
pressure regulator.
8) Connect fuel feed hose (1) and fuel return hose (2).
9) Connect connectors of injector wire (3) to injectors.
10) Install throttle body and intake collector, refer to “THROTTLE
BODY” in this section.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.