1999 SUZUKI GRAND VITARA Fuel

ENGINE MECHANICAL (H27 ENGINE) 6A2-27
12) Disconnect the following electric lead wires :
•Injector wire coupler
•CMP sensor coupler
•Ignition coil couplers
•CKP sensor coupler
•MAP sensor coupler
•TP sensor (1) coupler
•IAC valve (2) coupler
•Earth wire (3) from surge tank
•EVAP canister purge valve coupler
•EGR valve coupler
•Oxygen sensor -1 and -2 couplers referring to “Exhaust Man-
ifold” in this section
•Coolant temperature sensor coupler
•Knock sensor coupler
•Generator wires
•Starter wires
•Oil pressure wire
•P/S pump wire
•Earth wire from generator bracket
•Engine block heater (if equipped)
13) Remove clamps and brackets.
14) Disconnect the following hoses :
•Heater hose from heater water pipe
•Heater hose from water outlet cap
•EVAP canister hose from canister pipe
•Brake booster vacuum hose
15) Remove EVAP canister purge valve (5).
16) Disconnect the following hoses at the location shown in the
figure :
•Fuel feed hose (1) from fuel feed pipe
•Fuel return hose from (2) fuel return pipe
17) Remove P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
18) Remove A/C compressor assembly. Refer to “COMPRES-
SOR ASSEMBLY” in Section 1B.
19) Remove steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
20) Raise vehicle.
21) Remove front differential housing with differential from chas-
sis if equipped. Refer to “DISMOUNTING” in Section 7E.
22) Remove exhaust No.1 pipe. Refer to “EXHAUST MANI-
FOLD” in this section.
23) Remove exhaust manifold stiffener from transmission.
4. Clamp bracket
6. EGR valve
7. Heater hose
2
14
3
75
6

ENGINE MECHANICAL (H27 ENGINE) 6A2-29
3) Tighten bolts and nuts fastening cylinder block and transmis-
sion to specified torque.
Tightening torque
Transmission to cylinder block bolt and nut (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Remove lifting device
5) Tighten torque converter bolts to specified torque (for A/T
vehicle).
Tightening torque
Torque converter bolt (c) :
65 N·m (6.5 kg-m, 47.0 lb-ft)
6) Tighten bolts and nuts of exhaust No.1 pipe (1) to specified
torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (d) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
7) Install front differential housing with differential to chassis if
removed. Refer to “REMOUNTING” in Section 7E.
8) Install steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
9) Install A/C compressor assembly. Refer to “COMPRESSOR
ASSEMBLY” in Section 1B.
10) Install P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
11) Connect hoses, cables and electric wires.
12) Adjust accelerator cable play and A/T throttle cable play (for
A/T vehicle). Refer to “ACCELERATOR CABLE ADJUST-
MENT” and “A/T THROTTLE CABLE ADJUSTMENT (A/T
VEHICLE)” in Section 6E2.
13) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
14) Refill cooling system, referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
15) Check to ensure that all fasteners and clamps are tightened.
16) Upon completion of installation, verify that there is no fuel
leakage, coolant leakage, P/S fluid leakage or exhaust gas
leakage at each connection.
1. Bolt (short)
2. Bolt (Long)

ENGINE FUEL 6C-1
6C
SECTION 6C
ENGINE FUEL
CONTENTS
General Description ....................................... 6C-1
Fuel System ................................................. 6C-1On-Vehicle Service ........................................ 6C-2
Fuel Tank ..................................................... 6C-2
Fuel Lines .................................................... 6C-5
General Description
Fuel System
The main components of the fuel system are fuel tank, fuel pump, fuel filter and fuel level gauge and it includes
three lines, fuel feed line, fuel return line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to Section 6E2.NOTE:
For the descriptions (items) not found in this section, refer to the same section of Service Manual
mentioned in the FOREWORD of this manual.
1. Fuel tank 6. Fuel feed line (to delivery pipe)
2. Fuel pump (with fuel level gauge) 7. Fuel return line (from delivery pipe)
3. Fuel filter 8. Fuel vapor line (to EVAP canister)
4. Fuel filter cap 9. Fuel tank protector
5. Breather hose 10. Belt

6C-2 ENGINE FUEL
On-Vehicle Service
Fuel Tank
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to Section 6
or Section 6-1.
2) Disconnect negative (–) cable at battery.
3) Before disconnecting fuel filler hose, give match marks on
fuel filler hose and fuel filler neck.
4) Disconnect fuel filler hose from fuel filler neck.
5) Insert hose of a hand operated pump into fuel filler hose and
drain fuel in space “A” in the figure (drain fuel through it till
fuel stops).
6) Remove fuel tank filler hose protector.
Disconnect filler hose from fuel tank and breather hose from
fuel filler neck.
7) Remove fuel tank inlet valve. Use care not to damage inlet
valve when removing.
8) Drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
9) Disconnect fuel filter inlet hose from filter.CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
CAUTION:
Do not force hose of a hand operated pump into fuel
tank. Doing so can damage inlet valve.
1. Fuel filler hose
2. Fuel tank inlet (check) valve
1. Tank
2. Breather hose
3. Filler hose
4. Inlet valve
CAUTION:
Never drain or store fuel in an open container due to pos-
sibility of fire or explosion.
1. Fuel filter
2. Fuel filter outlet hose
3. Fuel filter inlet hose

ENGINE FUEL 6C-3
10) Disconnect fuel vapor hose and return hose from pipes.
11) Remove fuel tank protector (if equipped) from vehicle.
12) Lower fuel tank gradually while holding it horizontally and
pull out coupler at fuel pump.
INSPECTION
After removing fuel tank, check hoses and pipes connected to
fuel tank for leaks, loose connections, deterioration or damage.
Also check fuel pump and level gauge gaskets for leaks, visually
inspect fuel tank for leaks and damage.
Replace any damaged or malconditioned parts.
1. Fuel pump
2. Coupler

6C-4 ENGINE FUEL
INSTALLATION
1) Install fuel pump assembly, fuel cut valve and vapor control
valve to fuel tank. Refer to “FUEL PUMP” in this section.
2) Connect fuel hoses to fuel tank, fuel cut valve, and vapor
control valve, check valve and fuel pump assembly.
After connecting, clamp hoses securely.
3) Install inlet valve to fuel tank. If deformed or damaged in any
other way, replace with a new one.
4) Install fuel tank by using fuel tank belts and then install pro-
tector to vehicle.
Tightening torque
Fuel tank bolt (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Fuel tank protector bolt (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
5) Connect fuel filler hose to fuel filler neck with match the
match marks. And then clamp the securely.
6) Connect fuel filler hose to fuel tank and breather hose to fuel
filler neck. Clamp them securely.
Tightening torque
Breather hose clamp (b) : 2.0 N·m (0.2 kg-m, 2.0 lb-ft)
Fuel filler hose clamp (c) : 4.0 N·m (0.4 kg-m, 3.0 lb-ft)
7) Install fuel filler hose protector.
8) Connect fuel vapor hose (1) and return hose (2) to fuel pipe
and clamp them securely.
9) Connect fuel filter inlet hose to fuel filter.
10) Connect coupler to fuel pump assembly.
11) Connect negative (–) cable to battery.
12) Upon completion of installation, check fuel system for leak-
age.
1. Fuel tank 9. Fuel tank protector
2. Fuel pump (with fuel level gauge) 10. Belt
3. Fuel filter 11. Filler neck
4. Fuel filler cap 12. Breather pipe
5. Breather hose 13. Filler hose
6. Fuel feed line (to delivery pipe) 14. Tank inlet valve
7. Fuel return line (from delivery pipe) 15. Fuel cut valve
8. Fuel vapor line (to EVAP canister)
1. Fuel filter
2. Fuel filter outlet hose
3. Fuel filter inlet hose

ENGINE FUEL 6C-5
Fuel Lines
Due to the fact that fuel feed line is under high pressure, this sys-
tem requires special consideration for service.
The feed pipe uses screw couplings and hose clamps.
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose
cracking and deterioration, or damage. Make sure all clamps are
secure. Replace parts as needed.

6C-6 ENGINE FUEL