2001 SUZUKI GRAND VITARA fuel cap

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 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

6E2-16 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
[Not using SUZUKI scan tool] (vehicle with monitor
connector)
1) Disconnect scan tool from DLC if connected.
2) Warm up engine to normal operating temperature.
3) Stop engine and connect duty meter (3) between duty output
terminal and ground terminal of monitor connector (1).
4) Using service wire (2), ground diagnosis switch terminal in
monitor connector.
5) Set tachometer.
6) Start engine and warm it up completely.
7) Check IAC duty and idle air control system referring to Diag-
nostic Flow Table B-4 “IDLE AIR CONTROL SYSTEM
CHECK” in this section.
•“OFF DUTY METER” is such duty meter that indicates
approx. 100% when terminal voltage is approx. “0 V”.
•“V
B” represents battery voltage while engine of vehicle being
checked is running.
8) Remove service wire from monitor connector.
9) Install cap to monitor connector.
10) Check that specified engine idle speed is obtained with A/C
ON if vehicle is equipped with A/C.
If not, check A/C ON signal circuit and idle air control sys-
tem.
A: Output duty select switch terminal
B: Diagnosis switch terminal
C: Blank
D: Ground terminal
E: Test switch terminal
F: Duty output terminal
A/C OFF A/C ON
Engine idle speed: 700 ± 50 r/min. 750 ± 50 r/min.
IAC duty at specified
idle speed:5 – 40 % (0.7 – 5.6 V
when battery voltage
is 14 V)–
NOTE:
IAC duty can be checked roughly by using voltmeter. I
AC duty to voltage relation is as follows.
ON DUTY METER
INDICATION
(%)OFF DUTY
INDICATION
(%)VOLT METER
INDICATION
(V)
0
50
10010
50
00
0.5 x V
B
VB

6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
8) After checking fuel pressure, remove fuel pressure gauge
(1).
9) Remove fuel pressure gauge, hose and 3-way joint.
10) Connect fuel feed hose and clamp it securely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
Fuel pump
ON-VEHICLE INSPECTION
1) Remove filler cap and turn ON ignition switch (2). Then fuel
pump operating sound should be heard from fuel filler (1) for
about 3 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “DIAG-
NOSTIC FLOW TABLE B-1” in Section 6-1
2) Fuel pressure should be felt at fuel return hose (1) for 3 sec-
onds after ignition switch ON.
If fuel pressure is not felt, advance to “DIAGNOSTIC FLOW
TABLE B-3” in Section 6-1. CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.
Place fuel container under joint.
Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.

6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Engine coolant temperature sensor (ECT sensor)
REMOVAL
1) Disconnect negative (–) cable from battery.
2) Drain cooling system.
3) Disconnect coupler from ECT sensor (1).
4) Remove ECT sensor from water outlet cap (2).
INSPECTION
Immerse temperature sensing part of ECT sensor in water and
measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t shown such characteristic as
shown in the figure, replace ECT sensor.
INSTALLATION
Reverse removal procedure noting the followings.
•Clean mating surfaces of sensor and water outlet cap (1).
•Use new O-ring.
•Tighten ECT sensor to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)
•Connect coupler to sensor securely.
•Refill cooling system.