Common Rail (High Pressure Fuel Injection Rail) Removal And Installation - Suzuki Grand Vitara 2011 Manual

1G-45 Fuel System: For Diesel Engine Model
Removal
1) Relief fuel pressure referring to "Fuel Pressure Relief
Procedure: For Diesel Engine Model".
2) Disconnect negative (–) cable at battery.
3) Clean fuel flow actuator and its surrounding area.
4) Disconnect fuel flow actuator connector.
5) Remove fuel flow actuator (1) from injection pump by
pulling and twisting it gradually.
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Installation
1) Apply clean fuel to O-rings.
2) Fit new fuel flow actuator (1) to injection pump.
3) Tighten new fuel flow actuator bolts (2) as follows.
a) Tighten fuel flow actuator bolts to 3 N⋅m (0.3 kgf-
m, 2.5 lb-ft).
b) Retighten fuel flow actuator bolts to 6 N⋅m (0.6
kgf-m, 4.5 lb-ft).
Tightening torque
Fuel flow actuator bolt (a): Tighten 3 N⋅m (0.3
kgf-m, 2.5 lb-ft) and 6 N⋅m (0.6 kgf-m, 4.5 lb-ft)
by the specified procedure.
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(a)
4) Connect fuel flow actuator connector.
5) Connect negative (–) cable at battery.
6) Check fuel leakage referring to "Fuel Leakage Check
Procedure: For Diesel Engine Model".
7) Check DTC referring to "DTC Check: For Diesel
Engine Model in Section 1A".
Common Rail (High Pressure Fuel Injection
Rail) Removal and Installation
WARNING
!
Before servicing fuel system, be sure to
observe "Precautions on Fuel System
Service: For Diesel Engine Model".
CAUTION
!
Never remove fuel rail pressure sensor from
common rail because this may cause fuel
circuit contamination problems.
If fuel rail pressure sensor fails, common rail
and all high pressure pipes must be replaced.
Removal
1) Remove all high pressure pipes referring to "High
Pressure Pipe Removal and Installation: For Diesel
Engine Model".
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2) Remove oil separator referring to "Oil Separator
Removal and Installation: For F9Q Engine in Section
1D".
3) Disconnect fuel return hose (1).
4) Remove common rail (2) from cylinder head.
Installation
1) Install common rail (1) to cylinder head, and tighten
common rail bolt by hand.
2) Install new high pressure pipes referring to "High
Pressure Pipe Removal and Installation: For Diesel
Engine Model".
3) Connect fuel return hose.
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