6C-2 Engine Fuel (K10B Petrol)

Precautions
Precautions for Fuel System Service
! WARNING
Before servicing on fuel system, the following points should be always observed in order to reduce the
risk of fire and personal injury.
• Disconnect negative (–) cable at battery.
• Do not smoke, and place no smoking signs near working area.
• Be sure to have CO2 fire extinguisher handy.
• Be sure to perform work in a well-ventilated area and away from any open flames (such as gas hot
heater).
• Wear safety glasses.
• To relieve fuel vapor pressure in fuel tank, remove fuel filler cap from fuel filler neck and then
reinstall it.
• As fuel feed line is still under high fuel pressure even after stopping engine, loosening or
disconnecting fuel feed line directly may cause dangerous spout of fuel. Before loosening or
disconnecting fuel feed line, make sure to relieve fuel pressure referring to “Fuel Pressure Relief
Procedure” in this section.
• A small amount of fuel may be released when the fuel line is disconnected. In order to reduce the
risk of personal injury, cover the fitting to be disconnected with shop cloth.
• Never perform service work when engine and exhaust system are hot.

! CAUTION
Use unleaded fuel only.
Leaded or low lead fuel can result in engine damage and reduce the effectiveness of the emission
control system.
 Engine Fuel (K10B Petrol) 6C-3

General Description
Fuel System Description Fuel Pump Description
The main components of the fuel system are fuel tank, The fuel pump assembly is an in-tank type electric
fuel pump assembly (with fuel level sensor, fuel pressure pump. Incorporated in the pump assembly are;
regulator), fuel filter, fuel feed line, fuel return line and a fuel pressure regulator (8), a fuel level sensor (6).
fuel vapor line.
For the details of fuel flow, refer to “Fuel Delivery System 3
2
Diagram” in this section.
1

Fuel Delivery System Description 5

The fuel delivery system consists of the fuel tank, fuel 6

8
pump assembly (with fuel pressure regulator), fuel filter,
delivery pipe, injectors and fuel feed line.
The fuel in the fuel tank is pumped up by the fuel pump,
sent into delivery pipe and injected by the injectors.
As the fuel pump assembly is equipped with fuel
pressure regulator, the fuel is filtered by the fuel filter and
its pressure is regulated before being sent to the feed
pipe. 7
The excess fuel at fuel pressure regulation process is I8C50A170001-01

returned back through the fuel return line into the fuel 1. Fuel return pipe 4. Breather pipe
tank. 2. Fuel feed pipe 5. Fuel cut valve
Also, fuel vapor generated in fuel tank is led through the 3. Fuel vapor pipe 7. Fuel pump filter
fuel vapor line into the EVAP canister.
For system diagram, refer to “Fuel Delivery System
Diagram” in this section.

Schematic and Routing Diagram

Fuel Delivery System Diagram

1 11

13 12
2
3
6

9
7 8
4

10

5
I8C50A170002-01

1. EVAP canister purge valve 5. Fuel injector 9. Fuel pump assembly 13. EVAP canister
2. Intake manifold 6. Fuel filter 10. Fuel tank
3. Fuel feed line 7. Fuel level sensor 11. Fuel vapor line
4. Fuel delivery pipe 8. Fuel pressure regulator 12. Fuel return line
6C-4 Engine Fuel (K10B Petrol)

Fuel Injector Control System Circuit Diagram

NOTE
For identification of each cylinder, refer to “Cylinder Identification Description” in Section 6E2.

Circuit Diagram

12
5
WHT/RED WHT/RED G58-6
4 6
BLK/YEL BLK/WHT C42-33 C41-6 BLK
7
C41-7 BLK
8
WHT/GRN C42-4 BLK/ORN
BLK/YEL BLK/YEL BRN/WHT C41-10

BLK/YEL BLK/RED BLK/RED C42-1

BLK/RED C42-2

B1 9 A1
2 3 BLU/YEL C41-5

1 B2 10 A2
BLU/WHT C41-4

B3 11 A3
BLU/RED C41-3

[A]
C41 C42 G58

[a]

[A]: ECM connector (View: [a]) B2: Fuel injector No.2 power supply circuit 4. Ignition switch 9. Fuel injector No.1
A1: Fuel injector No.1 drive circuit B3: Fuel injector No.3 power supply circuit 5. Circuit fuse box 10. Fuel injector No.2
A2: Fuel injector No.2 drive circuit 1. Main fuse box 6. “RADIO DOME” fuse 11. Fuel injector No.3
A3: Fuel injector No.3 drive circuit 2. “Ignition switch” fuse 7. “IG” fuse 12. ECM
B1: Fuel injector No.1 power supply circuit 3. “Main relay” fuse 8. Main relay
 Engine Fuel (K10B Petrol) 6C-5

Fuel Pump Control System Circuit Diagram

Circuit Diagram

11
5
WHT/RED WHT/RED G58-6
4 6
BLK/YEL BLK/WHT C42-33 C41-6 BLK
7
C41-7 BLK
8
WHT/GRN C42-4 BLK/ORN
BLK/YEL BLK/YEL BRN/WHT C41-10

BLK/YEL BLK/RED BLK/RED C42-1

BLK/RED C42-2
9
A1 B1
BRN C41-13
2 3 A2 B2
PNK
1
10
B3
BLK

[A] C41 C42 G58

[a]

[A]: ECM connector (View: [a]) B3: Fuel pump ground circuit 5. Circuit fuse box 10. Fuel pump
A1: Fuel pump relay power supply circuit (coil side) 1. Main fuse box 6. “RADIO DOME” fuse 11. ECM
A2: Fuel pump relay power supply circuit (switch side) 2. “Ignition switch” fuse 7. “IG” fuse
B1: Fuel pump relay drive circuit 3. “Main relay” fuse 8. Main relay
B2: Fuel pump power supply circuit 4. Ignition switch 9. Fuel pump relay
6C-6 Engine Fuel (K10B Petrol)

Diagnostic Information and Procedures

Fuel System Inspection
Troubleshooting
Step Action Yes No
1 Fuel pump inspection Go to Step 2. Check fuel pump circuit.
1) Remove fuel filler cap and turn ignition switch to ON Refer to “Fuel Pump
position. and Its Circuit Check” in
this section.
2) Confirm that fuel pump operating sound is heard from
fuel filler port for about 2 sec. and then it stops.

Is it in good condition?
2 Fuel pressure check Go to Step 3. Repair or replace
1) Check fuel pressure. Refer to “Fuel Pressure Check” in defective part.
this section.

Is it in good condition?
3 Power balance test Fuel system is in good Go to Step 4.
1) Check power balance. Refer to “Power Balance Test” in condition.
this section.

Is it in good condition?
4 Fuel injector circuit check Go to Step 5. Repair or replace
1) Check fuel injector circuit. Refer to “Fuel Injector Circuit defective part.
Check” in this section.

Is it in good condition?
5 Fuel injector check Substitute a known- Replace fuel injector.
1) Check fuel injector. Refer to “Fuel Injector Inspection” in good ECM and recheck.
this section. Refer to “ECM (Engine
Control Module)
Is it in good condition? Removal and
Installation” in Section
6E2.

Power Balance Test

! CAUTION
Never increase engine speed higher than
idling speed when power balance test has
been performed. It could damage the engine.

NOTE
For identification of each cylinder, refer to
“Cylinder Identification Description” in
Section 6E2. 1
(A)
Using SUZUKI Scan Tool
1) Place gear shift lever in “Neutral” and apply parking 3) Clear DTC referring to “DTC Clearance” in Section
brake. 6E2.
2) Connect scan tool to DLC (1) with ignition switch 4) Start engine and warm up to normal operating
turned OFF. temperature.
5) Using SUZUKI scan tool, select “Fuel Injector” in
Special tool “Active Test” and turn off each fuel injector.
(A): SUZUKI scan tool (SUZUKI-SDT)
6) With each fuel injector turned off, confirm that engine
speed falls lower than specified idle speed.
 Engine Fuel (K10B Petrol) 6C-7

7) If rates of engine speed decrease are not in scale,

check following items.
• Fuel injector circuit. Refer to “Fuel Injector Circuit
Check” in this section.
• Fuel injector. Refer to “Fuel Injector Inspection” in
this section.
• Spark plug. Refer to “Spark Plug Inspection” in
Section 6F.
• Ignition coil circuit. Refer to “Ignition System
Check” in Section 6F.
1
• Ignition coil. Refer to “Ignition Coil Assembly
Inspection” in Section 6F. I8C50A170005-01

• Engine compression. Refer to “Compression 4) Check that engine speed decreases from specified
Check” in Section 6A1. idle speed.
5) Repeat Step 3) and Step 4) for all cylinders, compare
Not Using SUZUKI Scan Tool rates of engine speed decrease.
6) If rates of engine speed decrease are not in scale,
1) Place gear shift lever in “Neutral” and apply parking check the following items.
brake.
• Fuel injector circuit. Refer to “Fuel Injector Circuit
2) Start engine and warm up to normal operating Check” in this section.
temperature.
• Fuel injector. Refer to “Fuel Injector Inspection” in
3) Disconnect fuel injector connector (1) for cylinder this section.
No.1.
• Spark plug. Refer to “Spark Plug Inspection” in
Section 6F.
• Ignition coil circuit. Refer to “Ignition System
Check” in Section 6F.
• Ignition coil. Refer to “Ignition Coil Assembly
Inspection” in Section 6F.
7) Clear DTC. Refer to “DTC Clearance” in Section
6E2.

Fuel Injector Circuit Check

NOTE
For identification of each cylinder, refer to “Cylinder Identification Description” in Section 6E2.

Circuit Diagram
Refer to “Fuel Injector Control System Circuit Diagram” about circuit diagram in this section.

Troubleshooting

NOTE
• Before troubleshooting, be sure to read “Precautions for Fuel System Service” in this section.
• When measuring circuit voltage and/or pulse signal at ECM connector, connect service wire to fuel
injector and fuel injector connectors.

Step Action Yes No

1 Fuel injector check for operating sound Fuel injector circuit is in Go to Step 2.
1) Using sound scope, check each injector for operating good condition.
sound with engine cranking.

Do all injectors make operating sound?

6C-8 Engine Fuel (K10B Petrol)

Step Action Yes No

2 Fuel injector resistance check Go to Step 3. Replace fuel injector.
1) Turn OFF ignition switch and disconnect connectors Refer to “Fuel Injector
from fuel injectors. Removal and
Installation” in this
2) Check for proper connection to fuel injector at each
section.
terminals.
3) If OK, check all fuel injectors for resistance. Refer to
“Fuel Injector On-Vehicle Inspection” in this section.

Are all injectors in good condition?

3 Fuel injector insulation resistance check Go to Step 4. Replace fuel injector.
1) Check that insulation resistance is infinity between each Refer to “Fuel Injector
fuel injector terminal and engine ground. Removal and
Installation” in this
Is it in good condition? section.
4 Fuel injector power supply circuit check Go to Step 5. Repair or replace fuel
1) Check that voltage between each fuel injector power injector power supply
supply circuit (B1, B2, B3) and engine ground is battery circuit.
voltage with ignition switch in ON position.

Is it in good condition?
5 Fuel injector drive circuit check Go to Step 6. Repair or replace fuel
1) Turn OFF ignition switch and disconnect connectors injector drive circuit.
from ECM.
2) Check that fuel injector drive circuits (A1, A2, A3) are as
follows.
• Wiring harness resistance of each fuel injector drive
circuit is less than 3 .
• Insulation resistance between each fuel injector drive
circuit and vehicle body ground is infinity.
• Circuit voltage of each fuel injector drive circuit is 0 – 1
V with ignition switch in ON position.

Are they in good condition?

6 Fuel injector check Substitute a known- Replace fuel injector.
1) Check fuel injector. Refer to “Fuel Injector Inspection” in good ECM and recheck. Refer to “Fuel Injector
this section. Removal and
Installation” in this
Is it in good condition? section.
 Engine Fuel (K10B Petrol) 6C-9

Fuel Pump and Its Circuit Check

Circuit Diagram
Refer to “Fuel Pump Control System Circuit Diagram” about circuit diagram in this section.

Troubleshooting

NOTE
• When measuring circuit voltage and/or pulse signal at ECM connector, connect service wire to fuel
pump and fuel pump connectors.

Step Action Yes No

1 Fuel pump control system check for operation Fuel pump circuit is in Go to Step 2.
1) Remove fuel filler cap and turn ignition switch (2) to ON good condition.
position.
2) Confirm that fuel pump operating sound in heard from
fuel filler (1) for about 2 seconds and then it stops.
3) Reinstall fuel filler cap after checking.

Is it in good condition?

IVSY01170013-01
2 Fuel pump relay power supply check Go to Step 3. Repair or replace fuel
1) Turn OFF ignition switch and remove fuel pump relay pump relay power
from main fuse box. Refer to “Fuel Pressure Relief supply circuit.
Procedure” in this section.
2) Turn ignition switch to ON position, check that voltage
between each fuel pump relay power supply circuit (A1 –
A2) and engine ground is battery voltage.

Is it in good condition?
3 Fuel pump relay check Go to Step 4. Replace fuel pump
1) Check fuel pump relay. Refer to “Fuel Pump Relay relay.
Inspection” in this section.

Is relay in good condition?

6C-10 Engine Fuel (K10B Petrol)

Step Action Yes No

4 Fuel pump relay drive circuit check Go to Step 5. Repair or replace fuel
1) Turn OFF ignition switch and disconnect connector from pump relay drive circuit.
ECM.
2) Check for proper terminal connection to ECM
connectors.
3) Check that fuel pump relay drive circuit (B1) is as
follows.
• Wiring harness resistance of fuel pump relay drive
circuit is less than 3 .
• Insulation resistance between fuel pump relay drive
circuit (B1) and vehicle body ground is infinity.
• Circuit voltage of fuel pump relay drive circuit (B1) is 0
– 1 V with ignition switch ON.

Are they in good condition?

5 Fuel pump relay drive signal check Go to Step 6. Substitute a known-
1) Turn OFF ignition switch. good ECM and recheck.
2) Install fuel pump relay to main fuse box and connect
connector to ECM.
3) Check that voltage between fuel pump relay drive circuit
(B1) and vehicle body ground is 0 – 1 V for 2 sec. after
ignition switch to ON position.

Is it in good condition?
6 Fuel pump power supply circuit check Go to Step 7. Repair or replace fuel
1) Turn OFF ignition switch. pump power supply
circuit.
2) Detach fuel tank. Refer to “Fuel Tank Removal and
Installation” in this section.
3) Disconnect connector from fuel pump.
4) Check that resistance between fuel pump power supply
circuit (B2) and vehicle body ground is infinity.

Is it in good condition?
7 Fuel pump power supply circuit check Go to Step 8. Repair or replace fuel
1) Connect service wire between fuel pump relay drive pump power supply
circuit (B1) and vehicle body ground. circuit.
2) With ignition switch in ON position, check that voltage
between fuel pump power supply circuit (B2) and vehicle
body ground is battery voltage.

Is it in good condition?
8 Fuel pump ground circuit check Replace fuel pump. Repair or replace fuel
1) Turn OFF ignition switch. Refer to “Fuel Pump pump ground circuit.
Assembly Removal and
2) Check that resistance between fuel pump ground circuit
Installation” in this
(B3) and vehicle body ground is less than 3 .
section.
Is it in good condition?
 Engine Fuel (K10B Petrol) 6C-11

Fuel Pressure Check

System Diagram
Special tool
(A): 09912M58442
(B): 09912M58432
(C): 09912M58490

(A)

(B)

(C)
3
6 5
2

1
I8C50A170008-01

1. Fuel injector 4. Fuel filter 7. Fuel tank

2. Fuel delivery pipe 5. Fuel pressure regulator
3. Fuel pump assembly 6. Fuel level sensor

Troubleshooting

NOTE
Before using the following flow, check that battery voltage is higher than 11 V. If it is lower, fuel
pressure becomes lower than specification even if fuel pump and line are in good condition.

Step Action Yes No

1 Was “Fuel Pump and Its Circuit Check” performed? Go to Step 2. Go to “Fuel Pump and
Its Circuit Check” in this
section.
2 Fuel pressure check 1 Go to Step 3. Go to Step 6.
1) Check fuel pressure. Refer to “Fuel Pressure Basic
Check” in this section.

Is check result satisfactory?

3 Fuel pressure check 2 Go to Step 4. Go to Step 6.
1) Start engine and warm up to normal operating
temperature.
2) Keep engine speed at 4,000 rpm.

Does fuel pressure show about same value as Step 2?

4 Fuel line check 1 Go to Step 5. Repair or replace
1) Check fuel pipe, fuel hose and joint for fuel leakage. defective part.

Are they in good condition?

5 Fuel line check 2 Fuel system is in good Repair or replace
1) Check fuel pipe, fuel hose and joint for damage or condition. defective part.
deformation.

Are they in good condition?

6 Was fuel pressure higher than specification in Step 2? Go to Step 7. Go to Step 8.
6C-12 Engine Fuel (K10B Petrol)

Step Action Yes No

7 Fuel line check 3 Fuel pressure regulator Repair or replace
1) Check fuel pipe, fuel hose and joint for damage or is in faulty condition. defective part.
deformation.

Are they in good condition?

8 Fuel line check 4 Clogged fuel filter, faulty Repair or replace
1) Check fuel pipe, fuel hose and joint for damage or fuel pump, faulty fuel defective part.
deformation. pressure regulator or
fuel leakage from hose
Are they in good condition? connection in fuel tank.

Fuel Pressure Basic Check d) Start engine and warm it up to normal operating
temperature, and measure fuel pressure at
1) Relieve fuel pressure in fuel feed line. Refer to “Fuel idling.
Pressure Relief Procedure” in this section.
Fuel pressure specification
2) Disconnect fuel feed hose from fuel delivery pipe.
At specified idle speed: 310 – 390 kPa (3.2 –
3) Connect special tools between fuel feed hose (1) 4.0 kg/cm2, 45.0 – 56.6 psi)
and fuel delivery pipe as shown in figure, and clamp
hoses securely to ensure that no leaks occur during e) Stop engine, and measure fuel pressure at one
checking. minute after stopping.

Special tool Fuel pressure specification

(A): 09912M58442 With 1 min. after engine (fuel pump) stop
(B): 09912M58432 (Pressure reduces as time passes): Over 200
(C): 09912M58490 kPa (2.0 kgf/cm2, 29.0 psi)
6) Relieve fuel pressure referring to “Fuel Pressure
Relief Procedure” in this section.
(A)
7) Remove special tools from fuel delivery pipe and fuel
(B) feed hose.
8) Connect fuel feed hose to fuel delivery pipe and
clamp it securely.
1 9) With engine stationary and ignition switch in ON
position, check for fuel leaks. Refer to “Fuel Leakage
Check Procedure” in this section.

(C)
I7V20A171002-01 Fuel Cut Operation Check
4) Check that battery voltage is 11 V or more. 1) Place gear shift lever in “Neutral” and apply parking
5) Measure fuel pressure as follows. brake.
If measured pressure is out of specification, repair or 2) Warm up engine to normal operating temperature.
replace defective part.
3) While listening to sound of injector (2) by using
a) Turn ignition switch to ON position to operate sound scope (1) or the like, increase engine speed
fuel pump. to higher than 3,000 rpm.
b) After 2 sec., turn it OFF.
c) Repeat Step a) and b) three or four times, and
then check fuel pressure.
Fuel pressure specification
Standard: 270 – 390 kPa (2.8 – 4.0 kgf/cm2,
39.2 – 56.6 psi)
(With fuel pump operating and engine
stopped)
 Engine Fuel (K10B Petrol) 6C-13

4) Check that injector operation sound stops when 5) If injector sound is not heard, perform “Fuel Injector
throttle valve is closed instantly and it is heard again Circuit Check” in this section.
when engine speed is reduced to approx. 2,000 rpm
or less.

Repair Instructions
Fuel System Components

(b)
4
1

8
9 6

10
7

(a)

(c)

12

(d)

13

16

14
15
11

1. Fuel filler cap
2. Fuel filler neck
3. Breather hose
4. Fuel pump plate
5. Fuel pump gasket
6. Fuel pump assembly
7. Fuel tank
8. Fuel vapor line
9. Fuel return line
10. Fuel filter
11. Fuel feed line
12. Fuel delivery pipe
13. Fuel delivery pipe insulator : 25 N!m (2.6 kgf-m, 18.5 lbf-ft)
14. Fuel injector : 31 N!m (3.2 kgf-m, 23.0 lbf-ft)
15. Injector cushion : Do not reuse.
16. O-ring
: 1.5 N!m (0.15 kgf-m, 1.1 lbf-ft)
: 10 N!m (1.0 kgf-m, 7.5 lbf-ft)
6C-14 Engine Fuel (K10B Petrol)

Fuel Hose Disconnecting and Reconnecting

For Connection other than Quick Joint
Clamp around fuel tank

NOTE
Be sure to contact fuel-hose-end to spool on fuel pipe or to the end of pipe joint when connecting fuel
hose and pipe.

[a] [b] [c] [d] [e] [f]

4 4 4 7 4 4

7 7 5 6 5 6

“a” “a” “a” “a”

“a”
“a”

[g] [h] [i]

4 4
7 7 “e”

(a) (a)

“a” “a” 1 3 2 3

[k] [m] [n]

“d” “b” “c” 3
“b” 2
[k]
1
3 1 2 [b]
1 3 2

[m] [m]
[a] [h]
[k]
[e] [g]

[n]
[c]

[f]
[d]

[k] [k]
[i]
I8C50A170040-01

“a”: 45" 1. Pipe 6. Vehicle backward

“b”: 3 – 7 mm (0.12 – 0.27 in.) 2. Hose 7. Vehicle rightward
“c”: 5 – 12 mm (0.20 – 0.47 in.) 3. Clamp : 1.5 N!m (0.15 kgf-m, 1.1 lbf-ft)
“d”: 25 – 30 mm (0.99 – 1.18 in.) 4. Vehicle upward
“e”: 42 – 48 mm (1.66 – 1.88 in.) 5. Vehicle forward
 Engine Fuel (K10B Petrol) 6C-15

Clamp other than around fuel tank Fuel Pressure Relief Procedure
NOTE ! CAUTION
Be sure to contact fuel-hose-end to spool on
Never perform this work when engine is hot.
fuel pipe or to the end of pipe joint, when
Doing so may cause adverse effect to
connecting fuel hose and pipe.
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance” in
Section 6E2.

1) Make sure that engine is cold.

2) Place gear shift lever in “Neutral” and apply parking
brake and block drive wheels.
3) Remove main fuse box cover and disconnect fuel
pump relay (1) from main fuse box (2).
4) Remove fuel filler cap in order to release fuel vapor
pressure in fuel tank, and then reinstall it.
5) Start engine and run it until engine stops for lack of
fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time to dissipate fuel pressure in lines.
I7V20A171005-01
Fuel connections are now safe for servicing.
1. Pipe [A]: On short pipe, fit hose as far as it reaches the
end of pipe joint as shown. 6) After servicing, connect fuel pump relay to main fuse
2. Hose [B]: On the following type pipe, fit hose as far as it box and install main fuse box cover.
reaches spool on fuel pipe.
3. Clamp “a”: 3 – 7 mm (0.12 – 0.27 in.)

2
For Quick Joint (other than Fuel Vapor Line)
Disconnecting
1) Remove mud, dust and foreign material between
pipe (1) and quick joint (fuel pipe) (2) by blowing
compressed air.
2) Unlock joint lock by inserting special tool between 1
pipe and quick joint.
I9L60B171005-01
Special tool
(A): 09919M47020
3) Disconnect quick joint from pipe.
Fuel Leakage Check Procedure
1 After performing any service on fuel system, check that
2 (A) there is no fuel leakage as follows.
1) Apply fuel pressure to fuel feed line according to the
following procedure.
a) Turn ignition switch to ON position to operate
2
1
fuel pump.
I4RS0A170019-01 b) After 2 sec., turn it OFF.
c) Repeat Step a) and b) three or four times.
Reconnecting
Insert quick joint (fuel pipe) to fuel pipe until they lock d) Make sure that fuel pressure is applied to fuel
securely (a click is heard), and confirm that quick joint line by placing hand on fuel feed hose and feel
(fuel pipe) is not disconnected by hand. fuel pressure.
2) Check that there is no fuel leakage from any part of
fuel system.
6C-16 Engine Fuel (K10B Petrol)
Fuel Line On-Vehicle Inspection
! CAUTION
As feed line (1) is under high pressure, use
special care when servicing it.
Visually inspect fuel lines for evidence of fuel leakage,
hose (1) crack, deterioration and damage.
Make sure all clamps are secure.
Replace parts as needed.
1 1) Install clamps to marked location on pipes. If clamp
I8C50A170041-01
Fuel Pipe Removal and Installation
Removal
1) Relieve fuel pressure in fuel feed line. Refer to “Fuel
Pressure Relief Procedure” in this section.
2) Disconnect negative (–) cable at battery.
3) Disconnect fuel hose (1) from fuel pipe (2) at front
and rear of each fuel pipe. Refer to “Fuel Hose
Disconnecting and Reconnecting” in this section.
4) Mark location of clamps (3) on fuel pipes, so that
clamps can be reinstalled to where they were.
5) Remove clamps from vehicle body, fuel pipes and
brake pipes.
! CAUTION
Be careful not to bent and damage fuel pipes
and brake pipes when removing clamp.
6) Remove fuel pipe.
1 2
I8C50A170042-01
Installation
is deformed, its claw is bent or broken, replace it with
new one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes referring to “Fuel Hose
Disconnecting and Reconnecting” in this section.
4) Connect negative (–) cable to battery.
5) With engine stationary, turn ignition switch to ON
position and check for fuel leaks. Refer to “Fuel
Leakage Check Procedure” in this section.
Fuel Filter Removal and Installation
Removal
1) Relieve fuel pressure in fuel feed line. Refer to “Fuel
Pressure Relief Procedure” in this section.
2) Disconnect negative (–) cable at battery.
3) Hoist vehicle.
4) Disconnect inlet hose (1) and outlet hose (2) from
fuel filter.
! WARNING
A small amount of fuel may be released after
fuel line is disconnected. In order to reduce
the risk of personal injury, cover the fitting to
be disconnected with a shop cloth. Be sure
to put that cloth in an approved container
when disconnection is completed.

5) Remove bracket nuts (3) and then fuel filter (4) with
bracket from fuel tank.
1
2
4 3) Connect connector to injector securely.
I8C50A170043-01
Installation
Reverse removal procedure noting the following.
• Upon completion of installation, with engine
stationary, turn ignition switch to ON position and
check for fuel leakage. Refer to “Fuel Leakage Check
Procedure” in this section.
Fuel Injector On-Vehicle Inspection
1) Using sound scope (1) or the like, check operating
sound of injector (2) when engine is running or
cranking.
Cycle of operating sound should vary according to
engine speed.
If no sound or unusual sound is heard, check injector
circuit (wire or connector) or injector.
I8C50A170038-01
2) Disconnect connector (1) from injector, connect
ohmmeter between terminals of injector and check
resistance.
If resistance is out of reference value greatly,
replace.
Reference resistance of fuel injector
11.6 – 12.4 at 20 "C, 68 "F
Engine Fuel (K10B Petrol) 6C-17
I2RH0B170008-01
Fuel Injector Removal and Installa-
tion
Removal
1) Relieve fuel pressure referring to “Fuel Pressure
Relief Procedure” in this section.
2) Disconnect negative (–) cable at battery.
3) Remove air cleaner assembly referring to “Air
Cleaner Assembly Removal and Installation” in
Section 6A2.
4) Disconnect fuel injector connectors.
5) Disconnect fuel feed hose (4) from fuel delivery pipe
(1).
6) Remove fuel delivery pipe by removing nuts (2).
7) Remove fuel injector(s) (3).
3
4
I8C50A170016-01
Installation
Reverse removal procedure for installation noting the
following.
• Replace injector O-ring (1) and cushion (2) with new
one using care not to damage it.
• Apply thin coat of fuel to O-rings, and then install
injectors (3) into fuel delivery pipe (4) and cylinder
head.
• Tighten fuel delivery pipe nuts (5) to specified torque.
6C-18 Engine Fuel (K10B Petrol)

Tightening torque 2) Disconnect fuel feed hose from delivery pipe.

Fuel delivery pipe nut (a): 25 N·m (2.6 kgf-m, 18.5 3) Set special tools as follows.
lbf-ft)
Special tool
5, (a) (A): 09912M58421
(B): 09912M57610
(C): 09930M86310
a) Fit washer (1) (inside diameter 13.5 – 14.5 mm
4
(0.532 – 0.570 in.)) to injector (2), and then
install injector to special tool (A).
b) Connect special tool (C) to injector.
c) Install special tool (B) to special tool (A).
1
d) Connect fuel feed hose to special tool (A).

3 (B)

2
I8C50A170017-01

• Make sure that injectors (1) rotate smoothly (2). If not,

probable cause is incorrect installation of O-ring (3). (A)
Replace O-ring with new one.

2 (C)

(A)

I6RW0B170014-01

4) Install suitable vinyl tube (1) onto injector nozzle to

prevent fuel from splashing out when injecting.
5) Put graduated cylinder (2) under injector.
6) Connect one of terminal of special tool (c) to battery
positive (+) terminal.
Special tool
I8C50A170018-01 (C): 09930M86310
• After installation, with engine stationary and ignition
switch in ON position, check for fuel leaks around fuel
line connection. Refer to “Fuel Leakage Check
Procedure” in this section. (C)

Fuel Injector Inspection

! WARNING 1

• Put injector and battery as far away as

possible to reduce risk of fire and personal 2
injury when connecting/disconnecting test I8T401172038-01
harness to/from battery.
7) Operate fuel pump and apply fuel pressure to
injector as follows:
1) Relieve fuel pressure. Refer to “Fuel Pressure Relief When using scan tool:
Procedure” in this section.

a) Connect scan tool to DLC (1) with ignition switch
turned OFF.
Special tool
(A): SUZUKI scan tool (SUZUKI-SDT)
1 9) Check fuel leakage from injector nozzle. Do not
(A)
b) Turn ignition switch to ON position, clear DTC
and select “ACTIVE TEST” mode on scan tool.
Refer to “DTC Clearance” in Section 6E2.
c) Turn on fuel pump using scan tool.
When not using scan tool:
a) Remove fuel pump relay from main fuse box.
b) Connect two terminals of relay using service wire
(1) as shown in figure.
! CAUTION
Check that connection is made between
correct terminals. Wrong connection can
cause damage to ECM, wire harness, etc.
1
I9L60B171006-01
c) Turn ignition switch to ON position.
8) Apply battery voltage to injector (1) for 15 seconds
and measure injected fuel volume with graduated
cylinder. Test each injector two or three times. If
injected volume is out of reference value greatly,
replace injector.
Engine Fuel (K10B Petrol) 6C-19
Reference injected fuel volume
49 – 51 cm3/15 sec. (0.104/0.087 – 0.107/0.089 US/
Imp pt/15 sec.)
operate injector for this check (but fuel pump should
be at work). If fuel leaks (1) more than the following
specifications, replace.
Fuel leakage
Less than 1 drop/min.
I2RH0B170013-01
10) Remove injector from special tool (A) and disconnect
special tool (C) from injector.
! WARNING
As fuel feed line is still under high fuel
pressure even after inspection, removing
injector directly may cause dangerous spout
of fuel. Before removing injector, make sure
to relieve fuel pressure as follows.
1. Stop operation of fuel pump.
2. Put graduated cylinder under injector.
3. Apply battery voltage to injector until no
fuel is injected from injector.
11) Carry out Steps 3) through 10) on each injector to
obtain three readings.
12) After checking, remove special tools from fuel
injector and fuel feed hose.
13) Connect fuel feed hose to fuel delivery pipe.
14) Install fuel injectors to cylinder head. Refer to “Fuel
Injector Removal and Installation” in this section.
15) Check for fuel leaks referring to “Fuel Leakage
Check Procedure” in this section.
6C-20 Engine Fuel (K10B Petrol)

Fuel Filler Cap Inspection 3) Hoist vehicle, and remove clamps (2), fuel filler hose
(1) and breather hose (3) from fuel tank.
! WARNING
3
2
• If cap requires replacement, only a cap
with the same features should be used.
Failure to use correct cap can result in fire
and personal injury.

Remove cap (1), and check gasket (2) for even filler 2
1
neck imprint, and deterioration or any damage. If gasket
is defective, replace cap.

I8C50A170044-01

4) Remove fuel tank inlet valves (1) using flat end rod
(2) or the like.

! CAUTION

• Be careful not to damage fuel tank inlet

valve (1) with flat end rod (2) or the like.
I2RH01170008-01 • Be careful not to damage tabs of fuel tank
inlet valve.

Fuel Tank Inlet Valve Removal and

Installation
Removal
1) Remove fuel filler cap.
2) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “a” shown in figure. I8C50A170049-02

! WARNING Installation
1) Install fuel tank inlet valves (1) to fuel tank.
• Store drained fuel in an airtight container
to reduce the risk of fire and personal
injury.

! CAUTION
Do not force pump hose into fuel tank.
I8T401172018-01

I8C50A170021-01
 Engine Fuel (K10B Petrol) 6C-21

2) Install breather hose (3) and fuel filler hose (1) to fuel Removal
filler neck and fuel tank and secure it with clamps (2). 1) Relieve fuel pressure in fuel feed line. Refer to “Fuel
For proper installation, refer to “Fuel Hose Pressure Relief Procedure” in this section.
Disconnecting and Reconnecting” in this section. 2) Disconnect negative (–) cable at battery.
Tightening torque 3) Perform Steps 1) to 3) of “Removal” in “Fuel Tank
Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m, Inlet Valve Removal and Installation” in this section.
1.1 lbf-ft) 4) Drain fuel tank by pumping fuel out through fuel tank
filler.
3 Use hand operated pump device to drain fuel tank.

! WARNING
Never store fuel in an open container due to
possibility of fire or explosion.

1 2, (a) 5) Disconnect fuel filter (3), fuel hoses (1) from fuel
pipes (2).

I8C50A170046-01

3) Lower vehicle and install fuel filler cap. 3

Fuel Tank Inlet Valve Inspection

Check fuel tank inlet valve for the following.
If any damage or malfunction is found, replace.
• Damage
• Smooth opening and closing
2
! CAUTION
1
Do not remove fuel tank inlet valve from fuel I9L60B171007-01
tank, when checking fuel tank inlet valve.
6) Support fuel tank (1) with jack (2) and remove fuel
Otherwise, tabs can be damaged.
tank bolts (3).

1
I8T401172016-01
3

3
Fuel Tank Removal and Installation 2

! CAUTION
I8C50A170027-02
When servicing fuel tank, it should be treated
carefully. Pay attention not to contact with
sharp edges or hot surfaces. In addition, fuel
tank should not be dropped since fuel tank,
fuel pump and other components can be
damaged by impact. If dropped, all
components should be replaced because
there is a risk of damage.
6C-22 Engine Fuel (K10B Petrol)

7) Lower fuel tank a little as to disconnect wire harness

at connector (1) and clamp bolt, then remove fuel 3
tank.

1 2, (a)

I8C50A170046-01

2. Clamp

I8C50A170028-01 5) Connect fuel hoses (1) to each pipe (2) and fuel filter
8) Remove fuel filter from fuel tank. (3) as shown in figure, and clamp them securely.
Refer to “Fuel Hose Disconnecting and
Installation Reconnecting” in this section.

! CAUTION
When connecting joint, clean outside
3
surfaces of pipe where joint is to be installed,
push joint into pipe till joint lock clicks and
check to ensure that pipes are connected
securely, or fuel leak may occur.

1) If any parts have been removed from fuel tank, install

them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2), and connect fuel
pump connector and clamp wire harness. 2

3) Install fuel tank to vehicle. 1

I9L60B171007-01
Tightening torque
6) Connect negative (–) cable to battery.
Fuel tank bolt (a): 31 N·m (3.2 kgf-m, 23.0 lbf-ft)
7) With engine stationary, turn ignition switch to ON
position and check for fuel leaks. Refer to “Fuel
Leakage Check Procedure” in this section.

Fuel Tank Inspection

! WARNING
Do not attempt any repair on tank using heat
of flame as an explosion resulting in personal
1
injury could occur.

• Check fuel tank for cracks, deformation or damage.

2 If any abnormality is found, replace fuel tank.
• Check fuel pump gasket for fuel leaks.
(a)
I8C50A170029-01
If any abnormality is found, replace corresponding
4) Connect fuel filler hose (1) and breather hose (3) as gasket.
shown in figure, and clamp them securely. Refer to
“Fuel Hose Disconnecting and Reconnecting” in this
section.
Tightening torque
Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m,
1.1 lbf-ft)
 Engine Fuel (K10B Petrol) 6C-23

Fuel Tank Purging Procedure

! CAUTION
Never remain water in fuel tank after washing,
otherwise fuel tank inside will get corrosion.

1) After removing fuel tank, remove all hoses, pipes,

fuel filter and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank. 1
I8C50A170048-01
3) Place fuel 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. Fuel Pump Relay Inspection
5) Completely flush out remaining water after washing.
Refer to “Main / Fuel Pump / Radiator Fan Control
6) Be sure to dry fuel tank assembly thoroughly out of Relay Inspection” in Section 6E2.
direct sunlight after washing.

Fuel Pump Assembly Removal and

Fuel Pump On-Vehicle Inspection
NOTE
Fuel pressure regulator is incorporated with
fuel pump assembly so individual inspection
of it is impossible.
1) Remove fuel filler cap and turn ignition switch (2) to
ON position. Then fuel pump operating sound should
be heard from fuel filler (1) for about 2 seconds. Be
sure to reinstall fuel filler cap after checking.
If check result is not satisfactory, go to “Fuel Pump
and Its Circuit Check” in this section.
Installation
Removal
1) Remove fuel tank from vehicle referring to “Fuel
Tank Removal and Installation” in this section.
2) Disconnect fuel breather hose (1) and fuel vapor
hose (2) from fuel pump assembly. Refer to “Fuel
Hose Disconnecting and Reconnecting” in this
section.
When disconnecting joint (3) of fuel feed line and
return line from fuel pipe (4), unlock joint by inserting
special tool (A) between pipe and joint lock first.
Special tool
(A): 09919M47020

IVSY01170013-01

2) Turn OFF ignition switch and leave it for 10 min. as it

is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after turning ignition switch to ON
position.
If fuel pressure is not felt, go to “Fuel Pressure Basic
Check” in this section.

I8C50A170031-01

5. Before disconnecting, blow off dust, etc. of this portion with compressed
air.
6C-24 Engine Fuel (K10B Petrol)

3) Remove fuel pump assembly (1) from fuel tank. Fuel Pump Inspection
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
contamination.
If filter is faulty, replace or clean and check for
presence of dirt in fuel tank.
• Check that resistance between terminals “1” and “2”
of fuel level sensor changes depending on float
position.
• Check resistance between terminals “1” and “2” at
each float position [a], [b] and [c].
I8C50A170032-01
If measured resistance is out of specification, replace
Installation fuel pump assembly.
! CAUTION Fuel level sensor specification
When connecting joint, clean outside surface Float position Resistance
of pipe where joint is to be inserted, push [a] 55.9 mm (2.20 in.) 38.0 – 42.0
joint into pipe till joint lock clicks and check [b] 105.1 mm (4.138 in.) 153.0 – 167.0
to ensure that pipes are connected securely, [c] 157.9 mm (6.217 in.) 276.7 – 283.3
or fuel leak may occur.

1) Clean mating surface of fuel pump assembly (1) and

fuel tank.
2) Install new fuel pump gasket (2) and fuel pump plate
(3) to fuel pump assembly then install fuel pump
assembly to fuel tank.
3) Tighten fuel pump bolts (4) to specified torque.
Tightening torque
Fuel pump bolt (a): 10 N·m (1.0 kgf-m, 7.5 lbf-ft)

I8C50A170035-02

4) Connect fuel feed hose (1), return hose (2) and fuel I8C50A170033-01
vapor hose (3) to fuel pump assembly.

5) Install fuel tank to vehicle referring to “Fuel Tank

Removal and Installation” in this section.
 Engine Fuel (K10B Petrol) 6C-25

Specifications
Tightening Torque Specifications
Tightening torque
Fastening part Note
N!m kgf-m lbf-ft
Fuel delivery pipe nut 25 2.6 18.5
Fuel filler hose clamp 1.5 0.15 1.1
Fuel tank bolt 31 3.2 23.0
Fuel pump bolt 10 1.0 7.5

NOTE
The specified tightening torque is described in the following.
“Fuel System Components” in this section
“Fuel Hose Disconnecting and Reconnecting” in this section

Reference:
For the tightening torque of fastener not specified in this section, refer to “METRIC INFOMATION” in Section 0A.

Special Tools and Equipment

Special Tool
09912M57610 09912M58421
Injector checking tool plate Checking tool set
This kit includes the
following items. 1. Tool body
and washer, 2. Body plug, 3.
Body attachment-1, 4.
Holder, 5. Return hose and
clamp, 6. Body attachment-2
and washer, 7. Hose
attachment-1, 8. Hose
attachment-2
09912M58432 09912M58442
Fuel pressure gauge hose Fuel pressure gauge
This tool is included in fuel This tool is included in fuel
pressure gauge set pressure gauge set
(09912M58413). (09912M58413).

09912M58490 09919M47020
3-way joint & hose Quick joint remover

09930M86310 SUZUKI scan tool (SUZUKI- 6

SDT)
Injector test harness — 1 2
This kit includes following
4
items. 1. SUZUKI-SDT 2. 3
DLC cable 3. USB cable 4. 5
AC/DC power supply 5.
Voltage meter probe 6.
Storage case

SECTION 6C1
Engine Fuel (F8D Bi-fuel CNG)
CONTENTS
Precautions....................................................6C1-3
Precautions for Fuel System Service ..........6C1-3
General Description ......................................6C1-4
Fuel System Description .............................6C1-4
Fuel Delivery System Description ...............6C1-4
Petrol Delivery System ............................6C1-4
CNG Delivery System .............................6C1-4
Fuel Pump Description ................................6C1-4
CNG Receptacle Description ......................6C1-4
CNG Cylinder Description ...........................6C1-4
CNG Cylinder Valve Description .................6C1-5
Manual CNG Cylinder Valve ...................6C1-5
Excess Flow Valve ..................................6C1-5
Shut-Off Valve .........................................6C1-6
Fusible Plug.............................................6C1-6
Pressure Relief Device............................6C1-6
CNG Fuel Filter Description ........................6C1-6
CNG Pressure Regulator Description .........6C1-6
Schematic and Routing Diagram.................6C1-7
Fuel Delivery System Diagram....................6C1-7
Petrol System ..........................................6C1-7
CNG System ...........................................6C1-7
Fuel Injector Control System
Circuit Diagram ...........................................6C1-8
Circuit Diagram........................................6C1-8
Fuel Pump Control System
Circuit Diagram ...........................................6C1-9
Circuit Diagram........................................6C1-9
Diagnostic Information and
Procedures ..................................................6C1-10
Fuel System Inspection .............................6C1-10
Petrol System ........................................6C1-10
CNG System .........................................6C1-10
Power Balance Test ..................................6C1-11
Using SUZUKI Scan Tool......................6C1-11
Not Using SUZUKI Scan Tool ...............6C1-12
Fuel Injector Circuit Check ........................6C1-12
Petrol System ........................................6C1-12
CNG System .........................................6C1-14
Fuel Pump and Its Circuit Check...............6C1-14
Circuit Diagram......................................6C1-14
Fuel Pressure Check.................................6C1-14
Petrol System ........................................6C1-14
CNG System .........................................6C1-15
Fuel Pressure Basic Check .......................6C1-16
Petrol System ........................................6C1-16
CNG System .........................................6C1-16
Engine Fuel (F8D Bi-fuel CNG) 6C1-1
Fuel Cut Operation Check ........................6C1-17
Repair Instructions .....................................6C1-17
Fuel System Components.........................6C1-17
Petrol System........................................6C1-17
CNG System .........................................6C1-18
Fuel Hose Disconnecting and
Reconnecting ............................................6C1-19
For Connection other than
Quick Joint ............................................6C1-19
For Quick Joint
(other than Fuel Vapor Line) .................6C1-20
Fuel Pressure Relief Procedure ................6C1-20
Petrol System........................................6C1-20
CNG System .........................................6C1-20
Fuel Leakage Check Procedure ...............6C1-20
Petrol System........................................6C1-20
CNG System .........................................6C1-20
Fuel Line On-Vehicle Inspection ...............6C1-22
Petrol System........................................6C1-22
CNG System .........................................6C1-22
Fuel Pipe Removal and Installation ..........6C1-22
Petrol System........................................6C1-22
CNG System .........................................6C1-23
Fuel Filter Removal and Installation..........6C1-24
Petrol System........................................6C1-24
CNG System .........................................6C1-24
Fuel Injector On-Vehicle Inspection ..........6C1-25
Petrol System........................................6C1-25
CNG System .........................................6C1-25
Fuel Injector Removal and Installation ......6C1-25
Petrol System........................................6C1-25
CNG System .........................................6C1-27
Fuel Injector Inspection.............................6C1-27
Petrol System........................................6C1-27
CNG System .........................................6C1-27
CNG Pressure Regulator
On-Vehicle Inspection...............................6C1-27
CNG Pressure Regulator
Removal and Installation...........................6C1-28
CNG Pressure Regulator Inspection.........6C1-29
Shut-Off Valve of
CNG pressure regulator ........................6C1-29
CNG Pressure Regulator Filter
Removal and Installation...........................6C1-29
Fuel Filler Cap Inspection .........................6C1-30
Fuel Tank Inlet Valve
Removal and Installation...........................6C1-30
6C1-2 Engine Fuel (F8D Bi-fuel CNG)
Fuel Tank Inlet Valve Inspection...............6C1-30
Fuel Tank Removal and Installation..........6C1-30
Fuel Tank Inspection.................................6C1-30
Fuel Tank Purging Procedure ...................6C1-30
Fuel Pump On-Vehicle Inspection ............6C1-30
Fuel Pump Relay Inspection .....................6C1-30
CNG Valve Control Relay Inspection........6C1-30
Fuel Pump Assembly
Removal and Installation...........................6C1-30
Fuel Pump Inspection ...............................6C1-30
CNG Cylinder On-Vehicle Inspection........6C1-30
CNG Cylinder
Removal and Installation...........................6C1-31
CNG Receptacle
On-Vehicle Inspection............................... 6C1-33
CNG Receptacle
Removal and Installation .......................... 6C1-33
CNG Receptacle O-Ring
Removal and Installation .......................... 6C1-35
Specifications ............................................. 6C1-36
Tightening Torque Specifications ............. 6C1-36
Special Tools and Equipment ................... 6C1-36
Special Tool .............................................. 6C1-36