fuel pump SUZUKI GRAND VITARA 1987 Service Repair Manual

TABLE OF CONTENTS
GENERAL, SPECIAL TOOLS AND SERVICE MATERIALS
PERIODIC MAINTENANCE SERVICE
TROUBLE SHOOTING
ENGINE
FUEL SYSTEM (CARBURETOR, AIR CLEANER FUEL PUMP AND FUEL FILTER)
EMISSION CONTROL SYSTEM
ENGINE COOLING SYSTEM
CAR HEATER
IGNITION SYSTEM
CRANKING SYSTEM
CHARGING SYSTEM
CLUTCH
GEAR SHIFTING CONTROL
TRANSMISSION
TRANSFER GEAR BOX
PROPELLER SHAFTS
DIFFERENTIAL
SUSPENSION
STEERING SYSTEM
BRAKES
BODY SERVICE
,i BODY ELECTRICAL EQUIPMENT
SERVICE DATA
0
1
2
5
6
7
8
9
10
1111
12
13
14
15
16
17
18
19
20
21
22
4
3
SECTION

1) Replace fuel hoses (pipe to fuel pump, pipe to
fuel filter and breather hose) in fuel feed and
return lines with new ones.
2) Remove fuel tank.
3) Replace return hose (tank to return pipe)
with new one.
4) Clamp hoses securely.
5) Install fuel tank referring to p. 4-35.
6) After installation, start engine and check it
for leaks.
27. IDLE SPEED INSPECTION
NOTE:
Before starting engine, place transmission gear
shift lever in “Neutral”, and set parking brake
and block drive wheels.
1) Warm up engine to normal operating tempe-
rature.
2) Check to ensure that idle speed is within
750 - 850 r/min (rpm).
3) If idle speed is not within specified range,
adjust idle speed. Refer to MAINTENANCE
SERVICE (p. 4-26) for procedures to check
and adjust idle speed.
28. IDLE MIXTURE INSPECTION
1) Warm up engine to normal operating tem-
perature.
2) Remove seal rubber of duty check coupler
and connect positive terminal of duty meter
to “Blue/Red” wire and negative terminal to
“Black/Green” wire.
1
1. Duty check coupler
2. Air intake case
3) Set tachometer.
4) Run engine at 1,500 - 2,000 r/min for 30
seconds and bring it to idle speed.
5) Check duty at specified idle speed. If it is out
of specification,adjust it to specification
according to following adjustment procedure.
Specified Duty10-50
at 750 - 850 r/min.I
After inspection, install seal rubber to duty
check coupler.
Idle mixture adjustment procedure is as follows:
1) Remove carburetor from intake manifold
following normal service procedure to gain
access to mixture adjusting screw pin covering
mixture adjusting screw.
2) Drive out mixture adjusting screw pin using
about 4.5 mm (0.18 in) thick iron rod as
shown below.
1-15

2-1. ENGINE
Cond it ion
Poor starting
(Hard starting)
Possible cause
Starter will not run
1. Main fuse blown off
2. Contact not closing in main switch, or this
switch open-circuited
3. Run-down battery
4. Defective magnetic switch of starter
5. Loose battery terminal connection
6. Defective brushes in starter
7. Loose battery cord connection
8. Open in field or armature circuit of starter.
Correction
Replace
Repair or replace
Recharge
Replace
Clean and retighten
Replace
Retighten
Repair or replace
No sparking
1. Defective spark plugAdjust gap, or replace
2. High tension cord short-circuited (grounded)Repair or replace
3. Cracked rotor or cap in distributorReplace
4. Defective signal generator or ignitorReplace
5. Maladjusted signal rotor air gap.Adjust
6. Contact not closing positively in main switch,Replace
or this switch open-circuited
7. Loose or blown fuseSet right or replace
8. Improper ignition timingAdjust
9. Defective ignition coil.Replace
Faulty intake and exhaust systems
1. Carburetor out of adjustment
2. Fuel pump not discharging adequately
3. Clogged fuel filter
4. Defective choke mechanism
5. Loose intake manifold
6. Dirty and clogged carburetor
7. Float level out of adjustment
8. Clogged fuel hose or pipe
9. Not enough fuel in the tank
10. Malfunctioning fuel cut solenoid valve
Adjust
Replace
Clean, or replace
Repair or replace
Retighten
Disassemble and clean
Adjust
Clean or replace
Refill
Check solenoid valve for
proper operation and
replace if necessary
Abnormal engine internal condition
1. Ruptured cylinder head gasket
2. Improper valve clearance
3. Weakened or broken valve spring
4. Loose manifold, permitting air to be
drawn in
5. Worn pistons, rings or cylinders
Replace
Adjust
Replace
Retighten and, as neces-
sary, replace gasket
Replace worn rings and
pistons and rebore as
necessary
2-2

Condition
Poor starting
(Hard starting)
Possible cause
6. Broken valve timing belt
7. Poor valve seating
8. Wrong kind of engine oil
9. Burnt valves
10. Sticky valve stem
Correction
Replace
Repair or replace
Replace
Replace
Correct or replace valve
and guide
Emission control
1. Malfunctioning PCV valve
2. Loose connection or disconnection of
vacuum hoses
Replace.
Connect securely.
3. ECM is poorly grounded.Ground ECM securely
Not enough powerInadequate compression
1. Improper valve clearance
2. Valves not seating tight
3. Valve stems tending to seize
4. Broken or weakened valve spring
5. Piston rings seized in grooves, or broken
6. Worn pistons, rings or cylinders
Adjust
Repair
Replace
Replace
Replace
Replace worn parts and
rebore as necessary
7. Leaky cylinder head gasketReplace
Improperly timed ignition
1. Improper ignition timing
2. Defective spark plug
3. Worn distributor terminals
4. Leaks, loose connection or disconnection of
high tension cord
5. Malfunctioning ignition timing advancers
Adjust
Adjust gap or replace
Dress or replace
Connect or replace as
necessary
Replace
Fuel system out of order
1. Clogged carburetor jets
2. Defective fuel pump
3. Clogged fuel filter
4. Malfunctioning choke system
5. Float level out of adjustment
6. Clogged fuel pipe
7. Clogged fuel tank outlet
8. Loose joint in fuel system
Disassemble and clean
Repair or replace
Replace
Adjust or replace
Adjust
Clean or replace
Clean
Retighten
Abnormal condition in air intake system
1. Air cleaner dirty and clogged
2. Poor returning motion of choke valve
Clean or replace
Repair, adjust or replace
Overheating tendency of engine
1. (Refer to the section entitled “over-
heating.“)
2-3

ConditionPossible causeCorrection
Not enough powerEmission control
1. Malfunctioning EGR valve
Check and replace as
necessary.
Check and replace as
2. Malfunctioning bowl vent solenoid valve.necessary.
Check and replace as
3. Malfunctioning high altitude switch.necessary
Check nad replace as
4. Malfunctioning throttle position switch
(wide open switch)
necessary
Others
1. Dragging brakes
2. Slipping clutch
.Repair or replace
Adjust or replace
Engine hesitatesAbnormal condition in electrical systems
(Momentary lack of1. Defective spark plug or plug gap out ofReplace or adjust gap
response as the acceler-
ator
adjustment
is depressed. Can2. Cracked rotor or cap in distributor,Replace
occur at all car speeds.resulting in leakage
Usually most severe3. Deteriorated ignition coil, or crackReplace
when first trying toresulting in leakage
make the car move, as4. Leaky high-tension cordsReplace
from a stop sign.)5. Ignition timing out of adjustmentAdjust as prescribed
Abnormal condition in fuel system
1. Improper adjustment of float level
2. Clogged carburetor jets
3. Malfunctioning accelerator pump
Adjust
Clean
Check and replace as
necessary
4. Inadequately discharging fuel pumpReplace
Abnormal condition in engine
1. Loss of compression pressure due to leaky
cylinder head gasket
Replace
2. Compression pressure too low because ofReplace and rebore as
worn pistons, rings, cylinders or burnt valvesnecessary
Emission control
1. Malfunctioning bowl vent solenoid valveCheck and replace as
necessary
2. Malfunctioning throttle position switch
(wide open switch)
3. Malfunctionnig high altitude switch
4. Malfunctioning EGR valve
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
5. Malfunctioning thermostatically controlled
air cleaner
Check and replace as
necessary
2-4

ConditionPossible causeCorrection
SurgesFuel system out of order
(Engine power varia- 1. Clogged fuel filterReplace
tion under steady2. Kinky, leaky or damaged fuel hoses and linesCheck and replace as
throttle or cruise.necessary
Feels like the car3. Malfunctioning fuel pumpCheck and replace as
speeds up and downnecessary
with no change in the4. Leaky manifold and carburetor gasketsReplace
accelerator pedal.)5. Improper float levelAdjust
Ignition system out of order
1. Improper ignition timing
2. Malfunctioning ignition timing advancers
(mechanical and vacuum)
Adjust
Check or replace
3. Leaky or loosely connected high tension cordCheck and repair or
replace
4. Defective spark plug (excess carbon deposits,Check and clean, adjust
improper gap, burned electrodes, etc..)or replace
5. Cracked rotor or cap in distributorReplace
Emission control
1. Malfunctioning bowl vent solenoid valve
2. Malfunctioning throttle position switch
(wide open switch)
3. Malfunctioning high altitude switch
4. Malfunctioning EGR valve
5. Malfunctioning thermostatically controlled
air cleaner
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary
Check and replace as
necessary.
Dieseling
(Engine continues to
run after ignition
switch is turned off.
it runs unevenly and
may make knocking
noise. )
Malfunctioning fuel cut solenoid valve in
carburetor
Check solenoid valve for
proper operation and
replace as necessary
Erratic idling
(Improper engine
idling)
Abnormal condition in ignition system
1. Defective spark plug
2. Leaky or disconnected high tension cord
3. Worn distributor terminals
4. Improper ignition timing
5. Cracked cap in distributor, leakage inside
Adjust or replace
Connect or replace
Replace
Adjust
Replace
2-5

ConditionPossible causeCorrection
Erratic idling
(Improper engine
idling)
Abnormal condition in fuel system
1. Clogged carburetor jets
2. Incorrect idle adjustment
3. Clogged air cleaner element
4. Leaky manifold, carburetor or cylinder
head gaskets
5. Improper float level
6. Malfunctioning choke system
7. Malfunctioning fuel cut solenoid valve
Clean
Adjust
Clean or replace
Replace
Adjust
Adjust or replace
Replace
Others
1. Loose connection or disconnection. of
vacuum hoses
Connect
2. Malfunctioning PCV valve
3. Low compression
4. Loose carburetor and intake manifold bolts
and nuts
Check and replace as
necessary
Previously outlined
Tighten bolts and nuts
5. Leaky carburetor and intake manifold
gaskets
Replace
Abnormal detonationAbnormal condition in ignition system
1. Spark plugs tending to overheatChange plug heat value
2. Improper ignition timingAdjust
3. Loose connection in high-tension or low-Retighten
tension circuit.
Abnormal condition in fuel system
1. Clogged fuel filter and fuel lines
2. Clogged carburetor jets
3. Improper adjustment of float level
4. Malfunctioning fuel pump
5. Air inhaling from intake manifold and
carburetor gaskets
Replace or clean
Clean
Adjust
Replace
Replace
Abnormal condition in engine
1. Excessive carbon deposit on piston crowns
or cylinder head
Clean
2. Blown cylinder head gasket, resulting in
low compression pressure
3. Improper valve clearance
4. Valves tending to seize
5. Weakened valve springs
Replace
Adjust
Replace
Replace
Others
Malfunctioning EGR valveReplace
2-6

9
Cond it ionPossible causeCorrection
OverheatingAbnormal condition in ignition system
1. Improper ignition timingAdjust
2. Wrong heat value of spark plugsChange heat value
Abnormal condition in fuel systems
1. Float level set too lowAdjust
2. Clogged jets in carburetorClean
3. Loose inlet manifoldRetighten
Abnormal condition in cooling system,,
1. Not enough coolantRefill
2. Loose or broken fan beltAdjust or replace
3. Erratically working thermostatReplace
4. Poor water pump performanceReplace
5. Leaky radiator coresRepair or replace
Abnormal condition in lubrication system
1. Clogged oil filterReplace
2. Clogged oil strainerClean
3. Deteriorated oil pump performanceReplace
4. Oil leakage from oil pan or pumpRepair
5. Improper engine oil gradeReplace with proper grade
oil
6. Not enough oil in oil panReplenish
Others
1. Dragging brakesRepair or replace
2. Slipping clutchAdjust or replace
3. Blown cylinder head gasketReplace
Engine noiseCrankshaft noise
Note: Before check- 1. Worn-down bearings, resulting in excessivelyReplace
ing the mechanicallarge running clearances
noise, make sure that:2. Worn connecting-rod bearingsReplace
0 Ignition timing is3. Distorted connecting rodsRepair or replace
properly adjusted.4. Worn crankshaft journalsRepair by grinding, or re-
l Specified spark plugplace crankshaft
is used.5. Worn crankpins.Repair by grinding, or re-
l Specified fuel is used.place crankshaft
Noise due to pistons, rings, pins or cylinders
1. Abnormally worn cylinder boresRebore to next oversize
or replace
2. Worn pistons, rings or pinsReplace
3. Pistons tending to seizeReplace
4. Broken piston ringsReplace
, Others
1’. Excessively large camshaft thrust playReplace
2. Excessively large crankshaft thrust clearanceAdjust as prescribed
3. Valve clearance too largeAdjust as prescribed
4. Not enough engine oilReplenish
2-7

Condition
Excessive engine oil
consumption
Possible cause
“Oil pumping” (Oil finding its way into
combustion chambers.)
1. Sticky piston ring
2. Worn piston ring groove and ring
3. Worn pistons or cylinders
Correction
Remove carbon and
replace rings
Replace piston and ring
Replace pistons and
rebore as necessary
Oil leakage along valve stems
1. Defective valve stem oil sealsReplace
2. Badly worn valve stemReplace
2-2. CARBURETOR
ConditionPossible causeICorrection
Fuel overflow from
carburetor
1, Float valve worn or dirty with foreign matterClean or replace
2. Float level set too highAdjust as prescribed
3. Float ruptured and containing some fuelReplace
4. Broken or otherwise defective gasketReplace
5. Loose float chamber securing screwsRetighten
2-3. EXHAUST AND MUFFLER
Condition
Poor muffling per-
formance
Possible cause
1. Loose exhaust pipe connection
2. Broken muffler gasket
3. Broken manifold, pipe or muffler
4. Exhaust manifold loose in place
5. Interference between body and muffler
Correction
Retighten
Replace
Repair or replace
Retighten
Repair, eliminating any
contact
2-4. CLUTCH
ConditionPossible causeICorrection
Slipping clutch Loss of clearance at the tip of release fork
2. Clutch facings dirty with oil
3. Clutch facings excessively worn
4. Weakened diaphragm spring
5. Distorted pressure plate or flywheel surface
6. Improper clutch pedal free travel
Adjust as prescribed
Replace
Replace
Replace
Replace
Adjust and, as necessary,
replace clutch facings
2-9
1.

3-2. ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL
The following parts of components do not require engine removal to receive services (replacement, inspec-
tion or adjustment):
Part or ComponentNature of Service1
1. Spark plug
2. Distributor
Replacement or inspection
Replacement, inspection or adjustment
1 3. Exhaust manifold1 Replacement or inspectionI
I 4. Oil filter1 ReplacementI
1 5. Oil pressure unit( Replacement
6. Cylinder head cover1 ReplacementI
I7. Rocker shaft1 Replacement or inspectionI
8. Rocker-arm
9. Rocker-arm spring
Replacement or inspection
Replacement or inspectionI
10. Cam shaft
11 Cylinder head
I12. Radiator
Replacement or inspection (Cylinder head removal required)
Replacement or inspection
Replacement or inspection (Cooling fan and fan shroud
removal required)I
13. Cooling fan
14. Camshaft timing belt pulley
Replacement
Replacement or inspection
I
15. Crankshaft timing belt pulley
16. Timing beltReplacement or inspection (Cooling fan and fan shroud
1 Replacement or inspection
removal required)
17. Fuel pump
18. Carburetor
Replacement
Replacement, inspection or adiustment
19. Intake manifold1 ReplacementI
20. Alternator
21. Starter motor
Replacement or inspection
22. Fan belt
23. Water pump
Replacement, inspection or tension adjustment
Replacement (Cooling fan and fan shroud removal required)
24.Pulleys (crank, generator, fan)Replacement
25. Timing belt cover)Replacement (Cooling fan and fan shroud removal required)
26. Water hose
27. Oil pan, oil strainer, and oil pump
Replacement or inspection
Replacement or inspection
28. Piston and connecting rodReplacement or inspection (Cylinder head and oil pan
removal required)
Replacement or inspection
3-5