fuel pump SUZUKI JIMNY 2005 3.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-61
6) Install exhaust manifold stiffener and exhaust pipe referring
to “Exhaust Manifold” in this section.
7) Install camshafts, timing chain and chain cover referring to
“Camshaft, Tappet and Shim”, “Timing Chain and Chain
Tensioner” and “Timing Chain Cover” in this section.
8) Install cylinder head cover and oil pan referring to “Cylinder
Head Cover” and “Oil Pan and Oil Pump Strainer” in this sec-
tion.
9) Install intake manifold stiffener and connect each hoses and
electric lead wires securely.
10) Install air cleaner outlet hoses.
11) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
12) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
13) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
14) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
15) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
16) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
17) Connect negative cable at battery.
18) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-71
5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying oil to rod bolts and tighten cap nuts (3) gradu-
ally as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat Step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice.
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
8) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
9) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection. NOTE:
Before installing bearing cap, make sure to check con-
necting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod” in this sec-
tion.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-73
Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove A/C compressor and/or P/S pump belt (if
equipped).
5) Remove generator belt.
6) Drain engine oil.
7) Drain coolant.
8) Disconnect radiator inlet and outlet hoses from each pipe.
9) Disconnect A/T fluid hoses (2) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
10) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
11) Remove radiator with cooling fan referring to Section 6B.
Then remove water pump pulley.
12) With hose connected, detach P/S pump from its bracket (if
equipped) referring to “Power Steering Pump” in Section
3B1.
13) If vehicle equipped with A/C compressor, work of right hand
steering vehicle differs from its of left hand steering vehicle.
Each work is as follows. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of engine
assembly.

Downloaded from www.Manualslib.com manuals search engine 6A1-78 ENGINE MECHANICAL (M13 ENGINE)
Install seal ring and exhaust pipe to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Reverse disconnected hoses, cables and electric wires for
connection.
7) Install air cleaner outlet hoses.
8) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
9) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
10) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
11) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
12) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
13) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) Connect negative cable at battery.
15) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

Downloaded from www.Manualslib.com manuals search engine ENGINE FUEL 6C-1
6F1
7A
7A1
7A
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
6G
6C
6K
9
10
10A
10B
SECTION 6C
ENGINE FUEL
CONTENTS
General Description ....................................... 6C-2
Fuel System ................................................. 6C-2
Fuel Tank ..................................................... 6C-2
Fuel Pump Assembly ................................... 6C-3
Fuel Filler Cap .............................................. 6C-3
On-Vehicle Service......................................... 6C-4Fuel Lines .................................................... 6C-4
Fuel Filler Cap.............................................. 6C-4
Fuel Tank ..................................................... 6C-4
Fuel Pump Assembly ................................... 6C-7
Tightening Torque Specification ................ 6C-10
Special Tool .................................................. 6C-10

CAUTION:
For vehicles with a catalytic converter, be sure to use unleaded fuel only. Use of leaded and/or low
lead fuel can result in engine damage and reduce the effectiveness of the emission control system.

Downloaded from www.Manualslib.com manuals search engine 6C-2 ENGINE FUEL
General Description
Fuel System
The main components of the fuel system are fuel tank, fuel pump assembly with fuel filter and fuel level gauge
and fuel cut valve, fuel feed line, fuel return line and fuel vapor line.
For the details of fuel flow and fuel vapor flow, refer to “Fuel Delivery System” and “Emission Control System” in
Section 6E.
Fuel Tank
The fuel tank is located under the rear section of the vehicle. The
fuel pump assembly is installed in fuel tank. Whenever servicing
the fuel pump assembly, the fuel tank must be removed from the
vehicle.
1. Fuel tank 4. Fuel filler cap 7. Fuel vapor line 10. Fuel filler hose clamp
2. Fuel pump assembly 5. Fuel feed line 8. Fuel filler neck Tightening torque
3. Breather hose 6. Fuel return line 9. Fuel tank mounting bolt

Downloaded from www.Manualslib.com manuals search engine ENGINE FUEL 6C-3
Fuel Pump Assembly
The fuel pump assembly (1) consists of fuel pump (6), fuel filter
(2), fuel level gauge (5) and fuel cut valve (4).
FUEL PUMP
For structure and operation of the fuel pump, refer to “Fuel Deliv-
ery System” in Section 6E.
FUEL CUT VALVE
The fuel cut valve consists of a float and a spring. It allows only
the fuel vapor to flow into the canister and prevents the fuel from
flowing into the canister.
Fuel Filler Cap
The fuel tank filler neck has a vacuum cap.
A ratchet tightening device on the threaded fuel filler cap reduces
the chances of incorrect installation, which would prevent sealing
fuel vapors.
After the gasket (2) on fuel filler cap and the filler neck flange con-
tact, the ratchet produces a loud clicking noise, indicating the seal
has been set.
This cap has a vacuum relief valve (1) inside.
The vacuum relief valve opens to relieve the vacuum created in
the fuel tank.
3. Suction filter

Downloaded from www.Manualslib.com manuals search engine ENGINE FUEL 6C-5
4) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space “A” in the figure (drain fuel through it
till fuel stops).
5) Hoist vehicle.
6) Remove exhaust center pipe referring to “Components” in
Section 6K and rear propeller shaft referring to “Propeller
Shafts” in Section 4B.
7) Disconnect coupler (1) for fuel pump assembly.
The coupler is close by left rear suspension coil spring (3).
8) Remove fuel tank filler hose protector.
Disconnect filler hose and breather hose from fuel filler neck.
9) Disconnect fuel vapor hose from pipe.
10) With fuel tank supported on a jack, remove fuel tank bolts.
11) Lower fuel tank a little and hold it. Unclamp fuel hoses and
disconnect them from fuel pump assembly (1).
When disconnecting joints of fuel feed line and return line
from pipe, unlock joint by inserting special tool between pipe
(3) and joint lock first.
Special tool
(A) : 09919-47020 CAUTION:
Do not force hose of a hand operated pump into fuel
tank. Doing so can damage inlet valve (2).
2. Fuel tank
2. Quick joint 5. Disconnect joint
4. Insert special tool

Downloaded from www.Manualslib.com manuals search engine 6C-6 ENGINE FUEL
12) Remove fuel tank (1) from vehicle. Remove fuel tank protec-
tor (3) and inlet valve (2) as necessary.
FUEL TANK PURGING PROCEDURE
The following procedure is used for purging the fuel tank.
1) After removing fuel tank, remove all hoses and fuel pump
assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Move 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.
Replace tank if its inside is rusty.
5) Completely flush out remaining water after washing.
CAUTION:
This purging procedure will not remove all fuel vapor. Do
not attempt any repair on tank where heat or flame is
required, as an explosion resulting in personal injury
could occur.

Downloaded from www.Manualslib.com manuals search engine ENGINE FUEL 6C-7
INSTALLATION
1) Install fuel pump (1) assembly to fuel tank. Refer to “Fuel
Pump Assembly” in this section. Install protector to fuel tank.
2) Install inlet valve to fuel tank.
If deformed or damaged in any other way, replace with a new
one.
3) Connect fuel filler and breather hoses to fuel tank and vapor
hose to fuel pump assembly. Clamp them securely.
4) Lift up fuel tank on jack.
Connect fuel feed hose (4) and return hose (3) to pipes as
shown in figure and clamp them securely.
5) Install fuel tank to vehicle and connect wire harness coupler.
6) Connect fuel filler hose and breather hose to fuel filler neck.
Connect fuel vapor hose to pipe. Clamp them securely.
7) Install fuel filler hose protector.
Fuel Pump Assembly
REMOVAL
1) Remove fuel tank from vehicle. Refer to “Fuel Tank” in this
section.
2) Disconnect wire harness coupler and fuel vapor hose from
fuel pump assembly.
3) Remove fuel pump assembly from fuel tank by removing
bolts. CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
2. Quick joint
WARNING:
Before starting the following procedure, be sure to
observe “Precaution on Fuel System Service” in Section
6.