Suzuki Vitara, Grand Vitara, XL7 2000-06

Fuel Pressure Regulator

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Removal & Installation



1.6L & 2.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Disconnect vacuum hose from fuel pressure regulator.
  8.  
  9. Remove fuel pressure regulator from fuel rail.
    CAUTION
    Fuel may be released when removing fuel pressure regulator. Keep shop towel under regulator and fuel rail to catch fuel. Remove shop towel when fuel release stops.

  10.  
  11. Disconnect fuel return hose from fuel pressure regulator.
  12.  

To install:

  1. Connect fuel return hose to fuel pressure regulator.
  2.  
  3. Install fuel pressure regulator to fuel rail with new o-ring.
  4.  
  5. Tighten regulator mounting bolts to 7 ft. lbs. (10 Nm).
  6.  
  7. Reconnect vacuum hose to fuel pressure regulator.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.
  12.  

2.5L & 2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove surge tank cover (if applicable).
  8.  
  9. Disconnect vacuum hose from fuel pressure regulator.
  10.  
  11. Remove fuel pressure regulator from fuel rail.
    CAUTION
    Fuel may be released when removing fuel pressure regulator. Keep shop towel under regulator and fuel rail to catch fuel. Remove shop towel when fuel release stops.

  12.  
  13. Disconnect fuel return hose from fuel pressure regulator.
  14.  

To install:

  1. Reconnect fuel return hose to fuel pressure regulator.
  2.  
  3. Install fuel pressure regulator to fuel rail and tighten mounting bolts to 8 ft. lbs. (11 Nm).
  4.  
  5. Reconnect vacuum hose to fuel pressure regulator.
  6.  
  7. Install surge tank cover if removed.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.
  12.  

 
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