Suzuki Vitara, Grand Vitara, XL7 2000-06

Fuel Rail (Supply Manifold) & Injectors

Print

Removal & Installation



1.6L And 2.0L Engines
  1. Relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front intake manifold bracket, if equipped
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Fuel injector harness connectors
     
    Fuel line bracket
     
    Fuel supply manifold
     
    Fuel injectors
     

  4.  

To install:

  1. Install or connect the following:

    Fuel injectors with new O-ring seals
     
    Fuel supply manifold. Tighten the bolts to 17 ft. lbs. (23 Nm).
     
    Fuel line bracket
     
    Fuel injector harness connectors
     
    PCV valve and hose
     
    Front intake manifold bracket, if equipped
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

2.5L, 2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Throttle body intake collector
     
    Fuel lines
     
    Fuel pressure regulator vacuum line
     
    Fuel injector harness connectors
     
    Fuel supply manifold connect pipe
     
    Fuel supply manifolds
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors with new O-ring seals
     
    Fuel supply manifolds. Tighten the bolts to 17 ft. lbs. (23 Nm).
     
    Fuel supply manifold connect pipe. Tighten the bolts to 22 ft. lbs. (30 Nm).
     
    Fuel injector harness connectors
     
    Fuel pressure regulator vacuum line
     
    Fuel lines
     
    Throttle body intake collector
     
    Air intake tube
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

2.7L Engine
  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.
  8.  
  9. Remove intake air pipe and surge tank pipe.
  10.  
  11. Disconnect fuel injector couplers and release fuel injector harness from clamps.
  12.  
  13. Disconnect fuel return hose from pressure regulator.
  14.  
  15. Disconnect vacuum hose from pressure regulator.
  16.  
  17. Remove fuel rail bolt.
  18.  
  19. Remove fuel union bolt of fuel rail (right side).
  20.  
  21. Remove fuel rails (right and left) from intake manifold.
  22.  

To install:

  1. Reverse removal procedure for installation noting the following.
  2.  
  3. Replace injector O-ring and insulator with new one using care not to damage it.
  4.  
  5. Check if cushion is scored or damaged. If it is, replace with new one.
  6.  
  7. Apply O-ring oil to O-rings, and then install injectors into fuel rail and intake manifold.
  8.  
  9. Make sure that injectors rotate smoothly. If not, probable cause is incorrect installation of O-ring.
  10.  
  11. Replace O-ring with new one.
  12.  
  13. Tighten fuel rail bolts to 18 ft. lbs. (25 Nm) and fuel union bolts to 22 ft. lbs. (30 Nm) and make sure that injectors rotate smoothly.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.

    Click image to see an enlarged view

    Fig. Fuel rails exploded view 2.7L engine

  18.  

 
label.common.footer.alt.autozoneLogo