2003 Suzuki XL-7 Base, 4WDFACTORY OEM SERVICE PROCEDURE

Fuel Pressure: Vitara

  1. Check fuel pressure as ignition switch is cycled on and off. See appropriate fuel pressure test under FUEL PRESSURE. If fuel pressure is 35.6-42.7 psi (2.5-3.0 kg/cm2 ) and holds at 25.6 psi (1.8 kg/cm2 ) or greater for one minute after fuel pump stops, go to next step. If fuel pressure is not present, go to step  3 . If fuel pressure is as specified, but does not hold, go to step  4 . If fuel pressure is low, go to step  5 . If fuel pressure is high, go to step  6 .
  2. Start engine and allow it to reach normal operating temperature. If fuel pressure is 29.8-37.0 psi (2.1-2.6 kg/cm2 ) with engine at idle, fuel pressure is okay. If fuel pressure is not as specified, check for clogged vacuum passage for fuel pressure regulator or faulty fuel pressure regulator. Repair as necessary and retest system.
  3. Pinch fuel return hose. Turn ignition on. If fuel pressure increases, replace fuel pressure regulator. If fuel pressure is not as specified, go to B-3: FUEL PUMP CIRCUIT INSPECTION . Repair as necessary and retest system.
  4. Disconnect fuel return hose from pressure regulator. Connect a separate hose to pressure regulator and insert hose end into a container. Recheck fuel pressure. If fuel is discharged into container, replace fuel pressure regulator. If fuel does not discharge into container, check for leaking injector or fuel rail, faulty fuel pump check valve or leaking fuel pressure regulator diaphragm. Repair as necessary and retest system.
  5. Pinch fuel return hose. Turn ignition on. If fuel pressure is 64.0 psi (4.5 kg/cm2 ) or greater, replace fuel pressure regulator. If fuel pressure is not as specified, check for clogged fuel filter, restricted fuel feed hose, faulty fuel pump or fuel leakage at hose connection in fuel tank. Repair as necessary and retest system.
  6. Disconnect fuel return hose from fuel pressure regulator. Connect a separate hose to pressure regulator and insert hose end into a container. Turn ignition on. If fuel pressure is 35.6-42.7 psi (2.5-3.0 kg/cm2 ), repair restriction in fuel return hose. If fuel pressure is not as specified, replace fuel pressure regulator and retest system.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.