Suzuki Aerio, Verona 2002-06

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure from the fuel system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following:

    Engine cover
     
    Vacuum hose from intake manifold
     
    Fuel injector electrical connections
     
    Fuel rail from cylinder head
     
    Fuel injector(s)
     
    Injector O-ring and discard
     

  8.  

To install:

  1. Install or connect the following:

    Grommet to the injector
     
    New injector O-ring
     
    Check if fuel rail insulators for damage or scoring and replace if necessary
     
    Insulators and cushions to fuel injector and fuel rail
     

  2.  
  3. Coat the injector O-rings with a thin coat of gasoline.

    Fuel injector into cylinder head and fuel rail
     
    Fuel rail mounting bolts and tighten to 18 ft. lbs. (25 Nm). Make sure injectors can rotate smoothly.
     
    Fuel injector electrical connections
     
    Vacuum hose to the intake manifold
     
    Engine cover
     

  4.  
  5. Connect the negative battery cable.
  6.  
  7. With the ignition ON and the engine OFF check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure from the fuel system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following:

    Fuel feeding pipe from fuel rail
     
    Intake manifold
     
    Fuel injector wiring harness connector
     
    Fuel rail assembly
     
    Fuel injector retaining clips
     
    Fuel injectors by pulling down and out

    Click image to see an enlarged view

    Fig. After removing the retaining clip, pull the injector down and out-2.5L engine

     

  8.  

To install:


NOTE
Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Install or connect the following:

    Injector to the fuel rail and secure with retaining clip
     
    Injector and fuel rail assembly
     
    Fuel injector wiring harness connector
     
    Intake manifold
     
    Fuel feeding pipe to the fuel rail
     

  2.  
  3. Connect the negative battery cable.
  4.  
  5. With the ignition ON and the engine OFF check for leaks.
  6.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Injector cover
     
    Accelerator cable
     

  4.  
  5. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     

  6.  
  7. Remove the injector holders and separate the injectors from the fuel supply manifold.
  8.  

To install:

  1. Install or connect the following:

    Injectors to the fuel supply manifold with new O-ring seals
     
    Injector holders
     
    Fuel supply manifold with injectors attached. Remove the injector holders.
     
    Fuel pressure regulator vacuum hose
     
    Accelerator cable
     
    Injector cover
     
    Negative battery cable
     

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

    Click image to see an enlarged view

    Fig. Injector removal

  4.  

6-Cylinder Engines
  1. Drain the fuel injection system.
  2.  
  3. Remove the plastic hoses between the turbocharger and charge air cooler and the air cleaner and turbocharger. Place them to one side and seal the openings.
  4.  
  5. Remove the protective cover above the nozzles
  6.  
  7. Disconnect the connectors from the injectors
  8.  
  9. Remove the mounting bolts from the fuel rail
  10.  
  11. Spray universal oil or similar around the injector terminals on the intake manifold.
  12.  
  13. Gently work the fuel rail and injectors loose.
    NOTE
    Handle the injectors carefully to avoid damage to nozzles and needles.

  14.  
  15. Remove:

    The bolts holding the mounting rail to the fuel rail
     
    The mounting rail
     
    The injector.
     

  16.  

To install:

  1. Lubricate the O-ring for the new injector using petroleum jelly.
  2.  
  3. Install the injector.
  4.  
  5. Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail
  6.  
  7. Tighten the mounting rail to the fuel rail
  8.  
  9. Press down the fuel rail.
    NOTE
    Ensure all the injectors are correctly positioned.

  10.  
  11. Screw the fuel rail into place. Use new bolts. Tighten to 88 inch lbs. (10 Nm)
  12.  
  13. Install all connectors on the injectors
  14.  
  15. Press the fuel line quick-release connector together until it clicks
  16.  
  17. Install the cover over the nozzles
  18.  
  19. Remove the seals. Install the plastic pipes between the turbocharger and charge air cooler and the air cleaner and turbocharger.
  20.  

8-Cylinder Engine
  1. Remove the upper intake manifold. Refer to Intake Manifold removal and installation.
  2.  
  3. Remove the crankcase ventilation hose between the cylinder heads by releasing the 2 clamps.
  4.  
  5. Remove the 3 bolts from the fuel rail
  6.  
  7. Remove the 2 bolts on the fuel pressure sensor.
  8.  
  9. Lift the fuel rail assembly with injector straight up and bend it aside.

    Click image to see an enlarged view

    Fig. Fuel rail assembly-V8

  10.  
  11. Unplug the connector of the injector.
  12.  
  13. Remove the circlip of the injector; pull the clip laterally.
  14.  
  15. Remove the injector; jiggle and pull it straight out.

    Click image to see an enlarged view

    Fig. Injector removal-V8

  16.  

To install:


NOTE
Lubricate the O-rings on the injectors with Vaseline or the like.

  1. Install the injector.
  2.  
  3. Install the circlip.
  4.  
  5. Plug in the connector to the injector.
  6.  
  7. Install the fuel rail assembly with injector.
  8.  
  9. Install the 3 bolts of the fuel rail.
  10.  
  11. Install the 2 bolts on the fuel pressure sensor.
  12.  
  13. Install the crankcase ventilation hose and 2 clamps.
    WARNING
    Make sure there is an audible click during connection.

  14.  
  15. Connect the fuel supply line and secure the line in the clamp.
  16.  
  17. Install the upper intake manifold.
  18.  

 
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