Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Fuel Pump

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel tank cap to release any fuel tank vapor pressure. Reinstall the fuel tank cap.
  4.  
  5. Using a screwdriver, loosen the fuel pump hose clamps, then slide the clamps down the hoses away from the pump assembly.
  6.  
  7. Detacch the fuel hoses from the pump, and drain the residual fuel from the hoses into a small metal catch can.
  8.  
  9. Loosen the fuel pump mounting bolts, then separate the pump from the cylinder head.
  10.  
  11. Remove the fuel pump actuating rod from the cylinder head, then remove and discard the old gasket.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Cross-sectional view of the mechanical fuel pump used on all carbureted engines covered by this guide



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Fig. Fig. 2: To remove the fuel pump, first disconnect and label all of the fuel lines from it



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Fig. Fig. 3: After removing the fuel pump from the cylinder head, the fuel pump actuating rod can also be removed and inspected for damage

To install:
  1. Clean the fuel pump-to-cylinder head gasket surfaces thoroughly.
  2.  
  3. Apply a coat of clean engine oil to the actuating rod, then insert it into the cylinder head.
  4.  
  5. Install the fuel pump, along with a new gasket, onto the cylinder head. Install and tighten the mounting bolts securely.
  6.  
  7. Reattach the fuel hoses to the fuel pump, then slide the retaining clamps up the hoses. The clamps should be positioned as shown in the accompanying illustration. Tighten the clamp screw until secure.
  8.  
  9. Clean any spilled fuel from the engine.
  10.  


CAUTION
If any fuel was spilled near the battery, or on the engine, allow the fuel fumes to dissipate before reconnecting the negative battery cable. Sparks and fuel vapor can cause fatal explosions.

  1. Connect the negative battery cable.
  2.  

TESTING



  1. Remove the fuel tank cap to release any fuel tank vapor pressure. Reinstall the fuel tank cap.
  2.  
  3. Using a screwdriver, loosen the fuel pump hose clamps, then slide the clamps down the hoses away from the pump assembly.
  4.  
  5. Detacch the fuel pump-to-carburetor hose from the pump, and drain the residual fuel from the hose into a small metal catch can.
  6.  
  7. Install a new piece of fuel line to the fuel pump. The new piece of fuel line should be long enough to reach 3 or 4 ft. (1m) away from the vehicle.
  8.  
  9. Position the disconnected end of the new fuel hose into a metal catch container; a metal coffee can works well.
  10.  
  11. Have an assistant sit inside the vehicle and, using the ignition switch, crank the engine for 8-12 seconds. Have your helper perform this 4 or 5 times, while you observe the disconnected end of the fuel hose. Fuel should emit from the fuel hose into the metal catch pan. If no fuel is emitted from the hose, inspect the fuel lines for obstructions and also check the fuel pump actuating rod. If there are no problems with the fuel lines or fuel actuating rod, install a known good fuel pump and retest. If the retest is works okay, the old fuel pump was faulty.
  12.  
  13. Remove the new fuel pump hose.
  14.  
  15. Reattach the original fuel hoses to the fuel pump, then slide the retaining clamps up the hoses. The clamps should be positioned as shown in the accompanying illustration. Tighten the clamp screw until secure.
  16.  
  17. Clean any spilled fuel from the engine.
  18.  


CAUTION
If any fuel was spilled near the battery, or on the engine, allow the fuel fumes to dissipate before reconnecting the negative battery cable. Sparks and fuel vapor can cause fatal explosions.

 
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