Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Fuel Injectors

Print

REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Release fuel system pressure as previously described.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. For 1.6L engines, remove the throttle cover, then remove the air intake pipe and hose. Detach the intake manifold No. 2 brace from the intake manifold.
  6.  
  7. Detach and label each fuel injector wiring harness connector.
  8.  
  9. Remove the fuel pressure regulator from the fuel delivery manifold, then drain the residual fuel from the delivery manifold into a small metal catch container.
  10.  
  11. Loosen the clamp bolts for the clamps holding the supply and return lines.
  12.  
  13. Loosen the fuel delivery manifold mounting bolts, then lift the manifold and injectors up and off of the engine.
  14.  

Insert clean shop rags, or paper towels, into the fuel injector holes in the intake manifold to prevent accidentally dropping nuts, bolts or other small parts into the engine. If something is dropped into the engine, the intake manifold, and perhaps the cylinder head, will need to be removed to retrieve the object.

  1. Carefully separate the fuel injectors from the delivery manifold.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the fuel injector-to-delivery pipe installation-be sure to use new grommets, O-rings and cushions during installation

  1. Remove and discard the O-ring from each fuel injector.
  2.  
  3. Remove the fuel injector bosses on the intake manifold of all dirt, grime and gum.
  4.  

To install:
  1. Install new O-rings onto the fuel injectors, then install the grommets.
  2.  
  3. Inspect the delivery manifold insulators and fuel injector cushions for damage, such as scoring; if any damage is evident, replace the insulators with new ones.
  4.  
  5. Install the insulators and cushions on the intake manifold.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Install the insulators and cushions on the intake manifold, then install the fuel delivery pipe with the fuel injectors



Click image to see an enlarged view

Fig. Fig. 3: Once the fuel delivery pipe and injectors are installed, the fuel injectors should spin freely in their seats-if they do not, one of the O-rings was improperly installed

  1. Apply a thin coat of clean engine oil onto the fuel injector O-rings, then install the fuel injectors onto the delivery manifold. Install the delivery manifold and fuel injectors onto the intake manifold, ensuring that the fuel injectors are properly seated in their bores. Do not attempt to tighten the delivery manifold mounting bolts to force the fuel injectors into place; they may not be properly aligned with the bores in the intake manifold.
  2.  
  3. Ensure that the fuel injectors spin freely in their bores. If they do not, the cause is the improper installation of their O-rings. Remove the fuel injectors and install NEW O-rings again.
  4.  
  5. Tighten the delivery manifold mounting bolts to 159-248 inch lbs. (18-28 Nm).
  6.  
  7. Install the fuel pressure regulator onto the delivery manifold.
  8.  
  9. Reattach the fuel supply and return lines.
  10.  
  11. Attach the wiring harness connectors to the fuel injectors.
  12.  
  13. For 1.6L engines, install the air intake pipe and hose.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Turn the ignition switch ON without starting the engine, and inspect the fuel supply and return lines, as well as the delivery manifold, for fuel leaks.
  18.  

TESTING



A stethoscope and Digital Volt-Ohmmeter (DVOM) are necessary for this test procedure.

  1. Start the engine and allow it to idle.
  2.  
  3. Use the stethoscope to listen to each of the fuel injectors while the engine is idling. The fuel injectors should produce an operating sound. If no sound or an unusual sound is heard, inspect the fuel injector and circuit for a defect.
  4.  
  5. Disengage the wiring harness connector from each of the fuel injectors.
  6.  
  7. Use the DVOM, set on the ohmmeter function, to measure the resistance between the two terminals of each fuel injector. The resistance should be 12-17 ohms for 1.6L engines, or 10.8-13.2 ohms for 1.8L engines. If any of the fuel injectors do not register a resistance value within the specified range, replace it with a new one.
  8.  
  9. Reattach the wiring harness connectors to the fuel injectors.
  10.  

 
label.common.footer.alt.autozoneLogo