Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Fuel Injector

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REMOVAL & INSTALLATION



  1. Release fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air intake case from the throttle body.
  6.  
  7. Remove the fuel feed pipe clamp from the intake manifold and disconnect the fuel feed pipe from the throttle body.
  8.  
  9. Remove the injector cover.
  10.  



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Fig. Fig. 1: To remove the fuel injector, first loosen the fuel supply line attaching bolts ...



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Fig. Fig. 2: ... then disconnect the line from the throttle body



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Fig. Fig. 3: Insert clean rags in the throttle body bore to prevent dropping anything into the engine ...



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Fig. Fig. 4: ... then loosen the fuel injector cover screws

  1. Disconnect the injector coupler, release its wire harness from the clamp and remove its grommet from the throttle body.
  2.  
  3. Place a cloth over the injector, and a hand on top of the rag. Using an air gun, gently blow low pressure compressed air into the fuel inlet port of the throttle body to unseat the injector. Pull the injector up and out of the throttle body assembly.
  4.  


WARNING
Be careful when using the compressed air. Using excessively high pressure may force the injector to jump out and may cause damage, not only to the injector itself, but also to other parts. Also, never immerse the fuel injector in any type of liquid solvent or cleaner, as damage will occur.

  1. Using a thin metal prytool, disengage the fuel injector wires from the six-terminal connector.
  2.  



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Fig. Fig. 5: Lift the cover off of the fuel injector (arrow) ...



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Fig. Fig. 6: ... then remove the old air intake case-to-throttle body gasket



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Fig. Fig. 7: Cover the fuel injector with a rag and your hand, then use compressed air to unseat the injector



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Fig. Fig. 8: Remove the fuel injector from the throttle body

To install:
  1. Insert the wire terminals into the six terminal connector until properly engaged. Give each wire a slight tug to ensure that they will not back out of the connector.
  2.  
  3. Apply a thin coat of gasoline to the new O-rings, then install the fuel injector in the throttle body. Ensure that the injector wiring harness fits in the groove in the throttle body securely.
  4.  


WARNING
Do not apply force to the wiring harness-to-injector connection; it is easily damaged.

  1. Reattach the wiring harness connector to the fuel injector, then install the injector cover. Apply a thin coat of locking compound to the screws, then tighten the injector cover screws snugly. The locking compound will keep the screws from backing out and falling into the engine during operation.
  2.  



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Fig. Fig. 9: Apply a thin coat of threadlocking compound to the fuel injector cover screws before assembly

  1. Apply a thin coat of gasoline to the fuel supply line O-ring, then reconnect the fuel supply line to the throttle body.
  2.  
  3. Connect the negative battery cable and turn the ignition repeatedly ON and OFF (leaving the ignition switch ON for 3 seconds each cycle), until fuel pressure is felt at the return hose.
  4.  
  5. Install the air intake case assembly.
  6.  
  7. Secure all wires and check for any leaks in the system.
  8.  

TESTING



  1. Disconnect the negative battery cable.
  2.  
  3. Detach the wiring harness connector from the fuel injector connector.
  4.  
  5. Attach the leads of a Digital Volt-Ohmmeter (DVOM), set on the ohmmeter function, to the two fuel injector terminals. Measure the resistance of the fuel injector, which should be 0.8-1.8 ohms at 68°F (20°C). If the resistance is not within the specified range, replace the fuel injector with a new one.
  6.  
  7. Reattach the wiring harness connector to the fuel injector.
  8.  
  9. Remove the air intake case from the throttle body.
  10.  
  11. Connect the negative battery cable.
  12.  



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Fig. Fig. 10: To test the fuel injector, detach the wiring harness connector from the fuel injector wiring ...



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Fig. Fig. 11: ... then measure the resistance between the two injector terminals-replace the injector if not within specifications

  1. While you feel the fuel return hose, have an assistant turn the ignition switch ON . Fuel pressure should be felt at the return hose for 3 seconds after the ignition switch is turned ON .
  2.  


CAUTION
When working around a running engine, remember to keep clear of all moving engine components (such as the engine cooling fan) and hot exhaust parts. Do not wear any loose clothing, which may accidentally be caught in a moving component and cause strangulation.

  1. Start or crank the engine, and observe the spray pattern of the fuel injector. The fuel spray pattern should be conical in shape. If no fuel is injected, inspect the wiring harness for continuity, and the wiring harness connectors for proper engagement. If fuel is being injected into the engine, but the spray pattern is not conical in shape, replace the fuel injector with a new one.
  2.  
  3. Stop cranking the engine, or turn the engine OFF , and inspect the fuel injector for gasoline leakage. If a leakage of more than one drop of fuel per minute is detected, replace the fuel injector with a new one.
  4.  
  5. Install the air intake case.
  6.  

 
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