Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Fuel Pump

Print

REMOVAL & INSTALLATION



See Figures 1 and 2

The fuel pump is mounted in the fuel tank, which must be removed to service the fuel pump.

  1. Remove the fuel tank from the vehicle, as described later in this section.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: The electric fuel pump is mounted inside the fuel tank



Click image to see an enlarged view

Fig. Fig. 2: Removing the fuel pump from the fuel tank

  1. Loosen the fuel pump retaining bolts, then lift the fuel pump up and out of the fuel tank.
  2.  
  3. Remove and discard the old fuel pump gasket.
  4.  

To install:
  1. Position the fuel pump, along with a new gasket, in the fuel tank, ensuring that the fuel pump retaining bolt holes are aligned.
  2.  
  3. Install and tighten the fuel pump retaining bolts securely and evenly.
  4.  
  5. Install the fuel tank into the vehicle.
  6.  

TESTING



On-Vehicle Inspection

See Figures 3 and 4

Remove the fuel tank filler cap.

  1. Have an assistant turn the ignition ON , while you listen at the fuel filler tube opening. The operation of the fuel pump should be heard from the fuel filler tube opening for approximately 3 seconds, then it should stop.
  2.  
  3. Turn the ignition switch OFF .
  4.  
  5. Open the hood to gain access to the fuel return line, connected to the fuel pressure regulator mounted on the throttle body.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: After turning the ignition switch ON, the sound of the electric fuel pump running should be heard from the fuel tank filler tube opening for approximately 3 seconds



Click image to see an enlarged view

Fig. Fig. 4: Fuel pressure should be felt at the fuel return line for 3 seconds after the ignition switch is turned ON as well-if either of these is missing, there is a problem with the fuel pump or its circuit

  1. Once again, have your assistant turn the ignition ON , while you feel for fuel pressure at the fuel return line near the throttle body. Fuel pressure should be felt at the return line for approximately 3 seconds after the ignition switch is turned ON .
  2.  
  3. If the fuel pump is not heard operating, or if no fuel pressure is felt at the return line, there is a problem with the fuel pump or its circuit.
  4.  
  5. Reinstall the fuel tank filler cap.
  6.  

Fuel Pump Circuit and Fuel Pressure Inspection

See Figures 5, 6, 7, 8, 9 and 10

For the inspection of the fuel pump circuit or fuel pressure, refer to the accompanying diagnostic charts.

For the fuel pressure inspection, it will be necessary to install a fuel pressure gauge as follows:

  1. Relieve the fuel system pressure.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Remove the small plug bolt from the fuel filter union bolt.
  6.  
  7. Attach a fuel pressure gauge set (such as Suzuki Tool 09912-58412) to the fuel filter union bolt.
  8.  



Click image to see an enlarged view

Fig. Fig. 5: Typical fuel pump circuit schematic for TFI engines



Click image to see an enlarged view

Fig. Fig. 6: Fuel pump circuit test chart



Click image to see an enlarged view

Fig. Fig. 7: Electric fuel pump pressure test components



Click image to see an enlarged view

Fig. Fig. 8: Electric fuel pump pressure test chart



Click image to see an enlarged view

Fig. Fig. 9: Electric fuel pump pressure test chart (continued)



Click image to see an enlarged view

Fig. Fig. 10: When testing the fuel pump pressure, a fuel pressure gauge must be connected to the fuel supply system at the fuel filter, as shown

Fuel Pump Relay Inspection

See Figures 11, 12 and 13

When testing the fuel pump circuit, it may be necessary to inspect the fuel pump relay for defects. Test the relay as follows:

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the fuel pump relay from its mounting bracket after disengaging the wiring harness connector from it.
  4.  



Click image to see an enlarged view

Fig. Fig. 11: Common fuel pump and main relay electrical circuit schematic



Click image to see an enlarged view

Fig. Fig. 12: Measure the fuel pump relay resistance with a Digital Volt-Ohmmeter (DVOM)-if the resistance is not within the specified range, replace the relay with a new one

  1. Using a Digital Volt-Ohmmeter (DVOM) set on the ohmmeter function, measure the resistance between relay terminals A and B, and between terminals C and D. The resistance between terminals A and B should register infinite resistance (no continuity). The resistance between terminals C and D should be 63-77 ohms at 77°F (10°C). If the resistances were not as indicated, replace the relay.
  2.  
  3. Connect a the negative lead of a 12 volt DC battery to terminal D of the relay, and the positive lead to terminal C of the relay. With the relay energized, measure terminals A and B for continuity. There should now be continuity between terminals A and B. If there is no continuity, replace the relay with a new one.
  4.  



Click image to see an enlarged view

Fig. Fig. 13: Connect a 12 volt DC battery to the relay (as shown), then measure the relay resistance again

  1. Install the relay, and reattach the wiring harness connector to it.
  2.  

 
label.common.footer.alt.autozoneLogo