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.
- Remove the fuel tank from the vehicle, as described later in this section.
- Loosen the fuel pump retaining bolts, then lift the fuel pump up and out of the fuel tank.
- Remove and discard the old fuel pump gasket.
- Position the fuel pump, along with a new gasket, in the fuel tank, ensuring that the fuel pump retaining bolt holes are aligned.
- Install and tighten the fuel pump retaining bolts securely and evenly.
- Install the fuel tank into the vehicle.
See Figures 3 and 4
Remove the fuel tank filler cap.
- 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.
- Turn the ignition switch OFF .
- Open the hood to gain access to the fuel return line, connected to the fuel pressure regulator mounted on the throttle body.
- 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 .
- 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.
- Reinstall the fuel tank filler cap.
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:
- Relieve the fuel system pressure.
- Raise and safely support the vehicle on jackstands.
- Remove the small plug bolt from the fuel filter union bolt.
- Attach a fuel pressure gauge set (such as Suzuki Tool 09912-58412) to the fuel filter union bolt.
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:
- Disconnect the negative battery cable.
- Remove the fuel pump relay from its mounting bracket after disengaging the wiring harness connector from it.
- 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.
- 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.
- Install the relay, and reattach the wiring harness connector to it.