Fuel Injector: Service and Repair

Fuel Injector Removal and Installation

Reference: Fuel Injector On-Vehicle Inspection

WARNING: Before starting the following procedure, be sure to observe Precautions on Fuel System Service in order to reduce the risk or fire and personal injury.

Removal
1. Relieve fuel pressure according to Fuel Pressure Relief Procedure.
2. Disconnect negative (-) cable at battery.
3. Remove surge tank cover.
4. Remove intake air pipe (1) and surge tank pipe (2).






5. Disconnect fuel injector couplers and release fuel injector harness from clamps
6. Disconnect fuel return hose (1) from pressure regulator.
7. Disconnect vacuum hose (2) from pressure regulator.
8. Remove fuel pipe bolt (3).
9. Remove fuel union bolt (4) of fuel delivery pipe (right side).
10. Remove fuel delivery pipes (right and left) (5) from intake manifold.






Installation
Reference: Fuel Injector Inspection
Reverse removal procedure for installation noting the following.
- Replace injector O-ring (1) and insulator (7) with new one using care not to damage it.
- Check if cushion (2) is scored or damaged. If it is, replace with new one.
- Apply O-ring oil to O-rings (1), and then install injectors (3) into delivery pipes (4) and intake manifold.
Make sure that injectors rotate smoothly (6). If not, probable cause is incorrect installation of O-ring. Replace O-ring with new one.

"A": Oil 99000-25320 (SUZUKI DI O RING OIL (500CC))

- Tighten delivery pipe bolts (5) and fuel union bolt (8) to specified torque and make sure that injectors rotate smoothly.

Tightening torque
Fuel delivery pipe bolt (a): 25 N.m (2.5 kg.m, 18.0 lbf.ft)
Fuel union bolt (b): 30 N.m (3.0 kg.m, 22.0 lbf.ft)






- After installation, with engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.