Fuel Rails & Injectors: Installation
- Replace injector "O" ring (3) with new one using care not to damage it. Install grommet (2) to injector. See Fig 1
.
- Check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators and cushions (4) to cylinder head. See Fig 1
.
- Apply thin coat of fuel to "O" rings (1) and then install injectors into delivery pipe and cylinder head. See Fig 2
.
- Tighten delivery pipe bolts (3) to specified torque and make sure that injectors rotate smoothly. See Fig 2
.
- Connect couplers to injector securely and clamp injector wire.
- Install engine cover referring to ENGINE COVER
.
- With engine "OFF" and ignition switch "ON", check for fuel leaks around fuel line connection.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
- Replace injector "O" ring (3) with new one using care not to damage it. Install grommet (2) to injector. See Fig 4
.
- Check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators (1) and cushions (4) to intake manifold or cylinder head. See Fig 4
.
- Apply thin coat of fuel to "O" rings (1) and then install injectors into delivery pipe and intake manifold or cylinder head. Make sure that injectors rotate smoothly. If not, probable cause is incorrect installation of "O" ring. Replace "O" ring with new one. See .
- Tighten delivery pipe bolts and make sure that injectors rotate smoothly. See Fig 5
& TORQUE SPECIFICATIONS
.
- Connect couplers to Injectors securely:
- Install PCV hose and breather hose and clamp then securely.
- Install clamp bolts for fuel feed pipe and return pipe.
- Connect battery negative cable.
- With engine "OFF" and ignition switch "ON", check for fuel leaks around fuel line connection.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
- Replace injector "O" ring (1) with new one using care not to damage it. Install grommet (2) to injector. See Fig 3
.
- Check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators and cushions (2) to intake manifold. See Fig 4
.
- Apply thin coat of fuel to "O" ring (1) and then install. injectors into delivery pipes (right and left) and intake manifold. Make sure that injectors rotate smoothly. If not, probable cause is incorrect installation of "O" ring or grommet (2). Replace "O" ring with new one. See Fig 5
.
- Tighten delivery pipe bolts (3) and make sure that injectors rotate smoothly. See Fig 5
.
- Install fuel connect pipe (1) and tighten union bolts to specified torque with new gaskets (3). See Fig 6
& TORQUE SPECIFICATIONS
.
- Install fuel feed pipe (2) and tighten union bolt to specified torque with new gaskets. See Fig 6
& TORQUE SPECIFICATIONS
.
- Connect vacuum hose (5) and fuel return hose (4) to fuel pressure regulator. See Fig 6
.
- Connect fuel feed hose (1) and fuel return hose (2). See Fig 1
.
- Connect connectors of injector wire (3) to injectors. See Fig 1
.
- Install throttle body and intake collector referring to THROTTLE BODY & INTAKE MANIFOLD
.
- With engine "OFF" and ignition switch "ON", check for fuel leaks around fuel line connection.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.