Fuel Injector Removal and Installation: Installation

Replace injector O-ring (1) with new one using care not to damage it. Install grommet (2) to injector.

Fig 1: Installing Grommet To Injector
Courtesy of SUZUKI OF AMERICA CORP.
Check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators and cushions (2) to intake manifold.

Fig 2: Installing Insulators And Cushions To Intake Manifold
Courtesy of SUZUKI OF AMERICA CORP.
Apply thin coat of fuel to O-rings (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.
Tighten delivery pipe bolts (3) and make sure that injectors rotate smoothly.

Fig 3: Tightening Delivery Pipe Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Install fuel connect pipe (1) and tighten union bolts to specified torque with new gaskets (3).
Tightening torque

Fuel connect pipe union bolt (b): 30 N.m (3.0 kg-m, 22.0 lb-ft)
Install fuel feed pipe (2) and tighten union bolt to specified torque with new gaskets.
Tightening torque

Fuel feed pipe union bolt (a): 30 N.m (3.0 kg-m, 22.0 lb-ft)
Connect vacuum hose (5) and fuel return hose (4) to fuel pressure regulator.

Fig 4: Connecting Vacuum Hose And Fuel Return Hose To Fuel Pressure Regulator
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel feed hose (1) and fuel return hose (2).
Connect connectors of injector wire (3) to injectors.

Fig 5: Connecting Connectors Of Injector Wire To Injectors
Courtesy of SUZUKI OF AMERICA CORP.
Install throttle body and intake collector referring to THROTTLE BODY REMOVAL AND INSTALLATION .
With engine OFF and ignition switch ON, check for fuel leaks around fuel line connection.