Fuel Injector Removal & Installation: Installation

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

Fig 1: Installing NEW Injector O-Ring & Grommet
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 & 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.
Tightening torque:

Delivery pipe bolt (a): 25 N.m (2.5 kg-m, 18.5 lb-ft)

Fig 3: Tightening Delivery Pipe Bolts & Ensuring Injectors Rotate Smoothly
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: Installing Fuel Delivery Components
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel feed hose (1) and fuel return hose (2).
Connect connectors of injector wire (3) to injectors.
Install throttle body and intake collector referring to THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION (H25 ENGINE) (Grand Vitara) or THROTTLE BODY & INTAKE MANIFOLD REMOVAL & INSTALLATION (H27 ENGINE) (XL-7).
With engine stop and ignition switch at ON position, check for fuel leaks around fuel line connection.

Fig 5: Connecting Injector Connectors
Courtesy of SUZUKI OF AMERICA CORP.