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Home >> Suzuki >> 2008 >> XL7 Base, FWD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Repair Instructions >> Fuel Injector and Fuel Rail Replacement >> Removal Procedure
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Removal Procedure

Fig 1: Identifying Upper Intake Manifold
G05465698Courtesy of SUZUKI OF AMERICA CORP.
  1. Remove the upper intake manifold. Refer to UPPER INTAKE MANIFOLD REPLACEMENT .
  2. Disconnect the fuel feed pipe quick connect fitting (3) from the fuel rail. Refer to METAL COLLAR QUICK CONNECT FITTING SERVICE .
  3. Use compressed air in order to remove any debris from the around the area where the fuel injectors enter the lower intake manifold.
    Fig 2: Identifying Fuel Rail Bolts
    G05465699Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the fuel rail bolts.
    CAUTION:
    • Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
    • Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
  5. Remove the fuel rail with fuel injectors from the lower intake manifold.
    Fig 3: Identifying Fuel Injector Electrical Connector Lock
    G05465700Courtesy of SUZUKI OF AMERICA CORP.
  6. Disengage the fuel injector electrical connector lock.
    Fig 4: Identifying Fuel Injector Electrical Connector
    G05465701Courtesy of SUZUKI OF AMERICA CORP.
  7. Disconnect the fuel injector electrical connector.
    Fig 5: Identifying Fuel Injector Retainer Clip
    G05465702Courtesy of SUZUKI OF AMERICA CORP.
  8. Remove the fuel injector retainer clip.
    Fig 6: Identifying Fuel Injector And Fuel Injector Seals
    G05465703Courtesy of SUZUKI OF AMERICA CORP.
  9. Remove the fuel injector.
  10. Remove and discard the fuel injector seals.