Fuel Injector Inspection

Reference: FUEL INJECTOR REMOVAL AND INSTALLATION 

1. Relieve fuel pressure, see Fuel Pressure Relief Procedure .
2. Check fuel injector, see Fuel Injector On-Vehicle Inspection .
3. Remove fuel injector, see Fuel Injector Removal and Installation .
4. Replace O-ring of fuel injector (1) (fuel delivery pipe side) with spare parts (part number: 15710-09300) (2).
5. Set special tools as follows.

   Special Tool 

   (A): 09912-58421 

   (B): 09912-57610 

   (C): 09930-88540 

   1. Connect special tool (C) to fuel injector.
   2. Install special tool (B) to special tool (A).
   3. Connect fuel feed hose to special tool (A).
      Fig 1: Connecting Fuel Feed Hose To Special Tool

      Courtesy of SUZUKI OF AMERICA CORP.
6. Install suitable vinyl tube onto fuel injector nozzle to prevent fuel from splashing out when injecting.
7. Put graduated cylinder under injector.
8. Operate fuel pump and apply fuel pressure to fuel injector as follows:

   When using scan tool:

   1. Turn off ignition switch and connect scan tool to DLC (1).
   2. Turn ignition switch to ON position, clear DTC and select "ACTIVE TEST" mode on scan tool.
   3. Turn on fuel pump using scan tool.

      Special Tool 

      (A): SUZUKI scan tool (SUZUKI-SDT) 

      Fig 2: Turning Fuel Pump Using Scan Tool

      Courtesy of SUZUKI OF AMERICA CORP.

   When not using scan tool:

   1. Remove fuel pump relay from fuse box.
   2. Connect two terminals of relay connector using service wire (1) as shown in figure.
      CAUTION: Check to make sure that connection is made between specified terminals. Wrong connection can cause damage to ECM, wire harness, etc.
      Fig 3: Connecting Terminals Of Relay Connector Service Wire

      Courtesy of SUZUKI OF AMERICA CORP.
   3. Turn ignition switch to ON position.
9. Apply battery voltage to fuel injector (1) for 15 seconds and measure injected fuel volume with graduated cylinder. Test each fuel injector two or three times. If injected volume is out of reference value greatly, replace fuel injector.

   Reference injected fuel volume 

   49 - 51 cm3/15 sec. (0.104/0.086 - 0.108/0.090 US/lmp pt/15 sec.) 

10. Check fuel leakage from fuel injector nozzle. Do not operate fuel injector for this check (but fuel pump should be at work). If fuel leaks (1) more than the following specifications, replace.

    Fuel leakage 

    Less than 1 drop/min  .

    Fig 4: Checking Fuel Leakage From Fuel Injector Nozzle

    Courtesy of SUZUKI OF AMERICA CORP.
11. Remove fuel injector (2) from special tool (A) and disconnect special tool (C) from fuel injector.
    WARNING: As fuel feed line is still under high fuel pressure even after inspection, removing fuel injector directly may cause dangerous spout of fuel. Before removing injector, make sure to relieve fuel pressure as follows.

    1. Stop operation of fuel pump.
    2. Put graduated cylinder under fuel injector.
    3. Apply battery voltage to fuel injector until no fuel is injected from fuel injector.
12. Remove spare part (part number: 15710-09300) (1).
13. Carry out Steps  3) through  12) on each fuel injector.
14. After checking, disconnect fuel feed hose from special tool (A) and remove special tool (C).

    Special Tool 

    (A): 09912-58421 

    (B): 09912-57610 

    (C): 09930-88540 

    Fig 5: Identifying Fuel Feed Hose From Special Tool

    Courtesy of SUZUKI OF AMERICA CORP.