Fuel Injector Inspection

Reference: FUEL INJECTOR REMOVAL AND INSTALLATION 

1. Relieve fuel pressure. See FUEL PRESSURE RELIEF PROCEDURE .
2. Disconnect fuel feed hose from delivery pipe.
3. Set special tools as follows.

   Special Tool 

   (A): 09912-58421 

   (B): 09912-57610 

   (C): 09930-86310 

   1. Fit washer (1) (inside diameter 13.5 - 14.5 mm (0.531 - 0.570 in.)) to injector (2), and then install injector to special tool (A).
   2. Connect special tool (C) to injector.
   3. Install special tool (B) to special tool (A).
   4. Connect fuel feed hose to special tool (A).
      Fig 1: Connecting Fuel Feed Hose To Special Tool

      Courtesy of SUZUKI OF AMERICA CORP.
4. Install suitable vinyl tube onto injector nozzle to prevent fuel from splashing out when injecting.
5. Put graduated cylinder (2) under injector.
6. Connect one of terminal of special tool (c) to battery positive (+) terminal.
Fig 2: Connecting Terminal Of Special Tool To Battery Positive Terminal
Courtesy of SUZUKI OF AMERICA CORP.
7. Operate fuel pump and apply fuel pressure to injector as follows: When using scan tool:
   1. Connect scan tool to DLC (1) with ignition switch turned OFF.

      Special Tool 

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

      Fig 3: Connecting Scan Tool To DLC With Ignition Switch Turned OFF

      Courtesy of SUZUKI OF AMERICA CORP.
   2. Turn ignition switch to ON position, clear DTC and select "ACTIVE TEST" mode on scan tool. See DTC CLEARANCE .
   3. Turn ON fuel pump using scan tool.

   When not using scan tool:

   1. Remove fuel pump relay from connector.
   2. Connect two terminals of relay connector using service wire (1) as shown in figure.
      CAUTION: Check that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness, etc.
      Fig 4: Connecting Terminals Of Relay Connector Using Service Wire

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

   Reference injected fuel volume 

   90 - 92 cm ³  /15 sec. (0.19/0.158 - 0.194/0.162 US/Imp pt/15 sec.) 

   Fig 5: Applying Battery Voltage To Injector

   Courtesy of SUZUKI OF AMERICA CORP.
9. Check fuel leakage from injector nozzle. Do not operate 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 6: Checking Fuel Leakage From Injector Nozzle

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove injector from special tool (A) and disconnect special tool (C) from injector.
    WARNING: As fuel feed line is still under high fuel pressure even after inspection, removing 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 injector.
    3. Apply battery voltage to injector until no fuel is injected from injector.
11. Carry out Steps 3) through 10) on each injector to obtain four readings.
12. After checking, remove special tools from fuel injector and fuel feed hose.
13. Connect fuel feed hose to fuel delivery pipe.
14. Install fuel injectors to cylinder head. See FUEL INJECTOR REMOVAL AND INSTALLATION 
15. Check for fuel leaks. See FUEL LEAKAGE CHECK PROCEDURE .